GB2257958A

GB2257958A - Collapsible boxes

Info

Publication number: GB2257958A
Application number: GB9215202A
Authority: GB
Inventors: Patrick Doyle
Original assignee: LEWIS RAE HELEN
Current assignee: LEWIS RAE HELEN
Priority date: 1991-07-26
Filing date: 1992-07-17
Publication date: 1993-01-27
Anticipated expiration: 2012-07-17
Also published as: GB9215202D0; GB9116180D0; GB2257958B

Abstract

A collapsible container formed from a blank of flexible material comprises a circular, elliptical or polygonal base formed by two base halves (1, 2) joined by a diametral fold line (3). Attached by its mid-region to the perimeter of each base half (1, 2) is a side wall formed from hingedly joined side wall panels (6, 6a, 9, 10, 11, 12), and the free ends (17, 18, 19, 20) of the side walls are provided with flaps (13, 14, 15, 16) of 'L' shape. In the erected configuration, adjacent flaps (13, 14; 15, 16) are secured together and the ends of the fold line 3 are notched (4) to engage cutouts (24) at the internal corners of the 'L' shaped flaps. <IMAGE>

Description

IMPROVEMENTS RELATING TO PACKAGING The present invention relates to boxes, and particularly concerns a folding hat box which can be easily erected to a substantially cylindrical shape for use, but folds substantially flat for storage and transportation when not in use.

Hat boxes have hitherto been formed of fibreboard or other light sheet material, with a circular base and lid and a curved side wall. Such a construction, although providing a container of the appropriate shape, does not permit the collapse of the container when not in use, and so the retailer is forced to devote much expensive storage space to the storage of empty boxes.

The present invention provides a collapsible carton formed from a folded blank, the carton in an erected configuration having a circular, elliptical or polygonal base and a number of upstanding side walls in the form of a circular, elliptical or polygonal cylinder, and in a collapsed configuration being substantially flat.

According to a first aspect of the present invention, a blank for a collapsible carton comprises a base formed from two base halves joined by a diametral fold line and two elongate side walls joined at their respective mid-regions to respective base halves at opposing regions of the perimeter of the base by folds extending parallel to the diametral fold line, the length of each side wall corresponding to half the perimeter of the base, and each side wall being hingedly joined at its ends to two substantially 'L' shaped flaps each having a longer portion extending perpendicularly to the diametral fold line and a shorter portion extending parallel thereto from the end of the longer portion adjacent the diametral fold line.

The base may be circular, elliptical or polygonal, and7 if polygonal, has an even number of sides. In the most preferred embodiment the base is hexagonal, formed by two trapezia joined along the longer of their respective parallel sides.

Each side wall is preferably divided into an even number of side wall panels, the panels being joined by folds extending substantially perpendicularly to the diametral fold line so as to form two arrays of side wall panels extending in directions parallel to the diametral fold line, with a generally 'L' shaped flap being formed at each end of each array of side wall panels. A longer portion of the 'L' shaped flap preferably extends perpendicularly to the diametral fold line and a shorter portion extends parallel thereto from the end of the longer portion adjacent the diametral fold line. Preferably the base is a polygon having an even number of sides greater than four, and the diametral fold line extends between two opposite corners of the polygon. The diametral fold line may, however, extend between the midpoints of opposite sides.The base may alternatively be formed by two semi-circular or semi-elliptical base halves joined by the diametral fold line.

The side walls are preferably formed from generally rectangular panels which are substantially similar in shape, and may be perforated or otherwise shaped to permit the attachment of handles, carrying straps or the like.

The blank may be formed from any suitable flexible sheet material, such as corrugated board, fibreboard or plastics sheet. A more robust collapsible carton may be assembled from a plurality of rigid components joined by hinges.

An embodiment of the present invention will now be described in detail with reference to the accompanying drawings, in which: Figure 1 is a view of a blank for forming the carton; Figure 2 is an underneath plan view of the erected carton; Figure 3 is a sectional side view taken on plane III-III of Figure 2; Figure 4 is a sectional side view taken in the plane IV-IV of Figure 2; and Figure 5 is a plan view of a blank for a lid for the carton of Figures 2, 3 and 5.

Referring now to the Figures, the carton bank shown in Figure 1 comprises a generally hexagonal base formed from two isosceles trapezoidal base portions 1 and 2, joined at their respective longer parallel sides by a fold line 3. At each end of the fold line 3, a notch 4 is cut into the base along the line of the fold 3.

