GB2550125A

GB2550125A - Box and blank therefor

Info

Publication number: GB2550125A
Application number: GB1607952.7A
Authority: GB
Inventors: Elliott Jess
Original assignee: DS Smith Packaging Ltd
Current assignee: DS Smith Packaging Ltd
Priority date: 2016-05-06
Filing date: 2016-05-06
Publication date: 2017-11-15
Also published as: GB201607952D0; EP3241776A1

Abstract

A blank for a box comprising two additional crease line 38. Preferably, crease lines are perpendicular to length of the blank, and allow formation of flattened ring without folding of crease lines 44 forming corners of the box. Preferably, creases extend parallel to corrugations. Preferably, corners have 45° chamfers 26 with flaps 24 with edges that align with edge of perpendicular side to act as mandrels to form assembled box. Preferably, flaps have intermediate edges 50 to support inside edge of chamfer, and width of flaps corresponded to width between side walls 22. Preferably, mandrel flaps are form on top and bottom on shorter ends. A split panel comprises glue lap portion 48, where corrugated cardboard is crushed to form joint which is less than double the thickness of the non-crushed cardboard, preferably, 80-180%. Preferably, split panel is joined to form fourth whole side panel.

Description

Box and Blank therefor

This invention relates to a box or a blank for a box in which material savings can be provided, increased vertical load strength can be provided and in which easier transportation can be achieved.

Cardboard boxes of many designs are well known in the art. There is nevertheless a continuing desire to create boxes that are easier to assemble, easier to transport, more efficient in material usage for a given load quantity and an improved crush-strength for vertical loading, thus allowing increased stacking opportunity of multiple boxes. The present invention seeks to achieve one or more of these objectives.

According to the present invention, there is provided a blank for a box comprising four sides, four corners, and a bottom, the blank comprising panels for forming the sides of the box, the panels having flaps extending from a side thereof for forming the bottom of the box and four spaced panels for forming chamfered corners for the box, the four spaced panels being arranged parallel to one another along the length of the blank so as to extend in their longer dimension perpendicular to the length of the blank, wherein the flaps are separated relative to one another by their spacing along the blank or by cuts where adjacent.

More preferably there is also a top, and a blank for that box may comprise four sides, four corners, a top and a bottom, the blank comprising panels for forming the sides of the box, the panels having flaps extending from either side thereof for forming the top and bottom of the box and four spaced panels for forming chamfered corners for the box, the four spaced panels being arranged parallel to one another along the length of the blank so as to extend in their longer dimension perpendicular to the length of the blank, wherein the flaps extending to the sides of the panels for forming the sides of the box are separated relative to one another by their spacing along the blank or by cuts where adjacent.

By the provision of chamfered corners, for a given box size a shorter blank can be provided as the chamfer cuts off the peripheral dimension of the box (by cutting the corners). The saving is typically between 1 and 10% on the length of the blank. A similar arrangement may be provided where the blank is for a box with only a top, i.e. no bottom.

Preferably crease lines are formed in the blank to define hinge lines that separate the panels from the flaps on the blank.

Preferably the blank is made of a corrugated material. Preferably it is cardboard. Preferably it has a non-crushed thickness of between 1 and 10mm.

Preferably there are three whole panels for forming three of the sides of the box and a fourth split panel having a first end at one end of the blank and its second end at the opposing end of the blank for forming a fourth whole panel when the ends of the split panel are joined together. For this purpose, at least one of the ends of the split panel may comprise a glue lap portion.

Preferably the glue lap portion extends perpendicular to the longitudinal length of the blank, i.e. the direction along which the three whole panels are arranged.

Preferably the glue lap portion extends beyond a side edge, or side edges, of the end of the split panel that it is provided on, i.e. across the hinge line on the edge of that end of the split panel, across onto the flap provided thereon (as used for forming a part of the bottom or top of the final box).

Preferably both split panels have a glue lap portion. The two glue lap portions will generally be at the or each end of the blank.

Both glue lap portions may extend across hinge lines into flaps used for forming a top or bottom of the final box.

Preferably the material of the blank is crushed at the overlap between the or both glue lap portions.

