US20200324933A1

US20200324933A1 - Corrugated box assembly with combination self-locking lid and tab-style fold over tab and method of construction

Info

Publication number: US20200324933A1
Application number: US16/384,512
Authority: US
Inventors: Mutty Greenfeld
Original assignee: Individual
Current assignee: Individual
Priority date: 2019-04-15
Filing date: 2019-04-15
Publication date: 2020-10-15

Abstract

A Corrugated Box Assembly with Combination Self-Locking Lid and Tab-Style Fold Over Tab includes a box assembly that lies flat as a box blank having two rectangular sidewalls, two square sidewalls, rectangular flaps, and square flaps. The box blank assembles into a rectangular box having six faces and twelve edges. A fold over tab extends along the lateral edge of rectangular sidewall. The fold over tab has an adhesive, so that when folded over the joint between the square sidewall and the rectangular sidewall, the sidewalls of box are fastened together. Also, fold over tab creates a bulge on outer surface of box to help loose boxes stacked into each other. Multiple tongues and slots interlock in an intimate relationship to form constructed box. Multiple stacking tabs extend from top flaps to mate with corresponding stacking holes in an adjacent box assembly to stabilize multiple stacked boxes.

Description

FIELD OF THE INVENTION

The present invention relates generally to a Corrugated Box Assembly with Combination Self-Locking Lid and Tab-Style Fold over tab and Method of Construction. More so, the present invention relates to a box assembly that lies flat as a box blank having two rectangular sidewalls, two square sidewalls, rectangular flaps, and square flaps; whereby the box blank constructs to a rectangular box defined by six faces and twelve edges; whereby at least one fold over tab extends longitudinally along the joint between the square sidewall and the rectangular sidewall; whereby the fold over tab adds a bulge to the outer surface of the box body, so as to help loose a stack of boxes; and further provides multiple stacking tabs extend from the top flaps to mate with corresponding stacking holes in an adjacent box assembly, so as to stabilize multiple boxes arranged in a stacked arrangement.

BACKGROUND OF THE INVENTION

The following background information may present examples of specific aspects of the prior art (e.g., without limitation, approaches, facts, or common wisdom) that, while expected to be helpful to further educate the reader as to additional aspects of the prior art, is not to be construed as limiting the present invention, or any embodiments thereof, to anything stated or implied therein or inferred thereupon.
It is known in the art that corrugated boxes are used for storage and shipping. These boxes provide some measure of product protection by themselves but often require inner components such as cushioning, bracing and blocking to help protect fragile contents. The boxes are designed to protect potential damage to the contents. For example, boxes unitized into a unit load on a pallet do not encounter individual handling while boxes sorted and shipped through part of their distribution cycle as mixed loads or express carriers can receive severe forces that damage the boxes. Moisture and debris are also inhibited from the object while inside the box.
Generally, corrugated fiberboard is a material consisting of a fluted corrugated sheet and one or two flat linerboards. It is made on “flute lamination machines” or “corrugators” and is used in the manufacture of shipping containers and corrugated boxes. The corrugated medium and linerboard board both are made of kraft containerboard, a paperboard material usually over 0.01″ thick. These boxes are often stacked for stowage, transporting, or awaiting to be filled, even when fully constructed.
Other proposals have involved corrugated boxes. The problem with these containers is that they do not provide both a stacking tab and a fold over tab. Also, the structural integrity does not benefit from stacking tabs and fold over tabs that enhance structural integrity of the box when carrying loads or being stacked. Even though the above cited corrugated boxes meet some of the needs of the market, a Corrugated Box Assembly with Combination Self-Locking Lid and Tab-Style Fold over tab and Method of Construction, is still desired.

