BR102021004745A2 - BOX, GROSS PIECE AND FOLDING METHOD - Google Patents

Abstract

box, blank and folding method. a box defining a bottom wall, a first side wall coupled to the bottom wall, a second side wall disposed opposite the first side wall and coupled to the bottom wall, a first end wall coupled to both the bottom wall and the first and second walls sides, and a second end wall disposed opposite the first end wall and coupled to both the bottom wall and the first and second side walls. the box being formed from a blank having a first side and a second side disposed opposite said first side. the first side defining the inner surface of the bottom wall and the inner and outer surfaces of the first and second side walls and the first and second end walls.

Description

BOX, GROSS PIECE AND FOLDING METHOD FUNDAMENTALS 1. FIELD

[0001] The present invention relates to a box, a blank and method for forming the box, and more particularly to a box formed from a blank with a first side and a second side, the first side defining the inner surface of the bottom wall of the box and the inner and outer surfaces of the side and end walls of the box.

2. DESCRIPTION OF RELATED TECHNIQUE

[0002] Reusable plastic boxes (RPCs) are widely used in the food industry to transport, store and distribute food such as fresh fruits and vegetables. Advantages of RPCs include a stackable interlock design, a “ready to display” design that can significantly reduce storage time, and a collapsible design that reduces storage space and transportation costs, allowing containers to be folded when not are in use. Disadvantages of RPCs include the risk of loss/theft and a relatively high cost resulting from the need to wash and sanitize the RPCs after each use and transport them to a facility for that purpose.

[0003] More recently, single-use corrugated alternatives to RPCs have been used. FIG. 4A shows a blank 90 for forming a box 300 according to the prior art. Blank 90 includes a treated side and an untreated side. The treated side can be printed with, for example, informational or promotional information, such as a brand name or logo, and/or treated with one or more coatings, such as, for example, one or more waterproof coatings. The outer side panels 114, 118 are folded around the bottom panel 116 to form the outer side walls of the box 300. The inner side panels 112, 120 are folded into the box 300 to form the inner side walls of the box. The inner end flaps 122, 124, 138, 140 are bent to form the inner end walls of the box 00. The outer end flaps 126, 128, 134, 136 are sandwiched between the inner end flaps and the end panels 130, 132 which bend to form the outer end walls of the box. Side flaps F11 and F12 fold down inside the box to form stacking tabs that protrude from a top edge of the side walls of the box. C15 cutouts on the inner and outer end flaps line up with each other and with the C17 cutouts to form loops that extend completely along the end walls of the box.

[0004] There are several disadvantages to the approach taken with box 300. First, box 300 does not provide a smooth or visually clean interior as a result of the inwardly folded stacking flaps and inner end flaps. Irregularities on the inner surface of the box 300 caused by these structures can also increase the risk of damage to the box contents. These irregularities can also interfere with the visibility and/or clarity of any content printed on the inside sides and end walls. The arrangement of box 300 also results in the lower inner surface of the box being formed from the untreated side of the blank. This setup can be considered aesthetically unpleasant and/or represent a missed opportunity to present the brand or other promotional content to customers. Finally, the configuration of the handles, which extend completely over the end walls of the box, can increase the risk of damage caused by “pokes” in the box's contents. The present invention aims to overcome or at least alleviate the problems of the prior art.

[0005] The conventional techniques were considered satisfactory for the intended purpose. However, there is an ever-present need for improved systems and methods for boxes, blanks and folding methods. This disclosure provides a solution to that need.

SUMMARY

[0006] A box for holding a plurality of items includes a bottom wall, a first side wall coupled to the bottom wall, a second side wall disposed opposite the first side wall and coupled to the bottom wall, a first end wall coupled to both of the bottom wall and the first and second side walls, and a second end wall disposed opposite the first end wall and coupled to both the bottom wall and the first and second side walls. Each bottom wall, first and second side walls, and first and second end walls both define an inner surface disposed adjacent an inner space defined by the box and an outer surface.

[0007] The box can be formed from a blank that has a first surface and a second surface disposed opposite the first surface. The inner surface of the bottom wall and the inner and outer surfaces of the first and second side walls and first and second end walls may each be defined substantially entirely by the first surface. The first side wall, second side wall, first end wall, and second end wall may define a top edge opposite the bottom wall, where the top edge defines rectangular portions that follow a rectangle and where the top edge defines at least one edge portion that is oblique with respect to the rectangular portions.

[0008] The blank may include a plurality of main panels hinged together in a linear series, the plurality of main panels comprising first and second inner side panels, first and second outer side panels, and a bottom panel. The first outer side panel can be hingedly connected to the first inner side panel, the first inner side panel can be hingedly connected to the bottom panel, the bottom panel can be hingedly connected to the second inner side panel and the second panel Inner side can be hingedly connected to the second outer side panel. The first outside side panel can define the outside surface of the first side wall, the first inside side panel can define the inside surface of the first side wall, the bottom panel can define the outside and inside surfaces of the bottom wall, the second inside panel can define the inner surface of the second side wall and the second outer side panel may define the outer surface of the second side wall. A first and second end panel may be hingedly connected to the bottom panel at respective opposite ends of the bottom panel, wherein the first end panel defines the inner surface of the first end wall and wherein the second end panel defines the inner surface of the second end wall.

[0009] The blank may include first and second inner end flaps hingedly connected to the first inner side panel at respective opposite ends of the first inner side panel. The blank may include third and fourth inner end flaps hingedly connected to the second inner side panel at respective opposite ends of the second inner side panel. The blank may include first and second outer end flaps hingedly connected to the first outer side panel at respective opposite ends of the first outer side panel. The third and fourth outer end flaps may be hingedly connected to the second outer side panel at respective opposite ends of the second outer side panel.

[0010] The first and third outer end flaps may define the outer surface of the first end wall along a first perimeter length of the top edge. The first end panel may be adjacent to the first and third inner end flaps and may define a second length along the top edge that is longer than the first length such that the first end panel curves inward to define at least one edge portion that is oblique with respect to the rectangular portions. The first inner end flap is connectable to the first inner side panel by the first oblique corner panel. The third inner end flap is connectable to the second inner side panel via a second oblique corner panel, wherein the first and second oblique corner panels may define at least one edge portion that is oblique relative to the rectangular portions. .

