CA2621029C - Shirt box - Google Patents

Abstract

A shirt box includes a substrate having a plurality of fold lines including a first set of generally parallel fold lines and a second set of generally parallel fold lines. Notches extend through the substrate in a first direction. First and second sets of panels are separated from one another by fold lines. The panels are foldable along respective fold lines to define a hollow central cavity for the shirt box and peripheral ends of the shirt box.
A bond permanently connects two non-adjacent panels in the first set while double-sided tape members are in adhesive contact with panels in the second set. Removable strips overlie a second side of the double-sided tape members while the shirt box is in a collapsible state, and are removable so as to size the hollow central cavity to receive a shirt or a shirt and tie combination.

Description

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SHIRT BOX
Technical Field The present invention relates to retail packaging and in particular, to a shirt box for displaying a shirt in an assembled state and being constructed to fold flat to permit easy bundling and shipping of a number of boxes.

Background In the retail sale of dress shirts and dress shirts and tie combinations, it is desirable to present the merchandise i.n a manner that permits potential customers to have a good look at the product. On the other hand, it is important for retailers to keep the product clean and free of any soil or stains that may result from handling, to protect against theft, and to maintain the shirts in an orderly and well-folded condition so that their displays remains attractive to passers by.

It is also desirable that the packaging that is used be economical to manufacturer, that it be made from a recyclable material, and that it be made with minimal waste.

It is also desirable to have a packaging that addresses the foregoing needs and which permits shirts to be stacked in great number to promote efficient shelf and display space usage.

The present invention satisfies these and other needs.
Summary In accordance with one aspect of the present invention, a combination of clothing articles and a substantially transparent box is constructed and arranged to include a collared shirt, a necktie supported by the shirt, and a single sheet of substantially transparent plastic having a series of first panels each defined by a respective fold in a series of first folds and a set of second panels each defmed by a respective fold in a set of second folds in the plastic sheet. A bond permanently connects one of the first panels to another of the first panels so as to define a hollow central cavity for the box. The hollow cavity is sized to receive the shirt and necktie. The second panels are folded to defme first and second peripheral ends of the box. The plastic sheet comprising the box includes a hole positioned relative to the clothing articles such that the outline of the hole overlies a portion of the articles.

In a further aspect, the invention includes the combination as described above having the necktie folded intermediate its ends and seated relative to the folded shirt by an elastic band which passes transversely to a length of necktie, within the fold. The band can coinprise a loop and can be sized to be stretchably received about the shirt collar.
Optionally, a clip can engage with the fabric of the necktie proximate to the fold to pinch the fabric and thereby emulate the appearance of a tie knot.

In a still further aspect, the invention as described above can include a band or loop disposed about the folded shirt, and a channel adjacent the loop. The necktie can be disposed within the channel.

In yet another aspect, the invention as described above has the bond connecting the first panels defined by a plurality of individual bond sites which are intermittently spaced apart. Optionally, the individual bond sites can be arranged in at least one line.

In still another aspect, the invention as defined above can further have double-sided tape members with opposing sides in adhesive contact with respective second panels to permit ready closing of the box once filled with' a shirt and tie.

In accordance with one aspect of the present invention, a combination of clothing articles and a substantially transparent box is constructed and arranged to include a collared shirt, a necktie supported by the shirt, and a single sheet of substantially transparent plastic having a series of first panels each defined by a respective fold in a series of first folds and a set of second panels each defined by a respective fold in a set of second folds in the plastic sheet. A bond permanently connects one of the first panels to another of the first panels so as to defme a hollow central cavity for the box. The hollow cavity is sized to receive the shirt and necktie. The second panels are folded to define first and second peripheral ends of the box. The plastic sheet comprising the box includes a hole positioned relative to the clothing articles such that the outline of the hole overlies a portion of the articles.

In a further aspect, the invention includes the combination as described above having the necktie folded intermediate its ends and seated relative to the folded shirt by an elastic band which passes transversely to a length of necktie, within the fold. The band can comprise a loop and can be sized to be stretchably received about the shirt collar.

Optionally, a clip can engage with the fabric of the necktie proximate to the fold to pinch the fabric and thereby emulate the appearance of a tie knot.

In a still further aspect, the invention as described above can include a band or loop disposed about the folded shirt, and a channel adjacent the loop. The necktie can be disposed within the channel.

In yet another aspect, the invention as described above has the bond connecting the first panels defined by a plurality of individual bond sites which are intermittently spaced apart. Optionally, the individuaf bond sites can be arranged in at least one line.

In still another aspect, the invention as defined above can further have double-sided tape members with opposing sides in adhesive contact with respective second panels to permit ready closing of the box once filled with a shirt and tie.

A shirt box suitable for receiving one or more shirts includes a single sheet of substantially transparent plastic that has a plurality of fold lines formed therein including a first set of generally parallel fold lines and a second set of generally parallel fold lines. The box includes a series of first panels, each being separated from a next panel in the series by a respective fold line in the first set of fold lines. The first panels are foldable along the respective fold lines in a first direction to define a hollow central cavity for the shirt box.
The box also includes a set of second panels each having a boundary along a respective fold line in the second set of fold lines to a respective first panel. The second panels are foldable along the respective fold lines in a second direction which is substantially perpendicular to the first direction to define first and second peripheral ends of the shirt box.

In this embodiment, the box includes first and second fastening panels that are part of the set of first panels are attached to another along a fastening region to connect the set of first panels in series and define the central cavity. The shirt box has a collapsible (collapsed) state in which the sides of the collapsed box are defined by first and second fold lines that are part of the first set of fold lines and in the fully assembled (closed) state, the box has a substantially trapezoidal shape the sides of which are defined by a third fold line that is different from the first fold line and a fourth fold line that is different from the second fold line.

In particular, the present invention is directed, in one aspect, to a method for packaging a necktie and shirt combination, comprising the steps of:
providing a shirt having a shirt collar; providing a necktie comprising a length of fabric having first and second ends; folding the necktie along a line transverse to the length of fabric and intermediate the first and second ends, to create at least one fold;
positioning an elastic band within the fold; wrapping the elastic band around the shirt collar; and pinching the necktie at a position proximate to the fold with a clip with the length of the fabric between the fold and the clip being exposed.

These and other aspects, features and advantages shall be apparent from the accompanying Drawings and description of certain embodiments of the invention.
Brief Description of the Drawings Fig. 1 is a top plan view of a first embodiment of the invention;

Fig. 2 is a perspective view of the embodiment of Fig. 1 showing the shirt box in a partially folded position;

Fig. 3 is a detailed end view of the embodiment of Fig. 1 showing a securement for securing the box in a closed state;

Fig. 4 shows the box of Fig. 3 in the closed state;
Fig. 5 is a cross-section through lines 5-5 of Fig 4;

Fig. 6 is a top plan view of a second embodiment of the invention;

Fig. 7 is a cross-section of the second embodiment taken along the same lines as that of Fig. 5;

Fig. 8 shows the shirt and tie combination disposed within the box;
Fig. 9 is a front view of the shirt and tie combination;

Fig. 10 shows a clip useful in configuring the tie to appear knotted;

Fig. 11 shows an elongated body useful in holding the shirt and tie combination in a preferred alignment;

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Still another aspect is directed to a combination of clothing articles packaged for sale comprising:
a folded shirt having a collar;
a necktie formed of a length of fabric having first and second ends, the necktie being folded along a line transverse to a length of the fabric and intermediate the first and second ends, to create at least one fold so as to define a closed end of the folded tie and creating a space between the folded tie through which a member can be inserted, wherein the first and second ends of the tie point in the same direction;
a clip engaged with the fabric proximate to the fold and between the shirt and tie, the clip having legs and open top slot between the legs for receiving the folded necktie, the legs pinching the fabric so as to emulate the appearance of a tie knot, the clip remaining open and a pinched portion of the necktie being exposed between the legs when the necktie is disposed therein to allow for easy removal of the folded necktie, wherein the closed end of the folded tie is positioned on one side of the clip proximate the collar and the first and second ends of the tie are positioned on an opposing side of the clip, the folded tie having a first portion that terminates in the closed end that is located on the one side of the clip and has an inward tapered look in a direction towards the clip, the folded tie having a second portion that is located on the opposing side of the clip, the second portion having an inward tapered look in a direction towards the clip; and a box having at least a transparent top to permit viewing of the shirt and necktie.