When joined together, the two split panels can provide a fourth side in the assembled box.

Where provided, the crush preferably results in the thickness of the join generally matching the thickness of the non-crushed material, or at least it being reduced relative thereto by a reasonable amount - preferably at least 20%. Therefore the thickness of the join is substantially less than double the thickness of the non-crushed material of the blank - preferably between 180% and 80% of the thickness of the non-crushed material. More preferably it is between 150% and 90% of the thickness of the non-crushed material of the blank.

Preferably, however, the thickness of the join is substantially similar to the thickness of the non-crushed material of the blank - i.e. within 20% thereof.

For this purpose the crush is preferably at least a 50% thickness change within the crushing machine (or pinch roller). It is to be appreciated, however, that there can be material bounce-back upon release of the crushing or pinching machine as the material - particularly a corrugate - has inherent elasticity, thus resulting in a thicker assembled arrangement in the final product. Furthermore the degree of bounce-back can be variable. Nevertheless, through the process of the crush, the material is softened, thus allowing later compression (in a stack or bale of blanks, for example) to be made more achievable within the stack, so even a non-target final crush thickness can have useful benefits.

The blank may be crushed on one or both sides, preferably on different sides for the two glue lap portions. With the latter, a more level or flush finish will be achieved between the join and the non-crushed material.

The crush results in a better stacking product, if stacked with the join pre-applied, or a smoother surface finish in the final assembled product, or an easier fold for the flap that bridges the join where the glue lap portion(s) bridges across to the flap.

According to a second aspect of the present invention, there is provided a blank for a box comprising sides, corners and at least a bottom, the blank comprising crease lines for forming the corners of the box between panels for forming the sides of the box and two additional crease lines formed across two panels of the blank that form two opposing sides of the box when assembled.

The additional crease lines, typically are arranged perpendicular to the length of the blank.

The additional crease lines allow the blank to be folded and glued (or otherwise joined) into a flattened ring prior to shipment without any folding of the crease lines used to form the corners of the box. As a result the shipped product is smaller in cross sectional area than a whole-flat blank, when viewed in plan. Further, this results in the final user not needing do that initial ring-forming (and gluing/joining) step. The pre-glued/joined blank for a box can thus be produced and glued in a single pass on a case maker, with the user only then needing to reshape the box into the open box shape, fold closed the bottom, tape or otherwise secure its bottom shut, load it, and then tape, or otherwise secure its top shut.

Because the additional crease lines are formed across panels of the blank that form sides of the box, rather than at the corners, the final assembly, or reshaping of the box into an open-box arrangement for loading becomes the first fold of the creases that form the corners of the box, thus firstly preventing excessive folding of any of the creases for the corners (i.e. the otherwise necessary 180 degree folds, so as to be flat for shipment), and secondly preventing unnecessary repeat folding of the corners (i.e. the 180 degree fold and then a 90 degree unfold - for a square/rectangular box). Both of these benefits maximise the final box strength as a repeat-folded corner, or a fully flat-folded and then-reopened corner, will be weaker than a once-folded corner. The additional crease lines thus unexpectedly increase the final product’s corner strength, which in turn, despite a potentially perceived weakness being introduced by the provision of additional crease lines, actually increase its vertical loading strength. This is particularly apparent where the corners, and thus usually also the additional crease lines, are arranged vertically in use.

Preferably the corners, and the crease lines therefore, and the additional crease lines, extend parallel to the corrugations of the material where the material is a corrugated material. As such, the present invention also provides a blank made of a corrugated material, for making a box, wherein crease lines for forming corners of the box that extend up from a bottom of the box, and two additional crease lines that extend, respectively, across one of two panels of the blank that form two opposing sides of the box, extend parallel to the corrugations of the corrugated material.

Preferably the corners are chamfered corners, either singly chamfered or multi-chamfered.

The additional crease lines preferably extend across the panels full width, and onto the flaps used to form the bottom of the box, and the top of the box if additional flaps for that are also provided. The additional crease lines thus pass through hinge-line-forming crease lines provided between the flaps and the panels.

All these features may also be combined with the preceding aspects or details of the present invention.