[0011] The first outer end flap can be foldably connected directly to the first outer side panel by a fold line without an intervening oblique corner panel, wherein the first oblique corner panel, the first outer side panel and the first outer end flap surrounds a first triangular corner compartment. The third outer end flap can be connected directly to the second outer side panel by a fold line without an intervening corner panel, wherein the second oblique corner panel, second outer side panel, and third outer end flap surround a second triangular corner compartment. The first and second triangular corner compartments can form a first pair of compartments at a first end of the interior space. The interior space may have a second end opposite the first end, wherein the second end includes a second pair of compartments mirroring the first pair of compartments.

[0012] The first outer end flap may be connected to the first outer side panel by a third oblique corner panel which overlaps the first oblique corner panel and forms a portion of the outer surface. The third outer end flap may be connected to the second outer side panel by a fourth oblique corner panel which overlaps the second oblique corner panel and forms a portion of the outer surface. The first, second, third and fourth oblique corner panels may form a first pair of oblique corners of the inner and outer surfaces at a first end of the inner space. The interior space may have a second end opposite the first end that includes a second pair of slanted corners mirroring the first pair of slanted corners.

[0013] A method of forming a box includes providing a blank as described above. The method includes folding the first outer side panel back over the first inner side panel and securing it thereto such that the second side surfaces of the first outer side panel blank and the first inner side panel are mated in a relationship. of face contact. The method includes folding the second outer side panel back over the first inner side panel and securing it thereto such that the second side surfaces of the second outer side panel blank and the second inner side panel are mated in a relationship. of face contact. The first outer side panel and the first inner side panel are folded around the bottom panel to form a first side wall of the box, an outer surface of the first side wall being defined by a first side surface of the first panel blank. outer side and an inner surface of the first side wall being defined by a first side surface of the first inner side panel blank, a first side surface of the lower panel blank defining an inner surface of a bottom wall of the box. The method includes folding the second outer side panel and the second inner side panel around the bottom panel to form a second side wall of the box, an outer surface of the second side wall being defined by a first side surface of the box blank. second outer side panel and an inner surface of the second side wall being defined by a first side surface of the second inner side panel blank. The first and second end panels are folded around the bottom panel to form respective first and second end walls of the box, a first side surface of the first end panel blank defining an inner surface of the first end wall a first side surface of the second end panel blank defining an inner surface of the second end wall. The method includes folding the first and third inner end flaps and the first and third outer end flaps into an overlapping arrangement with a second side of the first end panel blank and securing them thereto, a first surface. side of the first and third outer end flap blank defining an outer surface of the first end wall. The second and fourth inner end tabs and the second and fourth outer end tabs are folded in an overlapping arrangement with a second side of the second end panel blank and securing them thereto, a first side surface of the piece. blank of the second and fourth outer end flaps defining an outer surface of the second end wall such that the first side wall, second side wall, first end wall, and second end wall define an upper edge opposite the wall. bottom, wherein the top edge defines rectangular portions that follow a rectangle, and wherein the top edge defines at least a portion of the edge that is oblique with respect to the rectangular portions.

[0014] Folding the first, second, third and fourth inner end flaps and folding the first, second, third and fourth outer end flaps may include arching the first end panel inwardly to define at least a portion of the edge that is oblique with respect to rectangular portions. It is also contemplated that the method may include forming a first triangular corner compartment wherein the first oblique corner panel, first outer side panel, and first outer end flap surround a first triangular corner compartment and form a second compartment. a triangular corner panel wherein the second oblique corner panel, second outer side panel, and third outer end flap surround a second triangular corner compartment. It is further contemplated that the method may include folding the first outer end flap, wherein the first outer end flap is connected to the first outer side panel by a third oblique corner panel that overlaps a first oblique corner panel and shape. a portion of the outer surface and folding the third outer end flap wherein the third outer end flap is connected to the second outer side panel by a fourth oblique corner panel which overlaps a second oblique corner panel and forms a portion of the outer surface.

[0015] These and other features of the systems and methods of the subject disclosure will become more readily apparent to those skilled in the art from the following detailed description of the preferred embodiments taken in conjunction with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0016] So that those skilled in the art to which the subject disclosure pertains will readily understand how to make and use the devices and methods of the subject disclosure without undue experimentation, preferred embodiments thereof will be described in detail in this document below with reference to certain figures, in which:

[0017] FIG. 1 is a plan view of a blank for forming a box in accordance with an embodiment of this disclosure;

[0018] FIG. 2 is a perspective view of a box formed from the blank of FIG. 1;

[0019] FIGS. 3A-3E are perspective views showing various steps in construction of the box of FIG. two;

[0020] FIG. 4A is a plan view of a blank for forming a box according to the prior art;

[0021] FIG. 4B is a perspective view of a prior art box formed from the blank of FIG. 4A;

[0022] FIG. 5 is a perspective view of another embodiment of a box in accordance with this disclosure, showing a curved edge portion;

[0023] FIG. 6 is a plan view of a blank to form the box of Fig. 5;

[0024] FIG. 7 is a perspective view of another embodiment of a box in accordance with this disclosure, showing triangular corner compartments;

[0025] FIG. 8 is a plan view of a blank to form the box of Fig. 7;

[0026] FIG. 9 is a perspective view of another embodiment of a box in accordance with this disclosure, showing an eight-sided outer surface; and

[0027] FIG. 10 is a plan view of a blank to form the box of Fig. 9.

DETAILED DESCRIPTION OF THE PREFERRED MODALITIES

[0028] Detailed descriptions of specific packaging modalities, blanks and cartons are disclosed here. It will be understood that the disclosed embodiments are merely examples of the manner in which certain aspects of the invention may be implemented and do not represent an exhaustive list of all ways in which the invention may be carried out. As used in this document, the word "exemplary" is used extensively to refer to modalities that serve as illustrations, specimens, models, or patterns. Indeed, it will be understood that the packages, blanks and boxes described herein may be incorporated in various alternative forms. Figures are not necessarily to scale and some features may be exaggerated or minimized to show details of particular components. Well-known components, materials, or methods are not necessarily described in detail, in order to avoid obscuring the present disclosure. Any specific structural and functional details disclosed herein are not to be construed as limiting, but only as a basis for the claims and as a representative basis for teaching one skilled in the art to employ the invention in a different manner.