These and other aspects, features and advantages shall be apparent from the accompanying Drawings and description of certain embodiments of the invention.
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Brief Description of the Drawings Fig. 1 is a top plan view of a first embodiment of the invention;

Fig. 2 is a perspective view of the embodiment of Fig. 1 showing the shirt box in a partially folded position;

Fig. 3 is a detailed end view of the embodiment of Fig. 1 showing a securement for securing the box in a closed state;

Fig. 4 shows the box of Fig. 3 in the closed state;
Fig. 5 is a cross-section through lines 5-5 of Fig 4;

Fig. 6 is a top plan view of a second embodiment of the invention;
Fig. 7 is a cross-section of the second embodiment taken along the same lines as that of Fig. 5;

Fig. 8 shows the shirt and tie combination disposed within the box;
Fig. 9 is a front view of the shirt and tie combination;

Fig. 10 shows a clip useful in configuring the tie to appear knotted;

Fig. 11 shows an elongated body useful in holding the shirt and tie combination in a preferred alignment;

5c Fig. 12 shows the elongated body being folded;

Fig. 13 shows the elongated body in a folded state and disposed around the shirt;
Fig. 14 shows a second embodiment of the elongated body in a folded state and disposed around the shirt;

Fig. 15 is a top plan view of a third embodiment of the invention in an unfolded substrate form;

Fig. 16 is a partial top plan view of the embodiment of Fig. 15 showing the box in a partially folded collapsed state;

Fig. 17 is perspective view of one end of the embodiment of Fig. 15 in a first partially folded state;

Fig. 18 is a perspective view of one end of the embodiment of Fig. 15 in a second partially folded state;

Fig. 19 is a perspective view of one end of the embodiment of Fig. 15 in a closed state showing securement of an end panel;

Fig. 20 is a perspective view of the box of the embodiment of Fig. 15 in the closed state with a pair of shirts contained therein;

Fig. 21 is a top plan view of the. box of Fig. 15 with a tuxedo arrangement contained therein;

Fig. 22 is a bottom plan view of the embodiment of Fig. 21;

Fig. 23 is an exploded top perspective view of a shirt box according to embodiment of the present invention;

Fig. 24 is a cross-sectional view of the shirt box of Fig. 23 in a fully assembled state;

Fig. 25 is a partial rear plan view of the shirt box of Fig. 23 with a box cover being moved to a rear position; and Fig. 26 is cross-sectional taken along the line 26-26 of Fig. 25.
Detailed Description of Certain Embodiments of the Invention Referring to Fig. 1, a shirt box container 10 includes a substrate 20 in the form of a transparent plastic sheet having fold lines generally designated Fl and F2.
The fold lines Fl are generally parallel and preferably are parallel to one another. The fold lines F2 are also generally parallel and preferably are parallel to one another. The fold lines Fl, F2 define boundaries of respective panels of the substrate 20. A series of first panels 30 all fold in a first direction and include panels 32, 34, and 36. Each of the panels in the series 30 is disposed adjacent another panel in the series and is separated from a next panel by one of the fold lines F l.

As shown in Fig. 2, the first series of panels 30 is foldable along the fold lines Flalong a common, parallel direction to defme a hollow central cavity for the shirt box.
Referring now to Figs. 1 and 2, a set of second panels 40 have a boundary along the fold lines F2 to respective panels in the first series 30. Thus, panels 42 are bounded along one margin at the fold lines F2 to panel 34 and flaps 44 are bounded along fold lines F2 to panels 32. In the embodiment of Fig. 1, the second set of panels 40 further includes end flaps 46 which fold about fold line F2 and which are joined to a free end of panels 42.
Each of the panels 42 and 44 has a free end, opposite its bounded end and each is adjacent to a notch 50, which separate a portion of the panels 42, 44 from the remainder of the substrate 20. As can be appreciated from Fig. 2, the panels in the second set 40 are foldable along their respective fold lines F2 in a direction which is substantially perpendicular to the direction of fold lines Fl. In folding the second set of panels 40, peripheral ends of the shirt box 10 are defined.

The notches 50 are generally oriented to extend in the same direction as the fold lines F 1, and preferably are axially aligned with the fold lines F 1.

In accordance with a salient aspect of the present invention, the shirt box 10 can be configured in a partially assembled state in which a hollow central cavity for containing a shirt or a shirt and tie combination is defined, yet which is collapsible into a generally flat state until such time that a shirt (or a shirt and tie combination) is to be inserted into the box.
When the shirt box 10 is to be filled, it is brought to an uncollapsed state, the shirt is introduced into the hollow cavity, and the peripheral ends of the shirt box are bonded so as to define a substantially rectangular and sealed shirt box construction.

With further reference to Figs. 1 and 2, a securement 50 extends along an inner margin of the panel 36 for permanently connecting pane136 to another panel in the series, preferably one of the panels 32. As shown in Fig. 3, the securement 50 comprises a bond (e.g., thermal or adhesive) which is made between panels 36 and 32 so as permanently connect those panels and secure the shirt box 10 in a rectangular configuration. The bonds preferably comprise a contact cement; however, the bond can comprise other generally permanent connections as understood by those skilled in the art. Preferably, the bond is "permanent" in that it is of such character that it is not readily opened by a consumer, and yet is sufficiently strong to permit the box to be collapsed laterally, so that the panels of the first series 30 can be folded along fold lines Fl to define the shirt cavity while the peripheral ends remain unattached to thereby permit the shirt box to assume a flat condition.
Optionally, the bond includes a series of individual bond sites intermittently spaced apart and arranged (e.g. linearly, evenly spaced, or both) along the length of pane132 to define the securement. Each such bond site can be formed by applying heat and pressure such that the panels are adhered to one another. The resulting bond site can be indented on one side and bulged on the opposite side. Each individual bond site can therefore have the appearance of the two panels having been crimped together.