SUMMARY

Illustrative embodiments of the disclosure are generally directed to a corrugated box assembly with combination self-locking lid and tab-style fold over tab and method of construction. The box assembly provides a storage and shipping box having a generally rectangular cross-section made up of sidewalls and flaps for packing and carrying objects. When fully assembled, the box forms a rectangular cross section defined by six faces and twelve edges with locking tongues and slots that intimately interlock to construct the box and form a self-locking lid; at least one fold over tab extending along the outer edge of the body of the constructed box to create a bulge for removing multiple boxes stacked into each other; and stacking tabs extending from the top flaps to mate with corresponding stacking holes in an adjacent box assembly, so as to stabilize multiple boxes arranged in a stacked arrangement,
Box assembly is defined by a unique sidewall construction that utilizes a box body having two rectangular sidewalls with bottom and top rectangular die-cut flaps that are hingedly connected by score lines formed in the blanks. The box body also has two square sidewalls with bottom and top square die-cut flaps hingedly connected by score lines formed in the blanks, and a fold over tab at the edge of one of the rectangular sidewalls. The sidewalls join at lateral edges to form an enclosed region defined by a rectangular cross section.
A lockable lid is hinged to the body of the box assembly. Two of the rectangular die-cut flaps and two of the square die-cut flaps engage together to form a lid. The square die-cut flaps have locking tongues defined by heel portions adapted to lock under corresponding and adjacent slots that form in the rectangular die-cut flaps, after swinging through the slots. Such locking is achieved by folding the locking tongues of the lid into intimate engagement with corresponding slots in the rectangular die-cut flaps of the box assembly.
At least one fold over tab extends from the edge of one of the rectangular sidewalls when the box body is in the blank, unconstructed configuration. When the box body is constructed, the fold over tab extends longitudinally along the joint between a square sidewall and a rectangular sidewall. The fold over tab has an adhesive, so that when folded over the joint between the square sidewall and the rectangular sidewall, the sidewalls of box are fastened together. The fold over tab adds a bulge to the outer surface of the box body, so as to help loose a stack of boxes.
Fold over join tab adds strength to the vertices and edges of the box assembly, eliminating the need for fastening mechanisms to reinforce the vertices and corners of the box assembly. Additionally, fold over tab is shaped for easy stacking of multiple boxes, and to allow a bulge to separate stacked boxes.
In addition to the fold over tab feature, the flaps at the lid of the box assembly have locking tongues defined by heel portions adapted to lock under corresponding and adjacent slots that form in the rectangular die-cut flaps, after swinging through the slots. Such locking is achieved by folding the locking tongues of the lid into intimate engagement with corresponding slots in the rectangular die-cut flaps of the box assembly. Further, the box assembly provides stacking tabs that help stabilize stacking of multiple box assemblies.
In some embodiments, a fully constructed embodiment of the box assembly may include a plastic or cardboard corrugated container that assembles to a generally polyhedron-shaped box, and that can be easily folded from a collapsed, flat sheet to an operational, three-dimensional container that is defined by 6 faces and 12 edges.
In one aspect, the box assembly, comprises:

- two rectangular sidewalls defined by a pair of rectangular lateral edges, a rectangular top edge, and a rectangular bottom edge;
- two square sidewalls defined by a pair of square lateral edges, a square top edge, a square bottom edge, the rectangular and square sidewalls joining at the lateral edges in an alternating arrangement to form an enclosed region defined by a rectangular cross section and four parallel outer edges;
- at least one fold over tab longitudinally attached along the parallel outer edges;
- two die-cut top rectangular flaps hingedly connected by a top score line along the top edge of the rectangular sidewalls, the top rectangular flaps forming a pair of top locking slots, each top rectangular flap comprising two top stacking tabs, the top stacking tabs extendable from the top rectangular flaps;
- two die-cut bottom rectangular flaps hingedly connected by bottom score lines along the bottom edge of the rectangular sidewalls, each bottom rectangular flap forming two bottom locking slots, each bottom rectangular flap forming two bottom stacking holes, the bottom stacking holes adapted to intimately receive the top stacking tabs of the top rectangular flaps, whereby the top stacking tabs engage the bottom stacking holes to help stabilize stacking multiple box assemblies;
- two die-cut top square flaps hingedly connected by the top score line along the top edge of the square sidewalls, the top square flaps forming a pair of top locking tongues defined by a heel portion, the top locking tongues adapted to lock under the corresponding and adjacent top locking slots that form in the top rectangular flaps; and
- two die-cut bottom square flaps hingedly connected by the bottom score line along the bottom edge of the square sidewalls, each bottom square flap comprising two bottom locking tongues, the bottom locking tongues adapted to lock under the corresponding and adjacent bottom locking slots that form in the bottom rectangular flaps, each bottom square flap forming two end stacking holes adapted to receive the top locking tongues.