[0029] In the embodiments detailed herein, the term "box" refers, for the non-limiting purpose of illustrating the various features of the invention, to a container for transporting, storing and/or distributing items, such as, for example, fresh produce. However, it is contemplated that the teachings of the invention can be applied to various containers suitable for carrying a wide variety of articles.

[0030] With reference to FIG. 1, a first blank 10 for forming a box 200 is shown (see FIG. 2). The blank 10 is formed from a sheet of suitable substrate. It is to be understood that, as used herein, the term "suitable substrate" includes all types of foldable sheet material such as cardboard, corrugated board, paperboard, plastic, combinations thereof and the like. It should be recognized that one or another blank part number can be employed, for example, to supply the box described in more detail below.

[0031] In a preferred embodiment, the blank 10 is formed of a paperboard, corrugated board or cardboard in which one side of the blank, referred to herein as the "treated side", is printed and/or treated with a or more coatings, such as for example one or more waterproof coatings and/or one or more coatings designed to provide a smooth and/or visually attractive surface (for example a white or other colored surface). In one or more embodiments, informational or promotional material, such as a brand name or logo, may be printed on the treated side.

[0032] With reference to FIG. 1, blank 10 is generally rectangular in shape and includes a plurality of main panels 12, 14, 16, 18, 20 hinged in a linear series. End panels 30, 32 and end flaps 22, 24, 26, 28, 34, 36, 38, 40 are hingedly connected at their respective ends to a corresponding one of the main panels. In a configured condition, the box 200 forms an open-top structure having a base or bottom wall, first and second side walls, and first and second end walls.

[0033] The blank 10 includes a first outer side panel 12 hinged to a first inner side panel 14 by a fold line 42. The first inner side panel 14 is hinged to a bottom panel 16 by a fold line 44. Bottom panel 16 is hinged to a second inner side panel 18 by a fold line 46. Second inner side panel 18 is hinged to a second outer side panel 20 by a fold line 48.

[0034] The first outer side panel 12 is also hinged at a first end to the first outer end flap 22 via the fold line 50. The first outer side panel 12 is hinged at a second end to the second outer end flap 24 via fold line 60.

[0035] The first inner side panel 14 is also hinged at a first end to the first inner end flap 26 through fold line 52. The first inner side panel 14 is hinged at a second end to the second inner end flap 28 via fold line 62.

[0036] The bottom panel 16 is also hinged at a first end to the first end panel 30 via the fold line 54. The bottom panel 16 is hinged at a second end to the second end panel 32 via the fold line 64.

[0037] The second inner side panel 18 is also hinged at a first end to a third inner end flap 34 through fold line 56. The second inner side panel 18 is hinged at a second end to a fourth inner end flap 36 via fold line 66.

[0038] The second outer side panel 20 is also hinged at a first end to a third outer end flap 38 via fold line 58. The second outer side panel 20 is hinged at a second end to a fourth end flap external 40 via bend line 68.

[0039] In the illustrated embodiment, the various end flaps/end panels are defined by, and separated from the end flaps/adjacent panels by, cut lines extending from opposite ends of a corresponding one of the fold lines 42 , 44, 46, 48.

[0040] The first inner side panel 14 includes a plurality of first side flaps F1. The first side flaps F1 interrupt the fold line 42. Each of the first side flaps F1 is defined by a generally U-shaped parting line extending from the fold line 42 to an interior of the first outer side panel 12. illustrated embodiment, blank 10 includes two first side flaps F1. The first F1 side flaps are generally trapezoidal in shape. The first side flaps F1 are hingedly connected to a remaining portion of the first inner side panel 14 via respective fold lines 43a, 43b. Fold lines 43a, 43b are generally parallel to fold line 42, but offset from fold line 42 toward first outer side panel 12.

[0041] Likewise, the second inner side panel 18 includes a plurality of second side flaps F2 which may generally mirror the first side flaps F1. Second side flaps F2 interrupt fold line 48. Each of second side flaps F2 is defined by a generally U-shaped parting line extending from fold line 48 to an interior of second outer side panel 20. In the illustrated embodiment, blank 10 includes two second side flaps F2. The second side flaps are usually trapezoidal in shape. The second side flaps F2 are hingedly connected to a remaining portion of the second inner side panel 18 via respective fold lines 49a, 49b. Fold lines 49a, 49b are generally parallel to fold line 48, but offset from fold line 48 toward second outer side panel 20.

[0042] The blank 10 includes a plurality of first side openings C1. In the illustrated embodiment, blank 10 includes two first side openings C1. Each of the first side openings C1 is generally rectangular or trapezoidal in shape. Each of the first side openings C1 interrupts the fold line 44 and is arranged so that the opening extends to both the bottom panel 16 and the first inner side panel 14. Each of the first side openings C1 is aligned with a corresponding one of the first side flaps F1 in relation to a longitudinal axis of the blank 10.

[0043] Likewise, the blank 10 includes a plurality of second side openings C2 which may generally mirror the first side openings C1. In the illustrated embodiment, blank 10 includes two second side openings C2. Each of the second side openings C2 is generally rectangular or trapezoidal in shape. Each of the second side openings C2 interrupts the fold line 46 and is arranged so that the opening extends to both the bottom panel 16 and the second inner side panel 18. Each of the second side openings C2 is aligned with a corresponding one of the second side flaps F2 with respect to a longitudinal axis of blank 10.

[0044] The blank 10 also includes at least one first end opening C3. The first end opening C3 is usually rectangular or trapezoidal in shape. The first end opening C3 interrupts the fold line 54 and is arranged so that the opening extends to both the bottom panel 16 and the first end panel 30.

[0045] The blank 10 also includes at least one second end opening C4 which may generally mirror the first end opening C3. The second end opening C4 is usually rectangular or trapezoidal in shape. Second end opening C4 interrupts fold line 64 and is arranged so that the opening extends to both bottom panel 16 and second end panel 32.

The end flaps 22, 24, 26, 28, 34, 36, 38, 40 each include a generally U-shaped C5 cutout disposed on an outer edge of the flap. The cutouts C5 of the first, second, third and fourth outer end flaps 22, 24, 38, 40 are configured to align and overlap the respective cutouts C5 of the first, second, third and fourth inner end flaps 26, 28, 34, 36 when the box is in the configured condition.