The shirt box 10 further includes a first and second double sided tape member having a first side in adhesive contact with a respective panel in the second set of panels 40.
As illustrated in Figs. 1-3, the double-sided tape meinber is disposed on end panel 42. A
second side of the double-sided tape meinber 60 includes a removable strip 62 (best seen in Fig. 3) which overlies the second side of the tape member 60. The removable strip maintains the second side of the tape member 60 free of tackiness so that shirt boxes 10 can be stacked in a collapsed state without sticking to one another. However, the removable strip 62 can be separated from the second side of the tape member 60 by releasing it in the direction of arrow A so as to expose an adhesive surface which permits engagement of one pane142 with another pane142 (see Fig. 4). Once the panels 42 have been adhesively joined by the tape member 60, the shirt box 10 is in the second state in which the hollow central cavity is sized to receive the shirt or shirt and tie combination.

Preferably, the material of the substrate has a thickness so that, in combination with the fold lines Fl and F2, a stable, second state results in which the shirt boxes 10 can be stacked in great number, one upon another, to promote efficient shelf and display space usage.

In order to facilitate folding of the shirt box, in a preferred form, the end panels 46 have chamfered corners adjacent their respective free ends. The chamfered corners reduce interference of one panel member with another as the box is folded.

As illustrated in Figs. 1-4, it is preferred that the panels in the second set 40 extend symmetrically from the margins of the panels in the first series 30.

Fig. 5 is a cross-sectional view through the folded box in accordance with first the embodiment described above. Fig. 5 shows the relative relationship of the different panels with the shirt box 10 in the fully folded configuration.

Referring now to Fig. 6, a second embodiment of shirt box 10' is illustrated in which like reference numbers are used to refer to corresponding features. In relevant part, the second embodiment differs from the first embodiment in that it has been specially configured in order to minimize waste material as the substrate 20 is stamped from a web of material by providing an overall rectangular configuration free of cut-outs. As in the first embodiment, it is preferred that a single sheet of substantially transparent plastic is used to define the panels of the shirt box 10'; however, in order to minimize waste material, the end flaps 46 have been eliminated, and new flaps 48a and 48b are included in the second set of panels 40. The flaps 48A, 48B are folded about fold line F2 when the substrate 20 is folded to define the shirt box 10' . Thus, as shown in Fig. 7, the folded shirt box lacks the end panel 46, so the top and bottom margins of the folded box have the same thickness throughout the length of the shirt box. The additional flap 48a is accommodated within the folded box , as illustrated in Fig. 7.

The fold lines Fl and F2 can be continuous or discontinuous, but preferably are continuous and inore preferably comprise score lines in the substrate 10.
Depending on the material chosen for the substrate, fold lines can be defined by material at locations that are axially aligned with the notches 50. Also, at least one of the notches 50 preferably has a depth (that is, in a direction parallel to the axis of the fold lines F1) which is equal to the width of the flaps 44. By so-constructing at least some of the notches 50, a substantially rectangular shirt box 10, 10' can result.

Referring to Fig. 8, a shirt and tie combination 80 is disposed within the hollow central cavity of shirt box 10. Preferably, shirt box 10 is formed with a hole 90 in one of the panels that forms the box. Hole 90 is positioned such that the outline of the hole overlies a portion of the shirt and tie combination 80. This arrangement provides access to the garments inside the shirt box 10 so that consumers can touch and feel the garments yet does not compromise the structural integrity of the box 10.

Fig. 9 is a front view of the shirt and tie combination 80. The shirt 100 is preferably folded as shown. The shirt 100 includes a collar 101. A necktie 102 is located proximate to the collar. The necktie essentially comprises a length of fabric.
It may be any suitable fabric such as silk. The necktie may also comprise a combination of fabrics. The fabric of the necktie generally extends in the vertical direction (along line A-A') as shown in Fig. 9. The necktie has a first end 104 and a second end 105.

The necktie 102 is folded between the first and second ends to create a fold 103.
The fold is horizontal in Fig. 9, thus being in a direction transverse to that of the fabric of the necktie (namely, transverse to line A-A'). An elastic band 106 is placed within the fold, or within at least one of the several folds if several are present. The elastic band 106 is preferably manufactured from rubber, but may be manufactured from an elastic fabric, or a flexible elastic plastic material. The elastic band 106 passes through the fold in a generally horizontal direction, i.e. direction transverse to that in which the necktie extends. The elastic end is resiliently stretched upward and preferably around the collar 101. Preferably, the elastic band comprises a loop which is slightly shorter than the circumference of the collar, thus necessitating it to be stretched when wrapped around the collar.

A clip 107 is placed on the necktie in a position proximate to the fold. The clip 107 is preferably placed about 1-1.5 inches below the fold. The clip pinches the necktie in order to create the appearance of a knot, as shown in Fig. 9. If a knot is already present, the clip is not required. As can be seen in Fig 10, the clip 107 is preferably U-shaped.

Additional details concerning the arrangement of the necktie, elastic band and clip are disclosed in the currently co-pending U.S. Patent Application Publications No. US 2005/0160515 of Kim, filed January 23, 2004.

Referring to Figs. 11 and 12, an elongated body 200 is shown in Fig. 11 in an unfolded state and in Fig. 12 being brought to the folded state. The elongated body has first and second ends 201 and 202, and first and second attachment points 203 and 204 intermediate of the ends but positioned, as will be apparent, to secure the body in a closed-loop configuration while simultaneously defining a channel for receiving a necktie. The end 202 is brought into engagement with attachment point 203 whereas end 201 is brought into engagement with attachment point 202.

The elongated body 200 is used in conjunction with the shirt (100 in Fig. 13 ) with the necktie tie (102 in Fig. 12 ) attached to the shirt. When folded, the elongated body can be made to wrap around the shirt, as shown in Fig. 13.

Fig. 13 shows an end view of the elongated body 200 wrapped around a folded shirt 100. There it can be seen that when end 201 is connected to attachment point 204 and when end 202 is connected to attachment point 203, a channel 300, suitable for the insertion of the tie 102 therein, is defined. When the elongated body 200 is plastic, these attachment joints may be defined by cooperation of a lock-tab and a lock-joint, as disclosed in the . .. .~: . ...... .. .. . ... . .. . .. .. . . . . . ........ ... . ~ .. . ...
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currently co-pending U.S. Patent Application Publications No. US 2006/0010560 of Kim, filed June 23, 2005, or by any other method, 12a such as, for example, the use of glue, tape, staples, heat-seal, sewing, etc.
Sewing is a particularly preferred approach for achieving the engagement at the attachment points then when the elongated body 200 is made from fabric.

A second embodiment the elongated body of the present invention is depicted in Fig.
14. In this embodiment an elongated body 400 is used. The elongated body is made to form a main loop by attaching its ends 401 and 402. The main loop is suitable for the placement of a folded shirt 100 tlierein. An additional wa11405, composed, preferably of the same material as the elongated body 400, is attached to the elongated body 400 at two attachment points 403 and 404. A channel 406 is formed between the elongated body 400, the wa11405 and the attachment points 403 and 404 using any of the foregoing attachment methods noted above. The channe1406 is suitable for the placement of a tie therein.
Additional reference concerning the use of an elongated body in connection with a shirt and tie is disclosed in U.S. Patent No. 6,901,636, to Kim, issued June 7, 2005.

Referring to Figs. 15-20, a shirt box container 500 is made from a substrate 510 in the form of a transparent plastic sheet having a series of fold lines generally designated F1 and F2. The fold lines F1 are generally parallel and preferably are parallel to one another and can be characterized as being vertical fold lines that run from one end of the container to the opposite other end. The fold lines F2 are also generally parallel and preferably are parallel to one another and can be characterized as being horizontal fold lines. The fold lines Fl, F2 define boundaries of respective panels of the substrate 510.