One objective of the present invention is to provide a corrugated paper box fold over tabs and locking tongues construction with sufficient strength so as to be self-supporting and require no additional support means.
Another objective is to provide a polyhedron box having 6 faces and 12 edges when fully constructed.
Yet another objective is to provide multiple dimensions of sidewalls, so as to enhance the strength of the vertices and corners of the box; thereby eliminating the need for metallic staples and cloth tape to reinforce the vertices and corners of the box.
Yet another objective is to provide geometric corners that interlock with L-shaped slots to reinforce the vertices and corners of the fully constructed box, but also easily disengage for returning the box to the flat, sheet configuration.
Yet another objective is to provide a corrugated paper box structure which is adaptable to speedy assembly.
Yet another objective is to provide additional means to hold the corner structure exact when assembled.
Yet another objective is to furnish a box construction blank with simple peripheral configuration which enables like blank to be cut with but a minimum of scrap material.
Other systems, devices, methods, features, and advantages will be or become apparent to one with skill in the art upon examination of the following drawings and detailed description. It is intended that all such additional systems, methods, features, and advantages be included within this description, be within the scope of the present disclosure, and be protected by the accompanying claims and drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will now be described, by way of example, with reference to the accompanying drawings, in which:

FIG. 1 illustrates a top view of an exemplary box blank in a collapsed position, showing the sidewalls, flaps, tongues, and slots in relation to each other, in accordance with an embodiment of the present invention;

FIG. 2 illustrates a perspective top angle side perspective view of the constructed embodiment of the corrugated box assembly with combination self-locking lid and tab-style fold over tab, showing the flaps in an open position, in accordance with an embodiment of the present invention;

FIG. 3 illustrates a top view of the box assembly with combination self-locking lid and tab-style fold over tab, showing the flaps in an open position, in accordance with an embodiment of the present invention;

FIG. 4 illustrates a top view of the constructed embodiment of the box assembly with combination self-locking lid and tab-style fold over tab, showing the flaps in a closed position, in accordance with an embodiment of the present invention;

FIG. 5 illustrates a top view of the box assembly with combination self-locking lid and tab-style fold over tab, showing the flaps in an open position, in accordance with an embodiment of the present invention;

FIG. 6 illustrates a perspective bottom angle side perspective view of the box assembly, showing the flaps in a closed position, in accordance with an embodiment of the present invention;

FIG. 7 illustrates a top view of the box assembly, showing the flaps in a closed position, in accordance with an embodiment of the present invention;

FIG. 8 illustrates a top view of a collapsed configuration of the box assembly, showing the bottom and top flaps, in accordance with an embodiment of the present invention; and

FIG. 9 illustrates a flowchart of an exemplary method for assembling a corrugated box assembly with combination self-locking lid and tab-style fold over tab, in accordance with an embodiment of the present invention.

Like reference numerals refer to like parts throughout the various views of the drawings.