The end flaps 22, 24, 26, 28, 34, 36, 38, 40 each include a generally rectangular cutout C6 disposed on an outer corner edge of the flap. The C6 cutouts of the first, second, third and fourth outer end flaps 22, 24, 38, 40 are configured to align with and overlap the respective C6 cutouts of the first, second, third and fourth inner end flaps 26, 28, 34, 36 when the box is in the configured condition. In addition, the various cutouts C6 are configured to align and overlap a corresponding portion of the first or second end opening C3, C4 when the box is in the configured condition.

[0048] The blank 10 also includes four inner end flap openings C7. Each of the inner end flap openings C7 has a generally elongated rectangular shape. Inner end flap openings C7 are disposed along a central length of and interrupt their respective fold lines 52, 62, 56, 66 so that the openings extend in both of their respective inner end flaps 26 , 28, 34, 36 and a respective one of the first and second inner side panels 14, 18. The inner end flap openings C7 can facilitate the overlapping folding arrangement of the inner and outer end flaps by removing some volume from the folded edges of the inner end flaps.

[0049] Returning to the construction of the box, as illustrated in FIG. 2, the box 200 can be formed by a series of sequential folding operations. The folding process is not limited to the one described below and can be changed according to specific manufacturing requirements.

[0050] The blank 10 is positioned with its treated surface facing upwards, as shown in FIG. 3A.

[0051] The glue or other adhesive treatment can be applied to the untreated surface of the first outer side panel 12 or, alternatively, to the untreated surface of the first inner side panel 14. The glue or other adhesive treatment is also applied to the untreated surface of tabs F1 or, alternatively, to a corresponding portion of the untreated surface of the first inner side panel 14. The glue or other adhesive treatment is also applied to the untreated surfaces of the first and second inner end tabs 26, 28 or, alternatively, to the untreated surfaces of the first and second outer end flaps 22, 24.

[0052] The glue or other adhesive treatment can be applied to the untreated surface of the second outer side panel 20 or, alternatively, to the untreated surface of the second inner side panel 18. The glue or other adhesive treatment is also applied to the untreated surface of the flaps F2 or, alternatively, to a corresponding portion of the untreated surface of the second inner side panel 18. The glue or other adhesive treatment is also applied to the untreated surfaces of the third and fourth inner end flaps 34, 36 or, alternatively, to the untreated surfaces of the third and fourth outer end flaps 38, 40.

[0053] The inner side panels 14, 18 are folded inwardly around their respective fold lines 44, 46, while the outer side panels 12, 20 are simultaneously folded back around their respective fold lines 42, 48. results in the partially constructed box shown in FIG. 3B.

[0054] Folding of blank 10 along fold lines 44, 46, 42, 48 is continued until the untreated surfaces of the respective inner side panels 14, 18 and outer side panels 12, 20 are placed in a face contact relationship to each other and fixed together to form the side walls of the box. The untreated surfaces of the inner end flaps 26, 28, 34, 36 are also placed in face contacting relationship with the untreated surfaces of the respective outer end flaps 22, 24, 38, 40 and secured thereto. The folding machine (not shown) may include a fixed "hood" positioned on each side of the partially mounted box over the side panels at the approximate height of the fully constructed side walls. As the side walls are folded into place, the flaps F1, F2 make contact with the hood, causing them to fold outward along the respective fold lines 43a, 43b, 49a, 49b until they are in one plane. substantially perpendicular to that of the side walls. This results in the partial construction shown in FIG. 3C.

[0055] The F1 flaps are then folded fully back around the fold lines 43a, 43b and in the openings in the first outer side panel 12 which were defined by the F1 flaps. These openings allow the untreated surfaces of the F1 tabs to be placed in face contacting relationship with an untreated surface of the first inner side panel 14. The untreated surfaces of the F1 tabs are secured to the untreated surface of the first inner side panel. 14. The flaps F2 are also folded fully back around the fold lines 49a, 49b and in the openings in the second outer side panel 20 that were defined by the flaps F2. These openings allow the untreated surfaces of the F2 flaps to be placed in face contacting relationship with an untreated surface of the second inner side panel 18. The untreated surfaces of the F2 flaps are secured to the untreated surface of the second inner side panel 18. These steps result in the partially constructed box shown in FIG. 3D.

[0056] The first end panel 30 is folded inwardly around the fold line 54, thereby orienting the first end panel 30 in a substantially vertical orientation. Second end panel 32 is folded inwardly about fold line 64, thereby orienting second end panel 32 in a substantially vertical orientation. These steps result in the partially constructed box shown in FIG. 3E.

[0057] The glue or other adhesive treatment can be applied to the treated surfaces of the first, second, third and fourth inner end flaps 26, 28, 34, 36 or, alternatively, to corresponding portions of the untreated surfaces of the first and second panels 30, 32. The first, second, third and fourth inner end flaps 26, 28, 34, 36 (along with the first, second, third and fourth outer end flaps 22, 24, 38, 40) are folded inwardly about respective fold lines 52, 62, 56, 66 so that the treated surfaces of the first and third inner end flaps 26, 34 are placed in face contacting relationship with the untreated surface of first end panel 30 and treated surfaces of second and fourth inner end flaps 28, 36 are placed in face contacting relationship with untreated surface of second end panel 32. Treated surfaces d the first and third inner end flaps 26, 34 are secured to the untreated surface of the first end panel 30. The treated surfaces of the second and fourth inner end flaps 28, 36 are secured to the untreated surface of the second end panel 32. These steps result in the fully constructed box as shown in FIG. two.