More specifically, the substrate 510 is divided into a number of different panels that define particular segments or regions of the substrate 510. A series of first panels 512 all fold in a first direction and include panels 520, 522, 524, and 526. Each of these panels 520, 522, 524, 526 is disposed adjacent another panel in the series and is separated from a next panel by one of the fold lines Fl. As shown in Figs. 15-20, the first series of panels 512 is foldable along the fold lines Fl along a common, parallel direction to define a hollow central cavity for the shirt box. Two of these panels, namely, panels 520, 524, form a top wall (pane1524) and a bottom wall (panel 520), as well a pair of side walls that are defines by panels 522, 526. As shown in Fig. 20, when the box 500 is assembled, the box 500 has a trapezoidal shape in that it is a quadrilateral with two sides parallel.

In the illustrated embodiment, each of the panels 520, 524 has a generally rectangular shape and the widths of the panels 520, 524 are preferably equal.
In addition, the panels 522, 526 also have a generally rectangular shape, with the panel 522 being disposed between the panels 520, 524 and the panel 526 being formed on the other side of the panel 524. The panels 522, 526 have widths that are preferably equal to one another but are less than the width of the panels 520, 524.

Referring now to Fig. 15, the second series of panels 514 includes a pair of end panels 530 that have a boundary along the fold lines F2 to the panel 520. The end panel 530 is defined by two parallel edges 532, one of which defines the fold line F2, and a first end edge 534 that is perpendicular to edges 532 and a beveled end edge 536 that is formed at an angle to the edges 532. The end edge 536 is formed at an angle other than 90 degrees and therefore it is not parallel to the first end edge 534. The outer edge 534 has a greater width than the inner edge 534 as illustrated.

On one side of each end panel 530, a flap 560 is provided. The flaps 560 are bounded along one margin at the fold lines F2 to the panel 522. The flap 560 thus folds about fold line F2 and is generally in the shape of a trapezoid in that it includes two non-parallel side edges 562. It will be appreciated from Fig. 15, that the distance that the flap 560 extends from fold line F2 (the inner edge of the flap) is less than the distance that the end pane1530 extends from fold line F2. In other words, the outer edge of the end panel 530 is at a greater distance from the fold line F2 than the outer edge of the flap 560 as illustrated.

The pane1522 is bounded at its ends by the flaps 560 and along its sides by panel 520 and 524. In other words, the panel 522 is disposed between the panels 520 and 524 and is joined thereto along fold lines Fl.

On the other side of the panel 520 and the end panel 530, a first fastening panel 550 is formed and includes a main section 552 that extends between fold lines F2 and thus has a general rectangular shape and end sections 554 that extend from the fold lines F2 to the outer edge of the end pane1530. The end sections 554 thus extend the same distance from the fold lines F2 as the end panels 530; however, each end section 554 has a generally triangular shape, with the hypotenuse of the triangle being defined by an edge 556. The other two sides of-the end section 554 are defined by the end edge 534 and the edge 532 that defines the fold line F2.

A free edge 558 of the fastening panel 550 and in particular, of the panel 520, represents a free edge that is used to construct and configure the substrate 510 into its sealed folded construction shown in Fig. 20. This aspect will be described in greater detail below. The free edge 558 includes first fastening elements 551 that serve to fasten and securely attach the substrate 510 into its assembled but folded collapsed state.

A pair of end panels 540 is also provided and is constructed to have a boundary along the fold lines F2 to the pane1524 which is located between panels 522 and 526 and is joined thereof along fold lines Fl. The end panel 540 is defined by two parallel edges 542, one (inner edge) of which defines the fold line F2 and the other is an outer edge of the end pane1540. . The end panel 540 has a trapezoid shape and is therefore, also defined by a pair of angled edges 544. The angled edges 544 are tapered inward toward the fold line F2 so as to cause the inner edge (the fold line F2) to have a lesser width than the outer edge 542.

In the embodiment of Figs. 15-20, the panels 540 furtlier includes end flaps which fold about fold line F2 and which are joined to the outer edges (outer edge 542) of the panels 540. The end flap 580 similarly has a trapezoid shape and is defined by the edge 542 at fold line F2 and an outer edge 582, with a pair of angled edges 584 extending between edges 542, 582. In an opposite manner relative to the end panel 540, the end flap 580 is constructed so that the outer edge 582 has a less width than the width of the inner edge (F2 fold line/edge 542).

As can be seen, a slit 561 separates the flap 560 and the adjacent panel 540 and therefore, permits folding of the flap 560. There is a gap between the other side edge 562 of the flap 560 and the adjacent panel 530 and therefore, there is no slit present in this location.

As illustrated in Fig. 15, each of the panels 520, 522, 524 and 526 has a rectangular shape, with the width of the panels 522, 526 being less than a width of the panels 520, 524.
The panels 520, 524 can have the same dimensions and shapes and the panels 522, 526 can have the same dimensions and shapes.

On one side of each panel 540, a flap 570 is provided. The flaps 570 are bounded along one margin at the fold lines F2 to the panel 526. The flap 570 thus folds about fold line F2 and is generally in the shape of a trapezoid in that includes two non-parallel side edges 572 and an outer edge 574. It will be appreciated from Fig. 15, that the distance that the flap 570 extends from fold line F2 (the inner edge of the flap) is less than the distance that the outer edge 542 of the end panel 540 extends from fold line F2. In other words, the outer edge 542 of the end panel 540 is at a greater distance from the fold l'ine F2 than the outer edge 574 of the flap 570 as illustrated. Preferably, the distances that the flaps 560, 570 extend from the panels 522, 526, respectively, are equal and therefore, the outer free edges of the lie in the same plane.

Similar to the flap 560, the flap 570 is defined by the pair of side edges 572 that are angled with respect to the fold lines F2 and outer edge 574, with one of the side edges 572 being formed by a slit or cut that also defines one of the edges 542 of the panel 540.

One the other side of the panel 526 and the flaps 570, a second fastening panel 590 is formed and includes a main section 592 that extends between fold lines F2 and extends from the fold line Fl. The main section 592 can generally have a trapezoid shape and is defined by an inner edge 594 (fold line F1), an outer edge 596 that is parallel to the inner edge 594 and has a lesser length, and a pair of end edges 598 that extend between the inner edge 594 and the outer edge 596. The edges 598 are angled relative to the edges 594, 596.

The second fastening panel 590 is similar to and complementary to the first fastening panel 550 with the exception that the second fastening panel 590 does not include the end sections 554 that are present as part of the first fastening panel 550.

The outer edge 596 of the fastening panel 590 represents a free edge that is used to construct and configure the substrate 510 into its sealed folded construction shown in Fig.
16. This aspect will be described in greater detail below. The free edge 596 includes second fastening elements 591 that are complementary to the first fastening elements 551 and serve to fasten and securely attach the substrate 510 into its assembled but folded state shown in Fig. 16.

As can be appreciated from Figs. 15-20, the panels 530, 540 and flaps 560, 570, 580 are foldable along their respective fold lines F2 in a direction which is substantially perpendicular to the direction of fold lines F1. In folding the above panels, peripheral ends of the shirt box 500 are defined.