DETAILED DESCRIPTION OF THE INVENTION

The following detailed description is merely exemplary in nature and is not intended to limit the described embodiments or the application and uses of the described embodiments. As used herein, the word “exemplary” or “illustrative” means “serving as an example, instance, or illustration.” Any implementation described herein as “exemplary” or “illustrative” is not necessarily to be construed as preferred or advantageous over other implementations. All of the implementations described below are exemplary implementations provided to enable persons skilled in the art to make or use the embodiments of the disclosure and are not intended to limit the scope of the disclosure, which is defined by the claims. For purposes of description herein, the terms “upper,” “lower,” “left,” “rear,” “right,” “front,” “vertical,” “horizontal,” and derivatives thereof shall relate to the invention as oriented in FIG. 1. Furthermore, there is no intention to be bound by any expressed or implied theory presented in the preceding technical field, background, brief summary or the following detailed description. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification, are simply exemplary embodiments of the inventive concepts defined in the appended claims. Specific dimensions and other physical characteristics relating to the embodiments disclosed herein are therefore not to be considered as limiting, unless the claims expressly state otherwise.
A corrugated box assembly 100 with combination self-locking lid and tab-style fold over tab is referenced in FIGS. 1-9. Corrugated box assembly, hereafter “box assembly” provides a novel corrugated box construction defined by; fold over tabs joined at four parallel outer edges of the box; opposing top and bottom panels that fold independently of each other to create dual sided-packing features; and interlocking notches and slots that securely, yet temporarily secure a locking lid on the box in a closed positon when loaded with objects.
As referenced in FIG. 1, the sidewalls, panels, and interlocking slots, tabs, and tongues are configured as a flat box blank when the box assembly is collapsed. Yet, when fully assembled, box assembly 100 forms a generally rectangular cross-section defined by six faces and twelve edges with locking tongues and slots that make up a self-locking lid; stacking tabs extending from the top flaps; and at least one fold over tab extending along the outer edge of the body of the constructed box to fasten the constructed box, and also create a bulge in the constructed box that helps in separating stacked boxes.
However in other embodiments, the box assembly may form, without limitation, a hexagonal shape, a cube shape, a pyramid shape, a cylindrical shape. In any shape however, the self-locking lid and tab-style fold over tab 140 is utilized.
In some embodiments, box assembly 100 may include a plastic or cardboard corrugated container that assembles to a generally polyhedron-shaped box, and that can be easily folded from a collapsed, flat sheet to an operational, three-dimensional container that is defined by 6 faces and 12 edges.
The method 900 for assembly of box assembly 100 is relatively straight forward, as the sidewalls and flaps are folded inwardly to join at locking slots and tongues that interlock in intimate engagement to create a generally rectangular, upright box. Additionally, stacking tabs help stabilize stacking of multiple box assemblies. Further, the box assembly 100 can better support vertical and lateral loads, such as are present when many like boxes are stacked in a column, making box ideal for packaging and shipping heavy objects, fragile goods, and easily damaged produce, for example. And, as described above, box collapses to a flat box blank 102 when not operational for facilitated stowage and transporting.
FIG. 1 illustrates a top view of an exemplary box blank in a collapsed position, showing the sidewalls, flaps, tongues, and slots in relation to each other. As illustrated, box assembly, comprises a box blank 102 having two rectangular sidewalls 104 a, 104 b defined by a pair of rectangular lateral edges 106 a, 106 b, a rectangular top edge 108, and a rectangular bottom edge 110. Rectangular sidewalls 104 a-b are elongated, planar sheets of cardboard or plastic. In one non-limiting embodiment, rectangular sidewalls 104 a-b have a length of about 19⅝″, and a width of about 11″.
Turning now to FIG. 2, box assembly further comprises two square sidewalls 112 a, 112 b. Square sidewalls 112 a-b are elongated, planar sheets of cardboard or plastic. Square sidewalls 112 a-b are defined by a pair of square lateral edges 114 a, 114 b, a square top edge 116, a square bottom edge 118, and at least one grab hole 142 a, 142 b. The rectangular and square sidewalls join at the lateral edges in an alternating arrangement to construct an enclosed region 202 defined by a rectangular cross section and four parallel outer edges 204 a, 204 b, 204 c, 204 d.
In some embodiments, grab hole 142 a-b that forms in square sidewalls 112 a-b provides a surface area for gripping and carrying box. Grab hole 142 a-b may have a curved shape that fits the hand. In one embodiment, square sidewalls 112 a-b are disposed in a spaced-apart, parallel relationship from each other, and in a generally perpendicular relationship to rectangular sidewalls 104 a-b. In one non-limiting embodiment, square sidewalls 112 a-b have a length of about 11 11/16″, and a width of about 11″.
Box assembly 100 provides a unique sidewall construction that utilizes two different dimensions of sidewalls arranged in a generally rectangular shape with fold over tabs, which adds strength to the vertices and corners of box assembly 100. This helps reduce the need for fastening mechanisms, such as metallic staples and cloth tape to reinforce the vertices and corners of the box assembly 100.