According to a third aspect of the present invention there is provided a blank for forming a box comprising multiple sides, preferably four, and comprising corners which are chamfered by one or more chamfer surface, the blank comprising at least three panels for forming at least three sides of the box, wherein at least one flap extends from an edge of at least one of the panels, that flap having provided along its cut edge, a profile corresponding to an inside form of the assembled box to allow the flap to be used as a mandrel for forming the box.

Preferably the box is a four sided box and the chamfers each are a 45° chamfer whereby the flap comprises a 45° angled edge, relative to the hinge line of the flap for aligning with an inside of the corner chamfer of the box.

Preferably the flap also comprises a perpendicular edge along its side for aligning with an inside wall of another side of the box, one extending perpendicularly from the side of the box from which the flap extends.

Preferably the 45° angled edge spaces the perpendicular edge from the hinge line.

Instead of a 45° angled edge, a different intermediate edge may be provided for this spacing, although it preferably is shaped to support the inside surface of the chamfered corner, whether as a straight chamfer or a curved chamfer or a multi-chamfer chamfer. As such, an intermediate edge may space the perpendicular from the hinge line, the intermediate edge being shaped to support the inside surface of the chamfered corner.

Preferably the perpendicular edge is spaced from the hinge line such that the width of the flap on the panel of the blank, measured between two parallel edges thereof provided by two said perpendicular edges thereon, is wider than the width of the panel of the blank from which it extends.

Preferably the extent to which the flap is wider than its panel is defined by a distance corresponding to a difference between the length of the side panel and the inside width of the final box measured parallel to that side panel.

Preferably the side panel has a similar flap extending from both of its edges, i.e. a top as well as the bottom edge, so that the mandrel effect is provided for a top and the bottom of the box when assembling it.

Preferably the side panel having these flaps or the flap is a shorter side panel of the box - i.e. for a generally rectangular box.

The edges of the flaps on two adjacent panel, where provided, are preferably non-symmetrical about the corner centreline therebetween.

Preferably the line of contact line between two adjacent flaps - usually a cut-line - is displaced away from, i.e. to the side of, the corner centreline between the two panels from which they extend.

The flaps of the invention will preferably be internal flaps of the bottom (or top) of the assembled box. As internal flaps get folded first, i.e. before external flaps that get folded thereover, they conveniently provide the mandrel effect early in the assembly process. A second panel for forming a side wall opposing the first side wall (the side wall with the said flap(s)) may also be provided with such a flap or flaps.

In a preferred embodiment, the second panel having such a flap or flaps is formed from a split panel having two ends, wherein upon joining together the two ends of the split panel (each end, for example, being at a respective end of the blank), such as by using one or more glue lap portion provided thereon, the second panel and its mandrel forming flap or flaps are formed.

These features may also be combined with the preceding aspects or details of the present invention.

According to a fourth aspect of the present invention, there is provided a blank for a box comprising a plurality of sides, a plurality of corners, and a bottom, the blank comprising panels for forming the sides of the box, the panels each having a flap extending from a side thereof for forming the bottom of the box, the blank having two glue-lap portions for joining together two sections of the blank by overlaying the glue-lap portions and joining them together, preferably using glue, although other known connections can be provided such as tape or staples, wherein the blank is made of a corrugated material and the material is crushed at the overlap between the two glue-lap portions such that the thickness of the join is substantially less than double the thickness of the non-crushed material of the blank.

Preferably the thickness of the join is substantially similar to the thickness of the non-crushed material of the blank.

The thickness of the join is preferably between 180% and 80% of the thickness of the non-crushed material. More preferably it is between 150% and 90% of the thickness of the non-crushed material of the blank.

This crush, or the final effect thereof, can be as previously described with respect to the first aspect of the present invention.

Preferably the crush is provided before the joint is made.

Preferably the panels include at least two whole panels for forming a corresponding number of sides of the box and a split panel formed of the two sections of the blank for forming a further side of the box, the two sections being a first end of the split panel, provided at one end of the blank and a second end of the split panel at the opposing end of the blank. The ends of the split panel each have one of the two glue-lap portions, and those glue lap portions are provided at the ends of the blank.

The two ends of the split panel may be for forming a fourth whole panel when the ends of the split panel are joined together.