In accordance with a salient aspect of the present invention, the shirt box 500 can be configured in a partially assembled state in which a hollow central cavity for containing one or more shirts or one or more shirt and tie combinations is defined, yet which is collapsible into a generally flat state until such time that one or more shirts (or a shirt and tie combination) are to be inserted into the box. When the shirt box 500 is to be filled, it is brought to an uncollapsed state, the shirt is introduced into the hollow cavity, and the peripheral ends of the shirt box are bonded so as to define a substantially rectangular and sealed shirt box construction.

The first and second fastening elements 551, 591 are designed to interlockingly mate together for permanently connecting the pane1590 to the panel 550. According to one embodiment and as illustrated, the fastening elements 551, 591 are in the form of an interlocking based structure or a crimped based structure where the two panels 550, 590 are securely connected to one anotlier so as to form a closed box blank that and be stored flat prior to use. When the securement technique is an interlocking based structure, the elements 551, 591 when pressed together interlock with one another. The elements 551, 591 can thus be a snap-fit based system that interlocks with one another when mated together.

With further reference to Figs. 15-20, the shirt box 500 can further include first and second double sided tape members 600 that have a first side in adhesive contact with a respective panel in the second set of panels. As, illustrated in Fig. 15, the double-sided tape member 600 is disposed on end pane1580. A second side of the double-sided tape member 600 includes a removable strip 612 (best seen in Fig. 18) which overlies the second side 6f the tape member 600. The removable strip 612 maintains the second side of the tape member 600 free of tackiness so that shirt boxes 500 can be stacked in a collapsed state without sticking to one another. However, the removable strip 612 can be separated from the second side of the tape member 600 by releasing it in the direction of arrow A so as to expose an adhesive surface which permits engagement of one pane1580 with another panel 520 (see Figs. 18-19). Once the panels 580, 520 have been adhesively joined by the tape member 600, the shirt box 500 is in the state in which the hollow central cavity is sized to receive one or more shirts.

Preferably, the material of the substrate has a thickness so that, in combination with the fold lines F1 and F2, a stable, second state results in which the shirt boxes 500 can be stacked in great number, one upon another, to promote efficient shelf and display space usage.

In order to facilitate folding of the shirt box, in a preferred form, the end panels 530, 540, 580 can have chainfered corners adjacent their respective free ends. The chamfered corners reduce interference of one panel member with another as the box 500 is folded.

In the assembled, folded state, the angled sides of the trapezoidal shape box 500 are defined by panels 522, 526 and the top is defined by panel 524 and the bottom is defined by panel 520. In the assembled state, the ends of the box 500 are defined by the folded panels 530, 540 and flaps 560, 570. When the box 500 is fully assembled into the folded state of Figs. 19-20, the panel 530 and the corresponding end section 554 of the first fastening pane15501ie in the same plane.

In one embodiment of the present invention, the side edges of the partially folded, collapsed box 500 shown in Fig. 16 are defined by side edges that are different than the side edges,that define the sides of the fully assembled box 500 as shown in Fig. 20. More specifically, in the partially folded, collapsed state, one side edge of the box 500 is defined by the fold line F1 between panels 522, 524, while the other side edge of the box 500 is defined by the fold line Fl between the first fastening panel 550 and the panel 520. In contrast, when the box 500 is further folded from the collapsed state of Fig.
16 to the assembled, fully folded, closed state of Fig. 20, both of the side edges of the box 500 are different than the two side edges in the collapsed state. In particular, one of the side edges is defmed by the free edge 558 of the first fastening panel 550 which is joined to the edge 596 of the second fastening panel 590, and the other side edge of the box 500 is defmed by the fold line Fl between the panels 520, 522. It will therefore be appreciated both fold lines Fl associated with the first fastening panel 550 define the side edges of the box 500 in both the collapsed state of Fig. 16 and the assembled, closed state of Fig.
19. This is due to the fact that the first fastening panel 550 is folded over the panel 520 in the collapsed state and is then folded so that it is in the same plane as the pane1550 in the closed state of Fig. 19.

In the flat storage position (collapsed state) that allows a number of boxes 500 to be easily stacked on top of one another, the box 500 is folded about the fold line Fl between the panels 522, 524 so that the panel 524 is disposed above and lies across a portion of the panel 520 and a portion of the panel 522 and both panels 526, 590 lie above the panel 520.
The outer edge 596 of the fastening panel 590 does not extend all the way to the fold line F1 that is formed between the panel 520 and the fastening panel 550. In this orientation, the flaps 570 lie above the end panel 530 but do not extend all the way to the outer edge of the end panel 530. Each end pane1540 is disposed over a portion of the end panel 530 and one flap 560. The outer edge 542 of the end panel 540 preferably overlies the outer edge 532 of the underlying end panel 530 in this folded construction. The outer edge of the underlying flap 560 does not extend to the fold line F2 that is defined by the overlying outer edges of the end panels 530, 540.

One angled edge 544 of the end pane1540 that is adjacent the flap 570 is disposed over the end panel 530, while the other angled edge 544 does not overlie any structure and is angled outwardly from the fold line Fl between the panels 522, 524 and therefore, the tip where the angled edges 544 and 584 intersect represents the furthest point of one side of the unassembled, folded, collapsed box 500.

In the unasseinbled, folded, collapsed position of Fig. 16, the two side edges of the folded box are defined by the fold line Fl defined between the panels 522, 524 and the fold line Fl defined between the fastening pane1550 and the panel 520.

In the folded, closed position of Fig. 20, the fastening panel 550 is folded about the fold line Fl between the fastening panel 550 and the pane1520 and the end sections 554 are thus folded over the end panel 530. The free edge 558 of the fastening panel 550 is positioned proximate the fold line F1 between the fastening pane1590 and the panel 526.
When the fastening pane1550 is folded over, as shown, the first and second fastening elements 551, 591 generally align with one another in an overlying manner to permit the interconnection/fastening thereof. As discussed above, when the fastening elements 551, 591 are in the form of interlocking structures, the elements 551, 591 are joined together using appropriate tools. In the case of snap-fit elements, the elements 551, 591 are joined and mated to form an interlocking snap-fit connection between the elements 551, 591 or in the case of a crimp, using crimping tools.

To construct and assemble the box 500 into its normal condition for use as shown in Fig. 20, the box 500 is first formed by cutting a plastic sheet to have the shapes and cuts shown in Fig. 15 and is then folded about the fold line Fl between the panels 522, 524 and the fastening panel 550 is folded and the fastening elements 551, 591 are joined to yield, the folded construction described above and shown in Fig. 16. Next, the folded box 500 is manipulated by raising the panels 526, 526 relative to panel 520 by folding the structure about the fold line F1 between the panels 520, 522 as shown in Fig. 17. As the panel 524 is raised in the manner, the panel 522 no longer lies flat but starts to pivot upward at an increasing angle relative to the panel 520 and simultaneously, the panel 526 begins to lift away from its initially flat position by pivoting about the fold line Fl between the fastening panel 550 and the panel 520 (the side edge of the folded box).

As the panel 524 continues to be raised and the panels 522, 526 pivot upwardly toward an axis that is normal to the panel 520, the end panels 540 are also raised and assume a position above the end panels 530, with the flaps 560, 570 being positioned between the end panels 530, 540. As the panel 524 is raised, the flaps 560, 570 move in direction that causes them to become inore normal relative to the underlying panel 520. In this initial movement, the end sections 554 begin to pivot upwardly about the first end edge 534 (Fl fold line between the end section 554 and the end panel 530).