[0058] Referring again to FIG. 2, the folded flaps F1, F2 project upward from a top edge of the side walls of the box, forming stacking tabs that are configured to facilitate secure stacking of multiple boxes. The stacking flaps of a first box are configured to be received within side openings C1, C2 of a second box. In addition to facilitating the stacking of the box, the side openings C1, C2 can also promote ventilation and/or drainage of the box. End openings C3, C4 and overlapping cutouts C6 can also facilitate stacking, venting and/or draining the box. The overlapping cutouts C5 of the first inner and outer end flaps 26, 22 align with the overlapping cutouts C5 of the third inner and outer end flaps 34, 38 to form a first loop structure H1. Overlapping cutouts C5 of the second inner and outer end flaps 28, 24 align with overlapping cutouts C5 of the fourth inner and outer end flaps 36, 40 to form a second loop structure H2 (not shown) which generally can mirror the frame structure. handle H1. The H1, H2 handle frames are configured to receive the user's fingers for ease of lifting and carrying the box. In the illustrated embodiment, the loop structures H1, H2 do not extend completely through the end walls of the box. Such a configuration may be desirable to prevent a user's fingers from entering the interior of the box and hurting sensitive products or to prevent smaller items from spilling over the handles. In other embodiments, however, end panels 30, 32 may include handle cutouts aligned with cutouts C5 to create handle structures that extend completely through the end walls of the box.

[0059] Advantageously, blank 10 can produce a box 200 with a treated surface (eg print or water resistant coating) on all sides with the exception of the bottom surface of the base wall (i.e., the surface in which the box 200 rests) without the need to treat both sides of the blank 10, although in certain embodiments both sides of the blank can be treated. Thus, the inner and outer surfaces of the side walls and end walls, as well as the inner surface of the base wall, are all treated. As another advantage, the inner surfaces of the box's side and end walls can be substantially smooth and uninterrupted by bent edges, reducing the risk of damage to the fruit and providing a clean surface for presenting informational or promotional content.

[0060] Referring now to Figs. 5-6, a box 500 for holding a plurality of items includes a bottom wall 502, a first side wall 504 coupled to the bottom wall 502 along fold line 505, a second side wall 506 disposed opposite the first side wall 504, and coupled to bottom wall 502 along fold line 507, a first end wall 508 coupled to both bottom walls 502 along fold line 509, and first and second side walls 504, 506 along fold lines 511, 513 and a second end wall 510 disposed opposite the first end wall 508 and coupled to the bottom wall 502 and the first and second side walls 504, 506 along fold lines 515, 517 and 519, respectively. Each bottom wall 502, first and second side walls 504, 506, and first and second end walls 508, 510 both define an inner surface 572 disposed adjacent an inner space 580 defined by housing 500 and an outer surface 570.

[0061] The box 500 may be formed from a blank 520 having a first surface and a second surface disposed opposite the first surface, as described above, for example with reference to Figs. 1-2. The inner surface of the bottom wall 502 and the inner surfaces 525, 527, 529, 531 and outer surfaces 524, 526, 528, 530 of the first and second side walls 504, 506 and first and second end walls 508, 510 are each , defined substantially entirely by the first surface. First side wall 504, second side wall 506, first end wall 508, and second end wall 510 define an upper edge 540 opposite the lower wall, wherein the upper edge 540 defines rectangular portions 541 that follow a rectangle ( for example, as shown in Figs. 5-6), and wherein the upper edge 540 defines at least one edge portion 642 that is oblique relative to the rectangular portions.

[0062] The blank 520 comprises a plurality of main panels 521 hinged together in a linear series, the plurality of main panels 521 comprising first and second inner side panels 544, 546, first and second outer side panels 545, 547, and a bottom panel, 548. First outer side panel 545 is hingedly connected to first inner side panel 544 along fold line 650 (forming a portion of top edge 540), first inner side panel 544 is hingedly connected. hinged to bottom panel 548 along fold line 505, bottom panel 548 is hingedly connected to second inner side panel 546 along fold line 507 and second inner side panel 546 is hingedly connected to second panel outer side 547 along fold line 652 (forming a portion of top edge 540). First outer side panel 545 defines outer surface 524 of first side wall 504, first inner side panel 544 defines inner surface 525 of first side wall 504, bottom panel 548 defines outer 523 and inner surfaces 522 of bottom wall 502 , second inner side panel 546 defines inner surface 527 of second side wall 506 and second outer side panel 547 defines outer surface 526 of second side wall 506. First and second end panels 532, 534 are fashionly connected. hinged to bottom panel 548 at respective opposite ends of bottom panel 548 along fold lines 509, 515, wherein the first end panel 532 defines the inner surface 529 of the first end wall 508 and wherein the second end panel 534 defines the inner surface 531 of the second end wall 510.

[0063] The blank 520 may include a first and second inner end tabs 550, 552 pivotally connected to the first inner side panel 544 at respective opposite ends of the first inner side panel 544 along fold lines 651, 653. Blank 520 may include third and fourth inner end flaps 554, 556 hingedly connected to second inner side panel 546 at respective opposite ends of second inner side panel 546, along fold lines 655, 657. Blank 520 may include first and second outer end tabs 558, 560 hingedly connected to first outer side panel 545 at respective opposite ends of first outer side panel 545 along fold lines 511, 517. The third and fourth outer end flaps 562, 564 are hingedly connected to the second outer side panel 547 at respective opposite ends of the second outer side panel 547 along fold lines 513, 519.

The first and third outer end flaps 558, 562 may define the outer surface 528 of the first end wall 508 along a first perimeter length P1 of the upper edge 540. The first end panel 532 may be adjacent to the first and third inner end flaps 550, 554 and may define a second perimeter length P2 along the top edge 540 that is longer than the first length P1 such that the first end panel 532 curves inwardly to define the at least one edge portion 642 which is oblique with respect to the rectangular portions, which may be the case at both ends of the box 500, as indicated by the exaggerated double curved arrows in Fig. 6.

[0065] The bending procedure of blank 520 is similar to that described above in relation to Figs. 2 and 3A-E. Folding the first, second, third, and fourth inner end tabs 550, 552, 554, 556 and folding the first, second, third, and fourth outside end tabs 558, 560, 562, 564 may include arcing the first end panel 532 inward to define the at least one edge portion 541 that is oblique with respect to the rectangular portions and similarly curves the second end panel 534.

[0066] As shown in Figs. 7-8, a blank 720 and a box 700 similar to blank 520 and box 500 are shown. First inner end flap 750 is connected to first inner side panel 744 by first angled corner panel 742a along fold lines 751a and 751b. The third inner end flap 754 is connectable to the second inner side panel 746 through a second angled corner panel 742b along fold lines 755a and 755b, wherein the first and second angled corner panels 742a,b define at least one edge portion 742 that is oblique with respect to rectangular portions 741 of upper edge 740.