Preferably the box is square or rectangular, so there are at least three whole panels, and either a fourth panel or a split panel.

As in the first aspect of the invention, the blank may be crushed at the glue-lap portions on one or both sides, preferably on different sides for the two glue lap portions. With the latter, a more level or flush finish will be achieved between the join and the non-crushed material.

The crush results in a better stacking of a plurality of folded blanks, e.g. if stacked flat, but folded effectively in half, i.e. about two crease-lines on the blank, with the lap portion(s) joined to form a flattened ring with the blank. This allows a more compact bale of folded blanks - a lower height for the bale for a given number of folded blanks.

The crush may also (or instead) provide a smoother surface finish in the final assembled product - the box.

The crush may also (or instead) provide an easier fold for the flap used to form the bottom (or likewise a top, when provided) where that flap bridges the join. This is because there will not be a double thickness across the hinge line between the flap and the panel as a consequence of the join - it is instead flatter due to the crush thereof. For this, the glue lap portions extend from edges of the ends of the split panel into flaps attached thereto, the crush extending through the hinge line between the flaps and the ends of the split panel.

This aspect may also be used with any of the preceding aspects or details, not just the already described first aspect.

The present invention also provides a box formed using a blank of any one of the preceding aspects of the present invention - usually a box made of a corrugated material.

The present invention also provides a method of assembling a box as defined above using a blank according to the third aspect of the present invention, such that the blank provides its own mandrel during assembly. Other box designs, especially those with chamfered corners, usually require the box to be assembled over a mandrel to prevent it being assembled non-square, or non-symmetrically, or otherwise improperly.

The present invention also provides a stack of folded-flat blanks, the blanks being as defined above, and each being folded into a flattened ring. The stack may be a bale of blanks, having a securement strap around it.

These and other features of the present invention will now be described in greater detail, purely by way of example, with reference to the accompanying drawings, in which:

Figure 1 shows a plan view of a possible blank in accordance with the present invention;

Figure 2 shows the blank folded about its additional crease lines and glued at its glue lap portions ready for shipment to a customer as a flattened ring, perhaps within a bale of similarly arranged blanks;

Figure 3 shows a side view of the folded and flattened ring of the blank of Figure 2;

Figure 4 shows a flap of the blank of Figure 1 being used as a mandrel;

Figure 5 shows the other flaps of the blank of Figure 1 being folded over the mandrel flap for completing the closure of the base of the box;

Figure 6 shows a perspective view of the base and a side wall of the folded blank showing the join between the two glue lap portions presenting a generally more flush arrangement for the side of the box than a non-crushed arrangement would provide, the arrangement also providing an easier folding of the flap for its use as a mandrel;

Figure 7 shows a fully closed box made with the blank of Figure 1; and

Figure 8 schematically illustrates the material savings achieved utilising the chamfered corners of the present invention rather than conventional square corners using a conventional glue lap tab - the corresponding extension to the left being the additional material found in the conventional blank for a similarly sized box in terms of its length, width and height.

Referring first of all to Figure 1, there is shown a blank 10 for a box 12 (see Figure 7), wherein the box has four sides 14 and thus the blank 10 comprises panels 22 for forming the four sides of the box 12.

The box also has chamfered corners 16 and as there are four - to match in this instance the number of sides - the blank thus has four spaced panels 26, these spaced panels 26 being spaced apart by the panels 22 for the sides 14.

Each spaced panel is arranged parallel to the others, and are spaced along the length of the blank. As shown, they extend in their longer dimension perpendicular to the length of the blank.

This box 12 of Figure 7, as formed with this blank 10, is a closed box 12, and thus it also has a top 18 and a bottom 20 (see Figure 5). Flaps 24 extending either side of the edges (or hinge lines 46 thereat) of the panels are provided for forming, respectively, the top 18 and the bottom 20 of the box 12, i.e. when the box is fully assembled and closed.

As shown, each panel 22 for forming a side of the box has extending therefrom such a flap. These flaps may be described as closing flaps 24.