In this intermediate position, the end sections 554 are close to or even in a perpendicular orientation relative to the end pane1530 and the panel 522 can likewise be in position where the panel 522 is substantially perpendicular to the panels 520, 524 as shown in Fig. 17. When the ends sections 554 and the panel 522 are in perpendicular orientations, the panel 526 is at an angle other than 90 relative to the panel 520.

To go from the intermediate position to the final, closed position of Fig. 20, the box 500 is manipulated to cause the free edge 558 of the fastening panel 550 and the fold line Fl between the panel 526 and the fastening panel 590 to become the side edge of the complete, assembled box 500 structure. This is done by pushing down on in the area where the fastening panels 550, 590 are joined (i.e., near or along the joined fastening elements 551, 591) and then tucking the fastening panel 550 underneath the panel 526 by causing the first fastening panel 550 to lie flat and in the same plane as the panel 520 (as well as the same plane as the end panel 130 prior to its folding) as sho,,vn in Fig. 18. This is accomplished by folding the first fastening panel 550 about the fold line F1 between the first fastening panel 550 and the pane1520. In other words, the original side edge of the folded box construction, namely, the fold line Fl between the end pane1550 and the panel 520 no longer is the side edge of the assembled box 500 shown in Fig. 19.
Similarly, the other side edge of the box 500 is different in the collapsed and closed states in that in the collapsed state, the side edge is defined by the fold line Fl between the panels 522, 524 and in the closed state, the side edge is defmed by the fold line F1 between the panels 520, 522.

As a result of folding the first fastening panel 550 in this manner into a position where it lies in the same plane as the panel 520, the two panels 522, 526 of the box 500 form and define the two angled sides of the trapezoid shaped box 500. The assembly of the box 500 is then completed by bending the flaps 560, 570 inwardly towards the interior compartment of the box 500 (e.g., folded over towards the panels 522, 526, respectively) and then the end panels 530, including the end sections 554, are folded up towards the folded flaps 560, 570 and brought into contact therewith to close off the interior compartment of the box 500. As shown, the combination of the end section 554 and the adjoining end panel 530 itself defmes a trapezoid shaped end.

The final sealing of the box 500 is performed by folding down the end pane1540, at the fold line F2 between panels 540, 524 so as to fold the panel 540 over the folded end panel 530 so that the trapezoidal shaped end pane15401ies over the complementary trapezoidal shaped end panel 530, with one angled edge 544 being generally aligned with and overlying the edge 556 associated with the end section 554 and the other angled edge 544 being aligned with and overlying the edge 536. The end flap 580 is then folded about the fold line F2 so as to position the end flap 580 on an underside (bottom surface) of the pane1520. To secure the end flap 580 to this underside surface of the pane1520, the removable strip of the double-sided tape member 600 is removed so as to expose the second side of the tape member 600, thereby exposing an adhesive surface which permits the engagement of the end panel 580 with the underside of the panel 520. Once the panels 580 have been adhesively joined by the tape member 600, the shirt box 500 is in the second state, namely, the assembled state, in which the hollow central cavity is sized to receive one or more shirts.

It will be appreciated that the area of the end section 554 and the end panel 530 is about equal to the area of the end panel 540 which, unlike the end pane1530 does not include a fold line Fl since these two structures mate together as described herein. In addition, the bottom of the box 500 is defmed by the panel 520 and the first fastening panel 550, while the top of the box 500 is defined by the panel 524.

The fold lines F1 and F2 can be continuous or discontinuous, but preferably are continuous and more preferably comprise score lines in the substrate 520.

The set of first panels of the shirt box 500 thus includes a bottom pane1520, a top panel 524 and a pair of side panels 522, 526 that extend between the bottom and top panels 510, 524, each of the first and second side panels 522, 526 being formed at an angle other than 90 degrees with respect to the top panel 524 and the bottom panel 520. In the collapsed box, one side panel 5221ies adjacent and in the same plane as the bottom panel 520, while the other side panel 526 lies above the bottom panel 520 and in a different plane.
The first fold line is formed between the first fastening pane1550 and the, bottom panel 520 that is part of the first set of panels, wherein in the collapsed box 500, the first fastening panel 550 is folded over the bottom panel 520, while in the assembled state, the first fastening pane1550 and the bottom panel 520 lie at least substantially in the same plane.

It will be appreciated that the box 500 is constructed to receive and display one or more shirts. For example, when displaying two shirts, the shirts are arranged side by side and one shirt can at least partially overlie the other shirt so that both collars of the shirts are spaced apart and fully visible. It is also possible for one or more of the shirts to include a tie as described above with reference to previous embodiments.

Now referring to Figs. 21-22 in which a new application for the shirt box 500 is shown. In this embodiment, the shirt box 500 contains a tuxedo shirt arrangement 700 that includes a tuxedo shirt 710 that is arranged in a folded manner so that a collar 712 thereof is visible through the top panel 524 and sleeves 714 of the shirt 710 are folded over the front of the shirt 710 so that cuff links 716 that are already inserted and secured through button holes of the sleeves 714 are visible through the top panel 524. The shirt 710 has a bow tie 720 that is arranged around the collar 712 in the standard position and manner of wear so that once again, the consumer is shown how the bow tie 720 looks in its standard location. A clip or the like can be used to attach the bow tie 720 to the shirt 710 so that the bow tie 720 does not move relative to the shirt 710 during transportation or display.

The shirt 710, along with the attached bow tie 720 and cuff links 716, occupy a first section of the central cavity of the box 500, while a cununerbund 730 is disposed in and occupies a second section of the central cavity that is adjacent the first section. The cummerbund 730 can be folded so that its folded length is about the same as the length of the folded shirt 710. As is well known, the cummerbund 730 has a pair of free ends or straps 732, 734 that are releasably attached to one another, as by a hook or buckle type mechanism. In one aspect of the invention, a support structure 740, such as a piece of cardboard, is provided to support the folded cummerbund 730 and help locate and confine the cummerbund 730 to the second section of the box 500. The support structure 740 thus has a length that is about the same as the length of the folded shirt 710. The folded cummerbund 730 can be further secured to the support structure 740 by any number of different means, including, the use of a clip or the like (this further ensures that the cummerbund 730 will not move excessively relative to the support structure 740). By placing the cummerbund 730 in the second section of the box next to the folded shirt 710 in the first section, the consumer can view the cummerbund 730 directly next to the folded shirt 710. The consumer can thus view the complete tuxedo shirt arrangement prior to purchase to select the desired tuxedo shirt design.

In one aspect of this embodiment, one of the panels 540 contains a hanger 750 that has a hook member 752 to permit the box 500, with the tuxedo shirt arrangement contained therein for display to the consumer. The hanger 750 includes a body portion 754 from which the hook member 752 extends and the hanger 750 is preferably attached to the panel 540 by securely attaching an underside of the body portion 754 to the outer face of the panel 540. The hanger 750 can be attached using any number of different techniques, including using an adhesive (e.g., glue or cement) or by otherwise bonding or welding the hanger 750 to the panel 540.

It will also be appreciated that the tuxedo arrangement 700 does not have to include the cummerbund 730 and support structure 740 but instead, the shirt box 500 can contain only the folded shirt 710, along with the bow tie 720 and cuff links 716.