[0067] With continued reference to Figs. 7 and 8, the first outer end flap 758 is foldably connected directly to the first outer side panel 745 by a fold line 711 without an intervening oblique corner panel, wherein the first oblique corner panel 742a, the first outer side panel 745 and first outer end flap 758 enclose a first triangular corner housing 744a. The third outer end flap 762 can be directly connected to the second outer side panel 747 by a fold line 713 without an intervening corner panel, wherein the second oblique corner panel 742b, the second outer side panel 747 and the third flap outer end caps 762 surround a second triangular corner compartment 744b. The first and second triangular corner compartments 744a, 744b may form a first pair of compartments 744a, 744b at a first end 766 of interior space 780. Interior space 780 may have a second end 768 opposite first end 766, wherein the second end includes a second pair of compartments 744c, 744d mirroring the first pair of compartments.

[0068] It is also contemplated that a method of forming a box 700 may include the method as described above, and may further include forming a first triangular corner compartment 744a-d wherein the first oblique corner panel 742a, the first outer side panel 545 and first outer end flap 758 encircle a first triangular corner compartment 744a and form a second triangular corner compartment 744b wherein second oblique corner panel 742b, second outer side panel 747, and third edge flap outer end 762 encircles a second triangular corner compartment 744b.

[0069] Referring now to Figs. 9 and 10, a blank 920 and a box 900 similar to blank 720 and box 700 are shown. The first outer end flap 958 is connectable to the first outer side panel 545 by a third oblique corner panel 946a along fold lines 911a,b, which overlaps the first oblique corner panel 942a and forms a portion of the surface. outer 970. The third outer end flap 962 is connectable to the second outer side panel 947 by a fourth oblique corner panel 946b along fold lines 913a,b, which overlaps the second oblique corner panel 942b and forms a outer surface portion 970. The first, second, third, and fourth oblique corner panels 942a, 942b, 946a, 946b may form a first pair of oblique corners 1002 of inner 972 and outer surfaces 970 at a first end 966 of the interior space 980. Interior space 980 may have a second end 968 opposite the first end that includes a second pair of slanted corners 1004 mirroring the first pair of slanted corners 1002. Oblique corners 1002, 1004 define at least one edge portion that is oblique relative to rectangular portions 941 of upper edge 940.

[0070] It is further contemplated that a method of forming a box 900 may include the method as described above and may additionally include folding the first outer end flap 958, wherein the first outer end flap 958 is connected to the first outer side panel 945 by a third oblique corner panel 946a which overlies a first oblique corner panel 942a and forms a portion of the outer surface 970 and folds the third outer end flap 962 wherein the third outer end flap 962 is connected to the second outer side panel 947 by a fourth oblique corner panel 946b which overlaps a second oblique corner panel 942b and forms a portion of the outer surface 970.

[0071] It can be appreciated that various changes can be made within the scope of the present invention. For example, the size and shape of panels can be adjusted to create boxes with different sizes and dimensions. As another example, in certain modalities both sides (or neither side) of the stock can be treated.

[0072] It will be recognized that, as used herein, directional references such as "top", "base", "front", "rear", "end", "side", "inner", "outer", " top" and "bottom" do not limit the respective panels to such an orientation, but serve only to distinguish these panels from each other. Any reference to "hinged connection" should not be interpreted as necessarily referring to a single fold line only; Indeed, it is envisioned that a hinged connection can be formed from one or more of the following: a short slit, a brittle line or a bend line, without departing from the scope of the invention. It can be appreciated that various changes can be made within the scope of the present invention For example, the size and shape of panels and openings can be adjusted to accommodate articles of different sizes or shapes.

[0073] As used in this document, the terms "hinged connection" and "bend line" each refer to all types of lines that define the hinge characteristics of the blank or sheet material substrate, facilitate the folding portions of the blank or sheet material substrate relative to one another, or otherwise indicate optimal panel folding locations for the blank or sheet material substrate. Any reference to “hinged connection” should not be construed as necessarily referring to a single bend line only; in fact, a hinged connection can be formed from one or more bend lines.

[0074] As used herein, the term "fold line" may refer to one of the following: a scored line, a recessed line, an embossed line, a line of perforations, a line of short slits, a line of half-cuts, a single half-cut, an interrupted line of cut, aligned slits, a line of short stitches and any combination of the aforementioned options, without departing from the scope of the invention.

[0075] As used herein, the terms "weakened parting line", "parting line" and "fragile line" may refer to all types of lines formed in the blank or sheet material substrate that facilitate separating portions of the blank or substrate from each other's sheet material, or otherwise indicating optimal separation locations in the blank or substrate. As used in this document, the terms "weakened cutting line", "cutting line" and "fragile line" can refer to one of the following: a single cut line, a single partial depth cut line (for example , a single half-cut line), an interrupted cut line, a crease line, an interrupted crease line, a line of perforations, a line of short cuts, a line of short slits, a line of partial depth short cuts ( for example, a line of short half cuts), and any combination of the above mentioned options.

[0076] It should be understood that hinged connections, fold lines, weakened cut lines, frangible lines and cut lines may each include elements that are formed in the blank or sheet material substrate, including perforations, a line of perforations, a line of short slits, a line of half-cuts, a single half-cut, a line of cut, an interrupted line of cut, slits, creases, any combination thereof and the like. Elements can be sized and arranged to provide the desired functionality. For example, a line of perforations can be dimensioned or designed with degrees of weakness to define a bend line and/or frangible line. The perforation line can be designed to ease bending and resist breakage to provide a bend line, to ease bending and ease breaking with more effort to provide a frangible bend line, or to facilitate breakage with little effort to provide a frangible line.