The spaced panels 26 for forming the chamfered corners 16 of the box 12 do not have flaps extending from their ends in this illustrated embodiment. There is instead a cutout 50 at these locations - eight of them in total in the illustrated embodiment. However, the cut-outs 50 may instead be replaced by corner flaps which can be folded under the closing flaps 24 (into the insides of the boxes), although corner flaps of this kind can compromise a mandrel-forming function of those closing flaps if such corner flaps are provided, so they are preferred to be cut-outs instead. See below for a description of the mandrel function of the closing flaps 24, which mandrel function works best with the provision of the cut-outs 50.

In this embodiment - which may be destined for use as a potato box for carrying up to about 15kg of potatoes, the box 10 has relatively standardised dimensions, for familiarity by the end user. In this instance it is a box height of about 273mm, side lengths (between the chamfers) of about 337mm and 227mm and a width for the spaced panels defining the chamfered corners of 45mm. The resultant box is of a familiar height, width and length, despite the presence of chamfered corners - which corners have instead generally been square in the past.

It will of course be apparent to a skilled person that different dimensions will be appropriate instead in other circumstances, the sizes thus being dependent upon the desired final box size or shape and final desirable depth of any chamfers at the corners, which chamfers need not always be present, and which chamfers need not be uniform or present at every corner.

As shown in Figure 1, the panels 22 for the sides 14 of the box 12 have a variety of forms across the length of the blank 10. Two of the panels 22 are formed with two halves 60, each half of a pair being integral with the other half of that pair, and a first end of each of the halves 60 being integral to one of the spaced panels 26 with first crease lines 36 providing the spatial separation therebetween. There is then a further panel 22 - arranged generally in the middle of the blank 10 - having its two ends also integral to spaced panels, with crease lines 36 again providing the spatial separation between those two ends and the space panels 26. There is then a final side forming panel - this time in the form of a split panel, the split panel having a first end 32 at one end of the blank 10 and a second end 34 at the opposite end of the blank 10. These first and second ends are shown to be both provided with a crushed glue lap portion 48, which will be described in further detail below. Note too the discussions above. They are for allowing the blank 10 to be folded as shown in Figures 2 and 3 into a flattened ring 40 for shipping purposes during which folding the split panel 34 becomes a single panel, and thus one side 14 of the box 12, as shown in Figures 2 and 6. There are thus four resultant panels 22 for forming the four sides 14 of the box 12.

Extending perpendicular to the length of the blank, there is also provided two additional crease lines 38, as shown in Figure 1. These additional crease lines 38 provide a spatial separation between the two halves 60 of the first-described panels 22 above. They facilitate the folding of the blank 10 into the shipping configuration of Figure 2, i.e. the flattened ring 40 arrangement.

These additional crease lines 38 are deliberately provided in a position that is spaced away from the crease lines 36 between the panels 22 and the spaced panels 26 such that the blank 10 can be folded into its flattened ring 40 configuration without folding the blank 10 about the crease lines 36 provided for the chamfered corners 16.

These additional crease lines 38 extend in this embodiment along the mid-point of the panels of the longer sides 14 of the box 12, as shown in Figure 1, thus defining the pairs of halves 60. They may be otherwise located on these halved panels, whereupon the halves are not equal halves, or the halved panels 22 may be the panels for the shorter sides of the box, with a corresponding rearrangement of the rest of the blank 10, but the arrangement shown is preferred as by having these longer side panels cut in their middle, the box remains symmetrical once assembled, and thus upon vertical loading there will be less twisting induced within the vertically loaded box.

As the chamfered corners 16 are singular chamfer chamfers, the blank 10 additionally has eight cut-outs 50 - one at each end of the spaced panels 26. In this embodiment, the cut-outs are triangular.

As shown it is preferred that the cut-out has a flat surface at its longest side. This longest side is shown to be co-linear with the hinge lines 46 between the flaps 24 and the panels 22.

As shown in Figures 2 and 5, the longest side 52 defines a top edge of the corners.