In addition, box assembly provides a fold over tab 140 that is configured to help create a box assembly 100 with greater vertical and lateral support (FIG. 1). Fold over tab 140 extends longitudinally along rectangular lateral edges 106 a, 106 b of rectangular sidewalls 104 a, 104 b. Fold over box 140 comprises an adhesive that helps fasten sidewalls together in assembled box assembly. Adhesive 158 may include glue on one side of fold over tab. Though in other embodiments, adhesive may include a staple, a weld, a nail, and the like.
In one embodiment, fold over tab 140 is configured to fold over an outer corner edge of box assembly, extending longitudinally along the outer lateral edge of the constructed box assembly. The adhesive 158 on fold over tab serves to fasten the sidewalls of the box assembly together. Fold over tab 140 also creates an outer bulge that helps in separating multiple box assemblies stacked into each other. In one non-limiting embodiment, fold over tab 140 has a width of about 1⅝″.
FIG. 3 illustrates a top view of the box assembly 100, showing top and bottom flaps 120 a-b, 126 a-b, 130 a-b, 136 a-b in an open position. As illustrated, box assembly 100 includes two die-cut top rectangular flaps 120 a, 120 b hingedly connected by a top score line 122 along the top edge of the rectangular sidewalls 104 a-b. Rectangular flaps 120 a-b laterally extend out past the width of rectangular sidewalls 104 a-b to create a width difference 800. Width difference 800 facilitates machine assemblage of corrugated box by providing a flap surface area to grab during assemblage folding.
Top rectangular flaps form a pair of top locking slots 124 a, 124 b, 124 c, 124 d utilized to intimately engage correlating top locking tongues 132 a-d in the top square flaps 130 a-b to construct the top portion of box assembly 100. The tongue and slot form an intimate relationship, where the tongue slides into the slot and remains affixed due to frictional forces and the weight of box assembly 100 and contents therein. This works to close the top of box assembly 100.
The interlocking slots 124 a-d and tongues 132 a-d also prevent tucking, as the flaps can be more easily accessed, and the packer does not have to put hands into the interior of the box to engage and disengage the flaps to a closed or open position. The flaps are easily accessed from the outside of the box assembly 100. In one non-limiting embodiment, top flaps have a width of about 4⅛″, and bottom flaps have a width of about 5″.
FIG. 4 illustrates top locking tongues 132 a-d extending from top flaps, serving as stabilizers to support multiple boxes in stacked arrangement. Additionally, each top rectangular flap comprises two top stacking tabs 150 a, 150 b, 150 c, 150 d that extend from the top rectangular flaps 120 a-b. Stacking tabs 150 a-d are defined by a square shape that is sized and dimensioned to intimately engage corresponding stacking holes 152 a-d. Stacking tabs 150 a-d support a linear, stacked arrangement of box assemblies.
Looking now at FIG. 5, box assembly further comprises two die-cut bottom rectangular flaps 126 a, 126 b that hingedly connect, through bottom score lines 128, along the bottom edge of the rectangular sidewalls. Each bottom rectangular flap 126 a-b forms two bottom locking slots 146 a, 146 b, 146 c, 146 d proximal to the periphery of the rectangular flap 126 a-b. Bottom locking slots 146 a-d intimately engage bottom locking tongues 148 a, 148 b, 148 c, 148 d of bottom square flaps 136 a-b to construct bottom portion of box. In one non-limiting embodiment, top flaps have a width of about 4⅛″, and bottom flaps have a width of about 5″.
This unique interlocking mechanism serves to significantly increase the strength of box assembly 100 when fully assembled and closed. The interlocking mechanism also works to provide additional rigidity to sidewalls on each of the corners when the box assembly 100 is fully assembled, without utilizing additional support means.
Looking now at a bottom view of box assembly 100 in FIG. 6, two bottom stacking holes 152 a, 152 b, 152 c, 152 d form in each bottom rectangular flap 126 a, 126 b. Bottom stacking holes 152 a-d form an intimate relationship with top stacking tabs 150 a-d to enable stacking multiple boxes. Top stacking tabs 150 a-d engage bottom stacking holes 152 a-d to help in stabilizing the stacking of multiple box assemblies.
In one non-limiting embodiment, the two bottom rectangular flaps 126 a-b and the two bottom square flaps 136 a, 136 b form at least one air hole 144 a, 144 b, 144 c, 144 d, 144 e, 144 f, 144 g, 144 h. Air hole 144 a-h can be useful for storing produce and other perishable items. Air holes may have circular, rectangular, elongated, ovular, or irregular shapes.
Looking back at FIG. 2, box assembly includes two die-cut top square flaps 130 a, 130 b that are hingedly connected by the top score line 122 along the top edge of the square sidewalls. Top square flaps 130 a-b form a pair of top locking tongues 132 a, 132 b, 132 c, 132 d defined by a heel portion 134 a, 134 b adapted to lock under the corresponding and adjacent top locking slots 124 a-d that form in top rectangular flaps 120 a-b. This interlocking arrangement allows for construction of top portion of box assembly 100. In one non-limiting embodiment, top flaps have a width of about 4⅛″, and bottom flaps have a width of about 5″.
As FIG. 7 shows, box assembly further comprises two die-cut bottom square flaps 136 a, 136 b hingedly connected by the bottom score line along the square bottom edge 118 of square sidewalls 112 a-b. Each bottom square flap 136 a-b comprises two bottom locking tongues 148 a, 148 b, 148 c, 148 d that intimately engage bottom square flaps 136 a-b to construct bottom portion of box. As FIG. 8 shows, each bottom square flap 136 a-b forms two end stacking holes 200 a, 200 b, 200 c, 200 d that receive the top locking tongues 132 a-d such that multiple box assemblies can be stacked in a stable manner. In some embodiments, bottom square flaps 136 a-b may form a bottom score line 156 a, 156 b.