As with the earlier embodiment, the shirt box 500 can be formed with hole 90 in one of the panels that forms the box 500. Hole 90 is positioned such that the outline of the hole overlies a portion.of the shirt or the tuxedo arrangement. This arrangement provides access to the garments inside the shirt box 500 so that consumers can touch and feel the garments yet does not compromise the structural integrity of the box 500.

Referring to Fig. 23, a shirt box 800 is formed of a base or bottom box portion 820, a removable box cover 830 that mates with the box portion 820, and an intermediate transparent shirt cover or protector 840 that is received within and is removable from the base 820 and between the box cover 830 and the base 820. While the box 800 can be formed of any nuinber of different materials, including synthetic materials, one exemplary box 800, as illustrated, is formed of a combination of paper material (e.g., reinforced cardboard, etc.) and synthetic material (e.g., a plastic) in the case of the shirt cover 40.

The base or box bottom 820 can be formed to have any number of different shapes, such as a square, oval, circle, triangle, rectangle (as shown), etc. The base 820 is defined by a bottom wall or floor 822 and a plurality of upstanding walls that extend upwardly from the floor 822. In the case of a rectangular shaped base 820, the upstanding walls consist of a pair of opposite end walls 824 and a pair of opposite side walls 826. The end walls 824 and side walls 826 are joined to one another to completely surround the floor 822 and form a bounded structure. The ends walls 824 and side walls 826 preferably are formed at or about at right angles to the floor 822. The floor 822 thus has an inner surface 823 on which a shirt or some other object rests, and an opposite outer surface or face 825 which represents the bottom surface of the entire box 800. The ends walls 824 have corresponding inner surfaces or faces 827 and the side walls 826 have corresponding inner surfaces or faces 829.

The base 800 is preferably formed from paper materials, such as rigid cardboard, and is constructed using conventional box making techniques so as to form a rigid, robust structure.

The box cover 830 includes a top wall or ceiling 832 and a plurality of walls that are arranged around and are integrally attached to the top wall 832 and in the illustrated embodiment, where the box cover 830 has a rectangular shape, the cover 830 includes a pair of opposing end walls 834 and a pair of opposing side walls 836. The end walls 834 and side walls 836 are joined to one another to completely surround the top wall 832 and form a bounded structure. The end walls 834 and side walls 836 preferably are formed at or about at right angles to the top wall 832. The top wall 832 thus has an inner surface 833 (an underside) that faces the floor 822 and an opposite outer surface or face 835 which represents the top surface of the entire box 810. The ends walls 834 have corresponding inner surfaces or faces 837 and the side walls 836 have corresponding inner surfaces or faces 839.

The box cover 830 is preferably formed from paper materials, such as rigid cardboard, and is constructed using conventional box making techniques so as to form a rigid, robust structure.

According to one exemplary embodiment of the present invention, the box cover 830 and more particularly, the top wall 832 thereof, includes an opening, window or cutout 850 formed therein to permit the item (e.g., shirt) contained in the box base 820 to be easily viewed. The formation of the opening 850 defines a peripheral edge 852 that defines the boundaries of the opening 850. It will be appreciated that the location, size and shape of the opening 850 can be varied and can be chosen from a great number of different sizes and shapes so long as a substantial portion of the object (shirt) in the base 820 can be easily viewed through the opening 850.

In the illustrated embodiment, the opening 850 has a rectangular shape and is centrally located within the top wall 832 so as to define top border portions represent portions of the top wall 832 that are formed around the opening 850. In other words, the opening 850 is preferably formed at a location such that the distance between the top edges of the opening 850 and wall 832 and the bottom edges of the opening 850 and wall 832 is about equal and the distance between the side edges of the opening 850 and the wall 832 is about equal. The illustrated opening 850 has rounded corners 54 to give a smoother, flowing appearance.

The mating of box cover 830 to the base 820 is similar to standard box design in that the end walls 832 and side walls 834 of the box cover 830 are received over the corresponding end walls 822 and side walls 824 of the base 820. The distance between the opposing side walls and end walls in each structure are thus selected so that a snug fit results between the box cover 830 and the base 820 when the box cover 830 is mated to the base 820. As shown in the Figures, the top wall 832 of the cover 830 extends inwardly from the end and side walls 822, 824 of the base 820 so as to conceal the end and side walls 822, 824 and thus, position the opening 850 over the floor 822 of the base to permit -clear viewing of the object (shirt). The sections of the top wall 832 around the opening 840 are in the form of flange-like sections of the box cover 830 that extend inwardly over a cavity or compartment 860 that is defined in the base 820 for receiving the shirt.

In contrast to conventional box designs where any transparent window portion is in the form of a flat sheet of transparent plastic that is adhered to an underside of wall sections formed around an opening formed in the box cover, the transparent portion of the box 800 29' of the present invention is in the form of a member that is separate and independent from both the base 800 and the box cover 830, and in particular, the transparent window section of the box 800 is provided by the shirt protector or cover 840.

The shirt cover 840 is a self-supporting, free standing, upstanding structure that is received within the compartment 860 and stands upright therein around the shirt or other object that is resting on the floor 822 of the base 820. The shirt cover 840 is defined by a top wall or panel 842 and a number of upstanding walls and more particularly, the shirt cover 840 has a pair of opposing end panels 844 and a pair of opposing side panels 846.
The shirt cover 840 is transparent or semi-transparent in nature and is typically formed of a plastic material and in particular, can be manufactured as a substrate'that is folded along fold lines to form a folded structure. For example, the shirt cover can have a pair of end fold lines 870 that are formed between the top panel 842 and each of the end panels 844 and a pair of side fold lines 872 that are formed between the top panel 842 and each of the side panels 846. The fold lines 870 are parallel to one another and the fold lines 872 are parallel to one another, with the fold lines 870 being perpendicular to the fold lines 872 and vice versa.

To form the upstanding, free standing structure 840, the side panels 846 are folded along the fold lines 872 and the end panels 844 are folded along the fold lines 870. It will therefore be appreciated that the individual end panels 844 are not directly attached to the side panels 846 and vice versa but instead, slots 847 are formed between adjacent panels.
The slots 847 permit each panel 844, 846 to have a degree of freedom or movement or flexing to permit the end panels 844 and side panels 846 to flex and be received within the adjacent and complementary end walls 824 and side walls 826.

The height of the shirt cover 840 is selected such that when the shirt cover 840 is placed in the compartment 860 on the floor 822, the top panel 842 is generally in the same plane as the top edges of the end panels 824 and side panels 826 of the base 820. When the shirt cover 840 is in its self supported, freely upstanding position, the distance from the top panel 842 to floor 822 is sufficient to permit the shirt or other object to be received therein such that when the shirt (object) sits on the floor 822, the top of the shirt is close to or even in slight contact with the top panel 842 of the shirt cover 840. The transparent or even semi-transparent nature of the protective shirt cover 840 permits the consumer to easily view the contents (e.g., a shirt) contained in the compartment 860 without manipulation of the box 800 and more particularly, without any manipulation of the box cover 830.