Figure 2 also shows that the other two sides of the triangular cut-outs 50 are non-symmetrical. The shortest side 54 of each cut-out is provided on the flaps that form the outer flaps of the top 18 and bottom 20, as also shown in Figure 5. The shape of that shortest side 54 is not particularly critical as it serves little function other than to define a shape of the bottom and top visible part of the closed box 12. The final side 56 of the triangular cut-outs 50, however, provides an important function and in line with the third aspect of the present invention have a shape corresponding to the inside profile of the chamfered corner 16 of the box 12. Thus, in this embodiment, they provide a 45° angular extension away from the longest side 52 and have a length corresponding to the inside length of the chamfered corner 16 once the box has been assembled. A sharp point between the final side 56 and the longest side 52, however, is generally not provided as a perpendicular or rounded first part may be provided to allow for the thickness of the material of the blank 10 and thus the resulting radius of the bend of the hinge line 56 between the flaps 24 and the panels 22 when the flaps 24 are folded perpendicular to the panels 22/sides 14.

Referring again to Figure 1, adjacent flaps 24 have in this embodiment an adjoining edge 44, which in this embodiment are perpendicular edges 44 - perpendicular to the hinge lines 46, and extending to the cut-outs 50. These perpendicular edges 44 are defined by a cut line between the flaps 24 on the blank 10, as shown in Figure 1. As the box in this embodiment is a rectangular box, this perpendicularity is important for the flaps 24 provided on the shorter sides 14, assuming that as shown they will be the inside flaps during the folding process and thus just as the 45° angled edge defines the inside shape of the corners 16, those perpendicular edges 44 define the perpendicularity of the adjacent side 14 to that which the flap in question is attached. This arrangement is beneficial as, as shown in Figure 4, the folded flap 24 during assembly of the box 12 can then provide the function of a mandrel such that the final side 56 thereof, which provides a 45° angled edge 42 and the perpendicular edge 44, together allow a correct and uniform folding of the two sides of the box, and the corner, all relative to one another.

Further, as a similar shape to that is provided at the opposing edge of that flap 24, this other side of the flap can likewise allow the opposing longer side to be correctly aligned, by that opposing edge also providing the mandrel function. Thus the final folding of the adjacent flaps, as shown in Figure 5, can be correctly aligned relative to one another. A similar flap 24 also on the other shorter side of the box likewise aligns the other side of the box.

Yet further, further similar flaps for the top of the box are provided for likewise providing an accurate folding of the top, just like the bottom.

The resulting box can thus be correctly and accurately shaped using the flaps as mandrels, and without having to rely upon a separate mandrel being provided.

Different shapes of chamfered corners and different sizes of boxes may require different shapes and configurations for these flap-edge components, as will be understood in the art.

This aspect of the invention provides a benefit in that a separate mandrel is not needed for forming the box, whereby the box can be erected correctly wherever it is being used - particularly beneficial for the vegetable market, where boxed may be then assembled “in the field”.

The present invention also comprises other inventive aspects and thus other embodiments might also be provided wherein the mandrel feature is not present.

Referring again to Figure 2, and also to Figures 3 and 6, it should first of all be observed that the additional crease lines 38 as shown in Figure 1 need not necessarily be centrally arranged relative to the panel 22 in which it sits. Instead they may each be spaced nearer to one of the two crease lines 36 for the corner panels. A corresponding move of the opposing additional crease line 38 in the other panel is necessary to ensure the fold of Figure 2 can be achieved, albeit with the spaced panels 26 then not being symmetrically arranged on the product ready for shipment. Moving only one will prevent a correct alignment of the glue lap portions.

As already described, positioning the additional crease lines non centrally in their respective panels 22 (i.e. forming non-equal halves 60) may introduce an element of twist into the assembled box upon vertical loading due to the non-symmetry thereof. It is preferred, therefore, that the additional crease lines 38 are centrally located in their respective panels 22.

Still referring to Figures 2, 3 and 6, the glue lap portion can be seen to have been crushed so as to allow (as in Figure 3) the edge profile of the joined pair of glue lap portions to define a thickness generally corresponding to the thickness of the non-crushed material. This provides a neater stacking when bailing multiple blanks together, i.e. with the blanks in their folded and pre-glued arrangement of Figures 2 and 3. In practice there can be bounce-back of the corrugate material, thus resulting in a thicker join than that shown. However, the biggest benefit arises when the resultant join is flush. The benefit of a thicker resultant join is nevertheless useful as having made an initial crush of the desired amount - before bounce-back - the material is softened, thus allowing the material more readily to squash again, thus facilitating both stacking of folded blanks and folding of the flaps that bridge the joint about their crease line 46: the crushing further facilitates an easier folding of the flap 24 that has therein the glue lap joint. To not have crushed the material would mean that a double thickness of material would need to be folded for that flap 24.