Further, as FIG. 8 illustrates, box assembly 100 includes two die-cut top rectangular flaps 120 a, 120 b hingedly connected by a top score line 122 along the top edge of the rectangular sidewalls 104 a-b. Rectangular flaps 120 a-b laterally extend out past the width of rectangular sidewalls 104 a-b to create a width difference 800. Width difference 800 facilitates machine assemblage of corrugated box by providing a flap surface area to grab during assemblage folding. In one non-limiting embodiment, width difference is at least ½″.
FIG. 9 illustrates a flowchart of an exemplary method 900 for assembling a corrugated box assembly with combination self-locking lid and tab-style fold over tab. As shown back in FIG. 2, the sidewalls, flaps, and interlocking tongues, stacking tabs, slots, and stacking holes of box blank 102 are flat when collapsed. However, when fully assembled, box assembly 100 forms a generally rectangular cross-section. Method 900 for assembly is relatively straight forward, as box assembly 100 is manipulated to a generally rectangular, upright positon, the panels on both open ends are folded down and interlocked through use of sidewalls, flaps, and interlocking tongues, stacking tabs, slots, and stacking holes.
In some embodiments, method 900 may include an initial Step 902 of providing a generally flat box blank, the box blank having: two rectangular sidewalls; two square sidewalls; four corner sidewalls, whereby the rectangular and square sidewalls joining at the lateral edges in an alternating arrangement to form an enclosed region defined by a rectangular cross section and four parallel outer edges; at least one elongated, L-shaped fold over tab, the fold over tab being longitudinally attached along the parallel outer edges; two die-cut top rectangular flaps hingedly connected by a top score line along the top edge of the rectangular sidewalls; two die-cut top square flaps hingedly connected by the top score line along the top edge of the square sidewalls; and two die-cut bottom square flaps hingedly connected by the bottom score line along the bottom edge of the square sidewalls.
Method 900 further comprises a Step 904 of folding the rectangular sidewalls towards each other, whereby the box assembly is partially formed. The sidewalls may fold along an indented crease or score line forming in the box blank. A Step 906 includes folding the square sidewalls towards each other, whereby the lateral edges of the rectangular and square sidewalls engage. A rectangular cross section forms at this point.
In some embodiments, a Step 908 comprises folding the fold over tab along the parallel lateral edges of the partially formed box assembly, whereby the adhesive helping to fasten the sidewalls together. The fold over tab is folded to extend longitudinally along the outer lateral edge of the constructed box assembly. The adhesive on the fold over tab, which may include glue, staples, a weld, and the like, serves to fasten the sidewalls of the box assembly together. The fold over tab also creates an outer bulge that helps in separating multiple box assemblies stacked into each other.
In some embodiments, a Step 910 may include folding the bottom rectangular flaps and the bottom square flaps inwardly. The bottom flaps come together to form a bottom portion of the box assembly. A Step 912 includes interlocking a bottom locking tongue from the bottom square flap with a corresponding and adjacent bottom locking slots from the bottom rectangular flap. The tongue and slot form an intimate relationship, where the tongue slides into the slot and remains affixed due to frictional forces and the weight of the box assembly and contents therein. In some embodiments, a Step 914 may include filling an enclosed region of the box assembly with an object.
In some embodiments, a Step 916 comprises folding the top rectangular flaps and the top square flaps inwardly. Method 900 may further comprise a Step 918 of interlocking a top locking tongue from the top square flap with a corresponding and adjacent top locking slots from the top rectangular flap, whereby the box assembly 100 is fully constructed and defined by six faces and twelve edges. A final Step 920 includes stacking multiple box assemblies, whereby a top stacking tabs intimately engage a bottom stacking hole in the sidewalls and flaps. This is effective in supporting boxes stacked on their flaps. However, when box assemblies are stacked into each other, fold over tab 140, which extends along the outer corner edge of assembled box, creates a bulge in the stacked boxes that allows for easy separation.
Although the process-flow diagrams show a specific order of executing the process steps, the order of executing the steps may be changed relative to the order shown in certain embodiments. Also, two or more blocks shown in succession may be executed concurrently or with partial concurrence in some embodiments. Certain steps may also be omitted from the process-flow diagrams for the sake of brevity. In some embodiments, some or all the process steps shown in the process-flow diagrams can be combined into a single process.
These and other advantages of the invention will be further understood and appreciated by those skilled in the art by reference to the following written specification, claims and appended drawings.
Because many modifications, variations, and changes in detail can be made to the described preferred embodiments of the invention, it is intended that all matters in the foregoing description and shown in the accompanying drawings be interpreted as illustrative and not in a limiting sense. Thus, the scope of the invention should be determined by the appended claims and their legal equivalence.