Since the protective shirt cover 840 is totally independent from the base 820 and the box cover 830, it can be easily removed from the base 820 to permit reception of the shirt on the floor 822 of the base 820. In addition, since the shirt cover 40 is totally independent from the box cover 830, the box cover 830 can easily be removed from the base without worrying about the integrity of the transparent window portion of the box 800, in this case, the protective shirt cover 840.

By folding the end panels 844 and side panels 846 about the fold lines 870, 872, a free standing, self-supported, upright structure is formed that can stand on the floor 822 without collapsing or otherwise deform due in part to the presence of the walls 824, 826 which serve to restrict any outward movement of the end panels 844 and the side panels 846 and retain the generally rectangular shape of the protective shirt cover 840.

The width of the top panel 842 is therefore about equal to or slightly less than the distance between the side walls 826 of the base 820 to permit reception of the protective shirt cover 840 into the compartment 860. The dimensions of the end panels 844 and side panels 846 are therefore complementary to the corresponding walls 824, 826 of the base 820 so that when the protective shirt cover 840 is received in the compartment 860, the protective shirt cover 840 at least substantially occupies the area of the compartment 860.

Fig. 24 is a cross-sectional view of the box 800 in an assembled condition where the protective shirt cover 840 is inserted into the compartment 860 of the base 820, where it remains as an independent, free-standing structure, and then the box cover 830 is inserted over the base 820 and the protective shirt cover 840 so that an underside of the top wall 832 of the box cover 830 seats against the top surface of the top panel 842 of the protective shirt cover 840. In this position, there is an appearance that the protective shirt cover 840 and the box cover 830 are an integral single structure since when the consumer views the top of the box cover 830, the underlying protective shirt cover 840 extends across and occupies the entire window/opening 850 and since the box cover 830 is securely held on the base 820, the flange-like structure of the top wall 832 of the box cover 830 serves to apply a force to the protective shirt cover 840 and prevent it from upward movement out of the compartment 860. In this manner, the protective shirt cover 840 is securely held in place and the appearance of the protective shirt cover 840 relative to the box cover 830 is one of a taut nature.

It,will be appreciated and as illustrated, at least the opposing side panels 846 seat against the floor 822 of the base 820; however, the shorter end panels 844 do not necessarily have to seat against the floor 822 and as shown in Fig. 24, the end panels 844 can have a height that is slightly less than the height of the side panels 846 and therefore, the end panels 844 do not seat against the floor 822. However, even in this embodiment, the height of the end panel 844 is selected so that the end pane1844 extends a substantial length of the end wall 824 of the base 820 as illustrated. The longer side panels 46 extend completely to the floor 822.

However, it will be appreciated that the end panels 844 can be formed so that they extend completely to the floor 822 in the same manner as the side panels 846.

As mentioned earlier, one of the disadvantages to having a protective plastic sheet directly attached to the underside of the box cover is that this type of arrangement is much more prone to fracture since a force applied directly to the top of the plastic sheet in the area of the window can easily cause a local dislodgment of the plastic sheet from the underside of the box cover. Not only does this create an unsightly appearance since the tautness of the plastic sheet is lost but it also jeopardizes the integrity of the object (e.g., a shirt) that is contained within the box since a person could easily insert a finger or other object into the area of dislodgment and come into direct contact with the object. In the case of a shirt contained in the compartment, the shirt could become soiled by such contact.

Preferably and as shown in the Fig, 23, the shirt box 800 is formed with an opening 870 in one of the surfaces (e.g., the floor 822) that forms the box. Opening 870 is positioned such that the outline of the hole overlies a portion of the article, such as a shirt, that is contained in the box 800. This arrangement provides access to the garments inside the shirt box 800 so that consumers can touch and feel the garments yet does not compromise the structural integrity of the box 800, especially, the integrity of the transparent protective shirt cover 840.

Figs 25 and 26 illustrate a second position of the components of the box 800 and more specifically, the box cover 830 has been removed from its position where it is inserted over the base 820 and instead, is placed on an underside or bottom of the base 820. In other words, the box cover 830 is removed and lifted off the base 820 so as to expose the protective shirt cover 840 and then is inverted and mated with the base 820 by receiving the base 820 within an interior space 831 that is defined by the end walls 832 and side walls 834 of the box cover 830. In this manner, the base 820 is received within the box cover 830 so that the end and side walls 834, 836 of the box cover 830 are received over and exterior to the corresponding end and side walls 824, 826 of the base 820 as is sliown in Fig. 26. Once again, even in this arrangement, the top panel 842 of the protective shirt cover 8401ies generally in the same plane as the top edges of the upstanding walls of both the base 820 and the box cover 830.

It will be appreciated that even in this second position when the box cover 830 is inverted and mated with the bottom of the base 820, the opening 870 is still accessible and the article in the box can be touched since the opening or window 850 is in registration with the opening 870 and the window 850 is free of any transparent, protective plastic sheet since, according to the present invention, the protective shirt cover 840 is completely separate from the box cover 830. The ability to access the opening 870 would not be possible with conventional box design where the window of the box cover is formed by adhering a transparent plastic sheet around a cutout formed in the box cover since the plastic sheet is permanently attached across the cutout and therefore, it would prevent a person from accessing the opening 870 in the floor 822 if the box cover was placed in the second position shown in Figs. 25 and 26.

It will also be appreciated that the arrangement of the protective shirt cover relative to the box cover 830 in the box 800 of the present invention provides improved stacking capability since the stacking of boxes applies a force, due its weight, to the underlying box and therefore, in the standard box cover design, in which the transparent plastic sheet is attached directly the box cover, the weight of one box can puncture and locally separate the plastic sheet from its point of attachment to the shirt box since the mass of the top box can not be borne by thin plastic sheet that is only attached along its peripheral edges to the underside of the box cover. Not only does this damage the integrity of the box but it also blemishes the appearance of the box. In contrast, since the protective shirt cover 840 is a separate, self-supported, upstanding structure, relative to the box cover 830, the shirt cover 840 is able to better support the weight of the top stacked box, which is also supported by the flange sections of the box cover 830. Since there is no direct attachment between the protective shirt cover 840 and the box cover 830, the weight of the top stacked box cannot cause detachment of the protective shirt cover from the box cover.
Instead, the self-supporting, free standing protective shirt cover 840 offers improved weight bearing capabilities.

While the invention has been described in connection with certain embodiments thereof, the invention is capable of being practiced in other forms and using other materials and structures. Accordingly, the invention is defined by the recitations in the claims appended hereto and equivalents thereof.

Claims (3)

1. A method for packaging a necktie and shirt combination, comprising the steps of: providing a shirt having a shirt collar; providing a necktie comprising a length of fabric having first and second ends; folding the necktie along a line transverse to the length of fabric and intermediate the first and second ends, to create at least one fold; positioning an elastic band within the fold;
wrapping the elastic band around the shirt collar; and pinching the necktie at a position proximate to the fold with a clip with the length of the fabric between the fold and the clip being exposed.

2. The method of claim 1, including the additional step of knotting the tie after the positioning step, wherein the knot defines a channel transverse to the length of the fabric and wherein the elastic band is further disposed within the channel.

3. A method for packaging a necktie and shirt combination, comprising the steps of: providing a shirt having a shirt collar; providing a necktie comprising a length of fabric having first and second ends; knotting the necktie to create a knot with a channel therein, the channel being transverse to the length of fabric;
positioning an elastic band within the channel; and wrapping the elastic band around the shirt collar.