Claims (22)

Box to contain a plurality of articles, the box characterized by the fact that it comprises:
a bottom wall, a first side wall coupled to the bottom wall, a second side wall disposed opposite the first side wall and coupled to the bottom wall, a first end wall coupled to both the bottom wall and the first and second side walls, and a second end wall disposed opposite the first end wall and coupled to both the bottom wall and the first and second side walls;
wherein each bottom wall, first and second side walls, and first and second end walls both define an inner surface disposed adjacent an inner space defined by the box and an outer surface;
wherein the box is formed from a blank comprising a first surface and a second surface disposed opposite the first surface;
wherein the inner surface of the bottom wall and the inner and outer surfaces of the first and second side walls and first and second end walls are each substantially entirely defined by the first surface; and
wherein the first side wall, second side wall, first end wall, and second end wall define an upper edge opposite the lower wall, wherein the upper edge defines rectangular portions that follow a rectangle, and wherein the upper edge defines at least one edge portion that is oblique with respect to the rectangular portions. Box according to claim 1, characterized in that the blank comprises a plurality of main panels hinged in a linear series, the plurality of main panels comprising first and second inner side panels, first and second outer side panels and a bottom panel;
wherein the first outer side panel is hingedly connected to the first inner side panel, the first inner side panel is hingedly connected to the bottom panel, the bottom panel is hingedly connected to the second inner side panel and the second side panel inner is hingedly connected to the second outer side panel;
wherein the first outer side panel defines the outer surface of the first side wall, the first inner side panel defines the inner surface of the first side wall, the bottom panel defines the outer and inner surfaces of the bottom wall, the second inner side panel defines the the inner surface of the second side wall and the second outer side panel define the outer surface of the second side wall; and
wherein the blank further comprises first and second end panels hingedly connected to the bottom panel at respective opposite ends of the bottom panel, wherein the first end panel defines the inner surface of the first end wall and wherein the second end panel defines the inner surface of the second end wall. Box according to claim 2, characterized in that the blank further comprises first and second inner end flaps hingedly connected to the first inner side panel at respective opposite ends of the first inner side panel;
wherein the blank further comprises third and fourth inner end flaps hingedly connected to the second inner side panel at respective opposite ends of the second inner side panel;
wherein the blank further comprises first and second outer end flaps hingedly connected to the first outer side panel at respective opposite ends of the first outer side panel; and
wherein the blank further comprises third and fourth outer end flaps hingedly connected to the second outer side panel at respective opposite ends of the second outer side panel. Box according to claim 3, characterized in that the first and third outer end flaps define the outer surface of the first end wall along a first perimeter length of the top edge; and
wherein the first end panel is adjacent to the first and third inner end tabs and defines a second length along the top edge that is longer than the first length such that the first end panel curves inwardly to define at least one edge portion that is oblique with respect to the rectangular portions. Box according to claim 3, characterized in that the first inner end flap is connected to the first inner side panel by a first oblique corner panel; and
wherein the third inner end flap is connected to the second inner side panel via a second oblique corner panel, wherein the first and second oblique corner panels define at least one edge portion that is oblique relative to the rectangular portions . A box according to claim 5, characterized in that the first outer end flap is foldably connected directly to the first outer side panel by a fold line without an intervening oblique corner panel, wherein the first outer side panel oblique corner, first outer side panel and first outer end flap enclose a first triangular corner compartment; and
wherein the third outer end flap is directly connected to the second outer side panel by a fold line without an intervening corner panel, wherein the second oblique corner panel, the second outer side panel, and the third outer end flap enclose a second triangular corner compartment. Box, according to claim 6, characterized in that the first and second triangular corner compartments form a first pair of compartments at a first end of the interior space; and
wherein the interior space has a second end opposite the first end, wherein the second end includes a second pair of compartments mirroring the first pair of compartments. Box according to claim 5, characterized in that the first outer end flap is connected to the first outer side panel by a third oblique corner panel which overlaps the first oblique corner panel and forms a portion of the outer surface ; and
wherein the third outer end flap is connected to the second outer side panel by a fourth oblique corner panel which overlaps the second oblique corner panel and forms a portion of the outer surface. Box according to claim 8, characterized in that the first, second, third and fourth oblique corner panels form a first pair of oblique corners of the inner and outer surfaces at a first end of the inner space; and
wherein the interior space has a second end opposite the first end that includes a second pair of slanted corners mirroring the first pair of slanted corners. Rough to form a box characterized by the fact that it comprises: a first surface;
a second surface disposed opposite the first surface and a plurality of panels and flaps, the plurality of panels and flaps configured to form an assembled box defining a bottom wall, a first side wall coupled to the bottom wall, a second side wall disposed opposite the first side wall and coupled to the bottom wall, a first end wall coupled to both the bottom wall and the first and second side walls, and a second end wall disposed opposite the first end wall and coupled to both the bottom walls and the first and the second side walls;
wherein each bottom wall, first and second side walls, and first and second end walls both define an inner surface disposed adjacent an inner space defined by the assembled box and an outer surface;
wherein the inner surface of the bottom wall and the inner and outer surfaces of the first and second side walls and first and second end walls are each substantially entirely defined by the first surface; and
wherein the first side wall, second side wall, first end wall, and second end wall define an upper edge opposite the lower wall, wherein the upper edge defines rectangular portions that follow a rectangle, and wherein the upper edge defines at least one edge portion that is oblique with respect to the rectangular portions. The blank according to claim 10, characterized in that the blank comprises a plurality of main panels hinged in a linear series, the plurality of main panels comprising first and second inner side panels, first and second side panels externals and a lower panel;
wherein the first outer side panel is hingedly connected to the first inner side panel, the first inner side panel is hingedly connected to the bottom panel, the bottom panel is hingedly connected to the second inner side panel and the second side panel inner is hingedly connected to the second outer side panel;
wherein the first outer side panel defines the outer surface of the first side wall, the first inner side panel defines the inner surface of the first side wall, the bottom panel defines the outer and inner surfaces of the bottom wall, the second inner side panel defines the the inner surface of the second side wall and the second outer side panel define the outer surface of the second side wall; and
wherein the blank further comprises first and second end panels hingedly connected to the bottom panel at respective opposite ends of the bottom panel, wherein the first end panel defines the inner surface of the first end wall and wherein the second end panel defines the inner surface of the second end wall. The blank according to claim 11, characterized in that the blank further comprises first and second inner end flaps hingedly connected to the first inner side panel at respective opposite ends of the first inner side panel;