Referring finally to Figure 8, superimposed over a standard linear blank for forming a rectangular box, is the blank 10 of the present invention. As can be seen, to the left hand end of the underlying blank 58, the material of that blank (for a conventional rectangular box) extends away from the similar end of the blank of the present invention. This is because it is longer than the blank of the present invention. This length reduction with the blank of the present invention occurs because in a conventional rectangular box the corners are square and thus there is no shortening of the perimeter length of the box by the provision of chamfered corners, whereas in the present invention’s example blank, there is chamfering of the corners. This preferred arrangement this provides a saving in length of the blank, the scale of which may be in the order of 1 to 10%, depending upon the chosen design of the chamfers. The illustrated embodiment is a saving of perhaps 5%.

The additional length of the blank, as found in conventional blanks, when multiplied for the many thousands of blanks that may be produced per product run for a client, equates to a very significant material increase compared to the present invention. The present invention thus also offers an environmental benefit over conventional designs.

It should also be noted that the slight loss in internal volume of the box arising as a result of the chamfered corners does not necessarily produce difficulties for the customer. Its consequence will depend upon the products to be loaded into the box.

Loose fruit or vegetables, for example, should not suffer at all. After all, such loose fruit or vegetables will generally be loaded into the boxes without the fruit or vegetables actually impinging on the corners of the box (due to the size and shape of the products - they will rarely be square-edged. For example, potatoes and other large vegetables will never be able to contact directly into the corner of a box due to the generally spherical nature of those vegetables, whereby the chamfered internal form of the corners does not in practice reduce the loading capacity of the box.

The present invention is therefore particularly appropriate for potatoes, onions and other loose products, especially ones having a shape and hardiness that allows for direct loading into the box in a non-densely packed manner. This applicability can also extend to non-food products such as balls.

The size of the box illustrated in the drawings is for a 15kg load of potatoes. This weight is chosen for manual handling purposes - heavier loads need mechanical lift assists under many local health and safety regulations. Other box sizes and shapes, including trays, however, can also benefit from the present invention’s various aspects, including those for heavier or lighter loads, or for heavier or lighter density loads. A further distinguishing feature of the present invention arises since in conventional designs the glue lap portion 48 extends longitudinally beyond the extent of the flaps for the top and bottom of the box as the fourth panel in conventional designs is neither a split panel nor an arrangement in which the material of the blank has been crushed. Thus, in conventional designs the glue lap portion does not form any part of the top or bottom of the box. As a consequence, any glue lap portion provided in the prior art would never need to fold across a hinge line between the side panel (to which it’s attached) and the flap for the top or bottom extending therefrom. Providing a crush in the flaps would thus never be needed in the prior art. The crush extending across to the flaps, or across that hinge line, as found in the preferred and illustrated blank of the present invention, is thus new.

The present invention has therefore been described above purely by way of example. Modifications in detail may be made to the present invention within the scope of the claims as appended hereto.

Claims

CLAIMS:

1. A blank for a box comprising sides, corners and at least a bottom, the blank comprising crease lines for forming the corners of the box between panels for forming the sides of the box and two additional crease lines formed across two panels of the blank that form two opposing sides of the box when assembled.

2. The blank of claim 1, wherein the additional crease lines are arranged perpendicular to the length of the blank.

3. A blank according to any one of the preceding claims, folded and joined into a flattened ring without any folding of the crease lines used to form the corners of the box.

4. A blank according to any one of the preceding claims, made of a corrugated material, wherein the crease lines for forming the corners of the box that extend up from the bottom of the box and the two additional crease lines that extend, respectively, across one of two panels of the blank that form two opposing sides of the box, extend parallel to the corrugations of the corrugated material.

5. A blank according to any one of the preceding claims, wherein the corners of the box are chamfered corners, either singly chamfered or multi-chamfered.