The blank is generally symmetrical about the fold line 3, and further comprises six side wall panels laid out in two sets of three as will now be described.

Attached by a fold line 5, 5a to the shorter of the parallel sides of each base portion 1, 2 are first side wall panels 6, 6a of generally rectangular configuration. Fold lines 7, 7a and 8, 8a extend at right angles to the fold lines 5, 5a to define the first side wall panels 6, 6a. Attached to the first side wall panels 6, 6a by folds 7, 7a and 8 and 8a are second side wall panels 9, 10, 11 and 12, all four of the second side wall panels 9, 10, 11 and 12 being rectangular in shape substantially to correspond in dimensions with the first side wall panels 6, 6a.

At the edges of second side wall panels 9, 10, 11 and 12 which are parallel to and opposite the fold lines 7, 7a and 8 and 8a, generally 'L' shaped flaps 13, 14, 15 and 16 are joined to the respective second side wall panels 9, 10, 11 and 12 via fold lines 17, 18, 19 and 20. Each 'L' shaped flap 13, 14, 15, 16 has a longer portion 13a, 14a, 15a, 16a extending parallel to its respective fold line 17, 18, 19 and 20, and a shorter portion 13b, 14b, 15b, 16b extending perpendicularly thereto at the end of the longer portion which is nearest the base 1, 2. At the junction of the longer and shorter portions of each flap a cutout 21, 22, 23, 24 is formed, the purpose of which will be described below.

To assemble the carton, the 'L' shaped flaps 13, 14, 15 and 16 are folded upwardly about fold lines 17, 18, 19 and 20 respectively to overlie the adjacent regions of the second side wall panels 9, 10, 11 and 12.

By folding the blank about fold line 5, the base portion 1 is then brought to overlie its adjacent first side panel 6. Base portion 2 is then brought to overlie base portion 1 by folding the blank about fold line 3, and finally by folding about fold line 5a the three side wall panels 10, 6a, and 12 are brought to overlie the respective side wall panels 9, 7 and 11, with base portions 1 and 2 'sandwiched' between side wall panels 6 and 6a, and the 'L' shaped flaps 13, 14, 15 and 16 positioned between side wall panels 9, 10, 11 and 12.

In this position, flaps 13 and 14 and flaps 15 and 16 are secured together, preferably by bonding with an adhesive.

Alternatively, a double-sided adhesive tape or staples may be used, or heat sealing or welding may be used if the blank is of a plastics material.

The blank thus assembled is erected to form a carton by separating the side wall panels 6 and 6a at their edges remote from the base portions 1 and 2, and by exerting pressure on the fold line 3 of the base to urge it towards the plane of the fold lines 5 and 5a. This action urges the fold lines 5 and 5a apart, and the hinging action of the side wall panels about fold lines 7, 7a, 8 and 8a brings the flaps 13, 14, 15, 16 radially inwardly toward the ends of fold line 3.

As can be seen from Figures 3 and 4, when the carton is erected, the flaps 13, 14, 15 and 16 extend radially inwardly with fold line 3 resting on the shorter portions 13b, 14b, 15b, 16b of the flaps. The longer portions 13a, 14a, 15a, 16a of the flaps engage in the notches 4 at the ends of fold line 3. Likewise, the recesses 21, 22, 23, 24 receive the sheet material of the base at the ends of fold line 3. Further downward movement of the base portions 1 and 2 is prevented by the shorter portions of the flaps, and upward movement is resisted by the engagement of the base in the recesses 21, 22, 23 and 24.

To avoid the appearance of gaps between the base portions 1 and 2 and the side wall panels 9, 10, 11 and 12, the base portions may be provided with wings 30 extending from their convergent edges and joined thereto by folds. It will be appreciated that during erection of the carton, engagement between the wings 30 and their respective side wall panels will bend them up to their.final positions as seen in Figures 3 and 4, wherein the wings lean outwardly against their respective side wall panels.

The blank shown in the Figures includes tabs 31 at the upper (in Figures 3 and 4) periphery of the carton, the tabs 31 being folded radially inwardly to stiffen the structure. Locking strips 32 are provided on diametrically opposite side wall panels, to engage and retain a lid (not shown) covering the open top of the carton.

Alternatively, the tabs 31 may be extended and shaped so as to form a cover for the carton top, thus removing the need for a separate lid.