Claims

What is claimed is:

1. A corrugated box assembly with combination self-locking lid and tab-style fold over tab, the assembly comprising:

a box blank having:

two rectangular sidewalls defined by a pair of rectangular lateral edges, a rectangular top edge, and a rectangular bottom edge;

two square sidewalls defined by a pair of square lateral edges, a square top edge, a square bottom edge, the rectangular and square sidewalls joining at the lateral edges in an alternating arrangement to form an enclosed region defined by a rectangular cross section and four parallel outer edges;

at least one fold over tab longitudinally attached along the rectangular lateral edges of at least one of the rectangular sidewalls, fold over tab comprising an adhesive, whereby fold over tab folds along the parallel outer edges of constructed box assembly;

two top rectangular flaps hingedly connected by a top score line along the top edge of the rectangular sidewalls, the top rectangular flaps forming a pair of top locking slots, each top rectangular flap comprising two top stacking tabs, the top stacking tabs extendable from the top rectangular flaps;

two bottom rectangular flaps hingedly connected by bottom score lines along the bottom edge of the rectangular sidewalls, each bottom rectangular flap forming two bottom locking slots, each bottom rectangular flap forming two bottom stacking holes, the bottom stacking holes adapted to intimately receive the top stacking tabs of the top rectangular flaps, whereby the top stacking tabs engage the bottom stacking holes to help stabilize stacking multiple box assemblies;

two top square flaps hingedly connected by the top score line along the top edge of the square sidewalls, the top square flaps forming a pair of top locking tongues defined by a heel portion, the top locking tongues adapted to lock under the corresponding and adjacent top locking slots that form in the top rectangular flaps; and

two bottom square flaps hingedly connected by the bottom score line along the bottom edge of the square sidewalls, each bottom square flap comprising two bottom locking tongues, the bottom locking tongues adapted to lock under the corresponding and adjacent bottom locking slots that form in the bottom rectangular flaps, each bottom square flap forming two end stacking holes adapted to receive the top locking tongues.

2. The box assembly of claim 1, wherein the square sidewalls are defined by at least one grab hole.

3. The box assembly of claim 1, wherein the top rectangular flaps are die-cut.

4. The box assembly of claim 1, wherein the bottom rectangular flaps are die-cut.

5. The box assembly of claim 1, wherein the two top square flaps are die-cut.

6. The box assembly of claim 1, wherein the two bottom square flaps are die-cut.

7. The box assembly of claim 1, wherein the two bottom rectangular flaps and the two bottom square flaps form at least one air hole.

8. The box assembly of claim 1, wherein the bottom square flaps form a bottom score line.

9. The box assembly of claim 1, wherein the box blank is defined by a cardboard or a plastic material.

10. The box assembly of claim 1, wherein the rectangular lateral edges are narrow and elongated.

11. The box assembly of claim 1, wherein the fold over tab is elongated and L-shaped.

12. The box assembly of claim 1, wherein the top locking tongues are indented in the top rectangular flaps.

13. The box assembly of claim 1, wherein the rectangular flaps laterally extend out past the width of the rectangular sidewalls to create a width difference.

14. The box assembly of claim 1, wherein a constructed configuration of the box blank is rectangular shape or a square shape.