wherein the blank further comprises third and fourth inner end flaps hingedly connected to the second inner side panel at respective opposite ends of the second inner side panel;
wherein the blank further comprises first and second outer end flaps hingedly connected to the first outer side panel at respective opposite ends of the first outer side panel; and
wherein the blank further comprises third and fourth outer end flaps hingedly connected to the second outer side panel at respective opposite ends of the second outer side panel. The blank according to claim 12, characterized in that the first and third outer end flaps define the outer surface of the first end wall along a first perimeter length of the top edge; and
wherein the first end panel is adjacent to the first and third inner end tabs and defines a second length along the top edge that is longer than the first length such that the first end panel curves inwardly to define at least one edge portion that is oblique with respect to the rectangular portions. The blank according to claim 12, characterized in that the first inner end flap is connected to the first inner side panel by the first oblique corner panel; and
wherein the third inner end flap is connected to the second inner side panel via a second oblique corner panel, wherein the first and second oblique corner panels define at least one edge portion that is oblique relative to the rectangular portions . The blank according to claim 14, characterized in that the first outer end flap is foldably connected directly to the first outer side panel by a fold line without an intervening oblique corner panel, wherein the first oblique corner panel, first outer side panel and first outer end flap enclose a first triangular corner compartment; and
wherein the third outer end flap is directly connected to the second outer side panel by a fold line without an intervening corner panel, wherein the second oblique corner panel, the second outer side panel, and the third outer end flap enclose a second triangular corner compartment. Blank according to claim 15, characterized in that the first and second triangular corner compartments form a first pair of compartments at a first end of the interior space; and
wherein the interior space has a second end opposite the first end, wherein the second end includes a second pair of compartments mirroring the first pair of compartments. The blank according to claim 14, characterized in that the first outer end flap is connected to the first inner side panel by a third oblique corner panel which overlaps the first oblique corner panel and forms a portion of the outer surface; and
wherein the third inner end flap is connected to the second inner side panel by a fourth oblique corner panel which overlaps the second oblique corner panel and forms a portion of the outer surface. The blank according to claim 17, characterized in that the first, second, third and fourth oblique corner panels form a first pair of oblique corners of the inner and outer surfaces at a first end of the inner space; and
wherein the interior space has a second end opposite the first end that includes a second pair of slanted corners mirroring the first pair of slanted corners. Method for forming a box, characterized by the fact that it comprises:
providing a blank having a first side of the blank and a second side of the blank disposed opposite the first side of the blank, the blank comprising a plurality of main panels hinged in a linear series, the plurality of main panels comprising a bottom panel, first and second inner side panels, and first and second outer side panels, wherein the first outer side panel is hingedly connected to the first inner side panel, the first inner side panel is hingedly connected to the bottom panel, the bottom panel is hingedly connected to the second inner side panel, and the second inner side panel is hingedly connected to the second outer side panel, the blank further comprising first and second side panels. end, first, second, third and fourth inner end flaps and first, second, third and fourth end flaps outer ends, wherein the first and second end panels are hingedly connected to the bottom panel at their respective opposite ends of the bottom panel, the first and second outer end flaps are hingedly connected to the first outer side panel at their respective opposite ends of the first outer side panel, the third and fourth outer end flaps are hingedly connected to the second outer side panel at respective opposite ends of the second outer side panel, the first and second inner end flaps are hingedly connected hingedly to the first inner side panel at respective opposite ends of the first inner side panel, and the third and fourth inner end flaps are hingedly connected to the second inner side panel at respective opposite ends of the second inner side panel;
fold the first outer side panel back over the first inner side panel and secure it thereto so that the second outer side panel blank's second side surfaces and the first inner side panel are mated in a contacting relationship of face;
fold the second outer side panel back over the first inner side panel and secure it thereto so that the second side surfaces of the second outer side panel blank and the second inner side panel are mated in a contacting relationship of face;
folding the first outer side panel and the first inner side panel around the bottom panel to form a first side wall of the box, an outer surface of the first side wall being defined by a first side surface of the first side panel blank. outer and an inner surface of the first side wall being defined by a first side surface of the first inner side panel blank, a first side surface of the lower panel blank defining an inner surface of a bottom wall of the box;
folding the second outer side panel and the second inner side panel around the bottom panel to form a second side wall of the box, an outer surface of the second side wall being defined by a first side surface of the second side panel blank outer and an inner surface of the second side wall being defined by a first side surface of the second inner side panel blank;
folding the first and second end panels around the bottom panel to form respective first and second end walls of the box, a first side surface of the first end panel blank defining an inner surface of the first end wall, a first side surface of the second end panel blank defining an inner surface of the second end wall; and
folding the first and third inner end tabs and the first and third outer end tabs into an overlapping arrangement with a second side of the first end panel blank and securing them thereto, a first side surface of the piece blank of the first and third outer end flaps defining an outer surface of the first end wall;
folding the second and fourth inner end flaps and the second and fourth outer end flaps into an overlapping arrangement with a second side of the second end panel blank and securing them thereto, a first side surface of the second and fourth outer end flap blank defining an outer surface of the second end wall,
wherein the first side wall, second side wall, first end wall and second end wall define an upper edge opposite the lower wall, wherein the upper edge defines rectangular portions that follow a rectangle, and wherein the upper edge defines at least one edge portion that is oblique with respect to the rectangular portions. The method of claim 19, wherein folding the first, second, third and fourth inner end flaps and folding the first, second, third and fourth outer end flaps includes arching the first end panel inwardly to define at least a portion of the border that is oblique with respect to the rectangular portions. Method according to claim 19, characterized in that folding the first, second, third and fourth inner end flaps and folding the first, second, third and fourth outer end flaps includes forming a first triangular corner compartment at that the first oblique corner panel, first outer side panel, and first outer end flap enclose a first triangular corner compartment; and
forming a second triangular compartment wherein the second oblique corner panel, second outer side panel, and third outer end flap enclose a second triangular corner compartment. Method according to claim 19, characterized in that folding the first, second, third and fourth inner end flaps and folding the first, second, third and fourth outer end flaps includes folding the first outer end flap, wherein the first outer end flap is connected to the first outer side panel by a third oblique corner panel which overlaps a first oblique corner panel and forms a portion of the outer surface; and
folding the third outer end flap wherein the third outer end flap is connected to the second outer side panel by a fourth oblique corner panel which overlaps a second oblique corner panel and forms a portion of the outer surface.

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