Figure 5 shows a blank for a lid suitable for fitting to the cartons of Figures 1 to 4. The blank may be transported flat, for erection at the point of sale. In Figure 5 broken lines indicate fold lines, while solid lines indicate slits in the material of the blank.

The lid blank comprises a central hexagonal portion 33, to the six sides of which are joined outer side wall flaps 34a to 34f.

To the radially outer edges of flaps 34a to 34f are joined inner side wall flaps 35a to 35f, and to the radially outer edges of the inner side wall flaps 35a to 35f are joined stiffening tabs 36a to 36f.

The outer side wall flaps 34 are further formed with interlocking tabs 37a to 37f respectively, which extend in a clockwise tangential direction from respective outer side wall tabs 34a to 34f.

To erect the lid, the blank is placed inside-up on a surface, and the interlocking tabs 37a to 37f are first folded upwardly at the join lines where they meet their respective outer side wall flaps 34.

The outer side wall flaps 34a to 34f are then folded up to be perpendicular to the central portion 33, with the interlocking tab 37 of each respective outer side wall flap 34 contacting the face of the outer side wall flap 34 next adjacent in the clockwise direction.

The inner side wall flaps 35 are then folded down over the interlocking tabs 36 of the adjacent flaps 34, and the stiffening tabs 36a to 36f are folded so as to lie adjacent the central portion 33.

Cutouts 38 formed in opposing tabs 35b and 35e cooperate with slits 39 to provide openings through which the locking strips 32 may enter to secure the lid to a carton.

While the blank illustrated is formed with six side walls and a hexagonal base, it will be readily appreciated by those in the art that any polygonal base having an odd number of pairs of sides may be divided by a fold line extending between opposite corners.

It will further be apparent that, if a polygonal base having an even number of pairs of sides is provided with a diametral fold extending between the midpoints of two opposite sides, the side wall panels will be arranged so that adjacent to each of the 'L' shaped flaps is a panel which in the erected state will form one half of a side wall panel.

Thus, any number of side wall panels may be provided to correspond with polygonal bases having an even number of sides. By providing two semi-circular or semi-elliptical base portions, with two side walls joined thereto at opposed points, it may be possible to form a circular or elliptical section cylindrical carton, similar in shape to a conventional hat box.

Claims

1. A collapsible carton comprising a base formed from two base halves joined by a diametral fold line and two elongate side walls joined at their respective mid-regions to respective base halves at opposing regions of the perimeter of the base by folds extending parallel to the diametral fold line, the length of each side wall corresponding to half the perimeter of the base, and each side wall being hingedly joined at its ends to two substantially 'L' shaped flaps each having a longer portion extending perpendicularly to the diametral fold line and a shorter portion extending parallel thereto from the end of the longer portion adjacent the diametral fold line.

2. A carton according to Claim 1, wherein each base half is semi-circular.

3. A carton according to Claim 1, wherein the base has an odd number of pairs of sides and the diametral fold line extends between opposite corners of the base.

4. A carton according to Claim 1, wherein the base has an even number of pairs of sides and the diametral fold line extends between the midpoints of a pair of opposing sides of the base.

5. A carton as claimed in any preceding Claim 4, wherein each side wall comprises a number of side wall panels hingedly joined together.

6. A carton according to any preceding Claim, wherein the respective base halves are formed with wings extending radially therefrom to engage the interior faces of the side walls.

7. A blank for forming a carton according to Claim 1, comprising a pair of base halves joined by a diametral fold line, a respective side wall being joined by a hinge to each base half, the side wall having a length substantially equal to half the perimeter of the base, and each side wall being provided at its ends with an 'L' shaped flap having a longer portion extending perpendicularly to the diametral fold line and a shorter portion extending parallel thereto from the end of the longer portion adjacent the diametral fold line.

8. A blank according to Claim 7, wherein the side walls are divided by transverse fold lines into a number of side wall panels.

9. A blank according to Claim 8, wherein each base half is an isosceles trapezium, and each side wall comprises three side wall panels hingedly connected together, the central panel of each side wall being hingedly connected to the shorter of the parallel sides of a respective one of the base halves.

10. A collapsible container substantially as herein described with reference to Figures 1 to 5 of the accompanying drawings.

11. A blank for forming a container substantially as described herein with reference to Figures 1 to 4 of the accompanying drawings.