15. The box assembly of claim 14, wherein the constructed configuration is defined by 6 faces and 12 edges.

16. A corrugated box assembly with combination self-locking lid and tab-style fold over tab, the assembly comprising:

a box blank having:

two square sidewalls defined by a pair of square lateral edges, a square top edge, a square bottom edge, the rectangular and square sidewalls joining at the lateral edges in an alternating arrangement to form an enclosed region defined by a rectangular cross section and four parallel outer edges, the square sidewalls further being defined by at least one grab hole;

at least one elongated, L-shaped fold over tab, the fold over tab being longitudinally attached along the parallel outer edges, one side of the fold over tab comprising an adhesive;

at least one elongated, L-shaped fold over tab longitudinally attached along the rectangular lateral edges of at least one of the rectangular sidewalls, fold over tab comprising an adhesive, whereby fold over tab folds along the parallel outer edges of constructed box assembly;

two die-cut top rectangular flaps hingedly connected by a top score line along the top edge of the rectangular sidewalls, the top rectangular flaps forming a pair of top locking slots, each top rectangular flap comprising two top stacking tabs, the top stacking tabs extendable from the top rectangular flaps;

two die-cut bottom rectangular flaps hingedly connected by bottom score lines along the bottom edge of the rectangular sidewalls, each bottom rectangular flap forming two bottom locking slots, each bottom rectangular flap forming two bottom stacking holes, the bottom stacking holes adapted to intimately receive the top stacking tabs of the top rectangular flaps, whereby the top stacking tabs engage the bottom stacking holes to help stabilize stacking multiple box assemblies, the two bottom rectangular flaps forming at least one air hole;

two die-cut top square flaps hingedly connected by the top score line along the top edge of the square sidewalls, the top square flaps forming a pair of top locking tongues defined by a heel portion, the top locking tongues adapted to lock under the corresponding and adjacent top locking slots that form in the top rectangular flaps, the two bottom square flaps forming the at least one air hole; and

two die-cut bottom square flaps hingedly connected by the bottom score line along the bottom edge of the square sidewalls, each bottom square flap comprising two bottom locking tongues, the bottom locking tongues adapted to lock under the corresponding and adjacent bottom locking slots that form in the bottom rectangular flaps, each bottom square flap forming two end stacking holes adapted to receive the top locking tongues, the bottom square flaps forming a bottom score line.

17. The box assembly of claim 16, wherein the box blank is defined by a cardboard or a plastic material.

18. The box assembly of claim 16, wherein a constructed configuration of the box blank is rectangular shape or a square shape.

19. The box assembly of claim 16, wherein the rectangular lateral edges are narrow and elongated.

20. A method for constructing a corrugated box assembly with combination self-locking lid and tab-style fold over tab, the method comprising:

providing a generally flat box blank, the box blank having:

two rectangular sidewalls;

two square sidewalls;

four corner sidewalls, whereby the rectangular and square sidewalls joining at the lateral edges in an alternating arrangement to form an enclosed region defined by a rectangular cross section and four parallel outer edges;

at least one elongated, L-shaped fold over tab, one side of the fold over tab comprising an adhesive;

two die-cut top rectangular flaps hingedly connected by a top score line along the top edge of the rectangular sidewalls;

two die-cut top square flaps hingedly connected by the top score line along the top edge of the square sidewalls;

two die-cut bottom square flaps hingedly connected by the bottom score line along the bottom edge of the square sidewalls;

folding the rectangular sidewalls towards each other, whereby the box assembly is partially formed;

folding the square sidewalls towards each other, whereby the lateral edges of the rectangular and square sidewalls engage;

folding the fold over tab along the parallel lateral edges of the partially formed box assembly, whereby the adhesive helping to fasten the sidewalls together;

folding the bottom rectangular flaps and the bottom square flaps inwardly;

interlocking a bottom locking tongue from the bottom square flap with a corresponding and adjacent bottom locking slots from the bottom rectangular flap;

filling an enclosed region of the box assembly with an object;

folding the top rectangular flaps and the top square flaps inwardly;

interlocking a top locking tongue from the top square flap with a corresponding and adjacent top locking slots from the top rectangular flap, whereby the box assembly is fully constructed and defined by six faces and twelve edges; and

stacking multiple box assemblies, whereby a top stacking tabs intimately engage a bottom stacking hole in the sidewalls and flaps.