6. A blank for forming a box comprising multiple sides and comprising comers which are chamfered by one or more chamfer surface, the blank comprising at least three panels for forming at least three sides of the box, wherein at least one flap extends from an edge of at least one of the panels, that flap having provided along its cut edge, a profile corresponding to an inside form of the assembled box to allow the flap to be used as a mandrel for forming the box.

7. The blank of claim 6, wherein the blank is for a four-sided box and the chamfers each are a 45° chamfer whereby the flap comprises a 45° angled edge, relative to the hinge line of the flap for aligning with an inside of the corner chamfer of the box.

8. The blank of claim 6 or claim 7, wherein the flap comprises a perpendicular edge along its side for aligning with an inside wall of another side of the box, when assembling it, that another side of the box extending perpendicularly from the side of the box from which the flap extends.

9. The blank of claim 8 when also dependent upon claim 7, wherein the 45° angled edge spaces the perpendicular edge from the hinge line.

10. The blank of claim 8, wherein an intermediate edge spaces the perpendicular from the hinge line, the intermediate edge being shaped to support the inside surface of the chamfered corner.

11. The blank of any one of claims 8 to 10, wherein the perpendicular edge is spaced from the hinge line such that the width of the flap on the panel of the blank, measured between two parallel edges thereof provided by two said perpendicular edges thereon, is wider than the width of the panel of the blank from which it extends.

12. The blank of claim 11, wherein the extent to which the flap is wider than its panel is defined by a distance corresponding to a difference between the length of the side panel and the inside width of the final box measured parallel to that side panel.

13. The blank of any one of claims 6 to 12, wherein the panel has a similar flap extending from both of its edges, to provide a mandrel for a top as well as the bottom when assembling it.

14. The blank of any one of claims 6 to 13, wherein the panel having the mandrelforming flap or flaps is a shorter side panel of a blank for forming a generally rectangular box.

15. The blank of any one of claims 6 to 14, wherein a second panel for forming a side wall opposing the first side wall is also provided with a similar mandrel-forming flap.

16. The blank of claim 15, wherein the second panel is formed from a split panel having two ends, wherein upon joining together the two ends of the split panel, the second panel and its mandrel forming flap are formed.

17. The blank of any one of claims 6 to 16, being also in accordance with any one of claims 1 to 5.

18. A blank for a box comprising four sides, four corners, and a bottom, the blank comprising panels for forming the sides of the box, the panels having flaps extending from a side thereof for forming the bottom of the box and four spaced panels for forming chamfered corners for the box, the four spaced panels being arranged parallel to one another along the length of the blank so as to extend in their longer dimension perpendicular to the length of the blank, wherein the flaps are separated relative to one another by their spacing along the blank or by cuts where adjacent.

19. The blank of claim 18, being also in accordance with any one of claims 1 to 17.

20. The blank of any one of the preceding claims, being for a box comprising both the bottom and a top, the blank comprising flaps for forming the top of the box.

21. The blank of any one of the preceding claims, wherein crease lines are formed in the blank to define hinge lines that separate panels for forming the sides of the box from the flaps on the blank.

22. The blank of any one of the preceding claims, made of a corrugated material.

23. The blank of any one of the preceding claims, made of cardboard.

24. The blank of any one of the preceding claims, having a non-crushed thickness of between 1 and 10mm.

25. The blank of any one of the preceding claims, wherein there are three whole panels for forming three sides of the box and a fourth split panel having a first end at one end of the blank and its second end at the opposing end of the blank for forming a fourth whole panel when the ends of the split panel are joined together.

26. The blank of claim 25, wherein at least one of the ends of the split panel comprises a glue lap portion.

27. The blank of claim 26, wherein the glue lap portion extends perpendicular to the longitudinal length of the blank.

28. The blank of claim 26 or claim 27, wherein the glue lap portion extends beyond a side edge, or side edges, of the end of the split panel that it is provided on, across any hinge line on the edge of that end of the split panel, and across onto the or each flap provided thereon.

29. A blank for a box comprising a plurality of sides, a plurality of corners, and a bottom, the blank comprising panels for forming the sides of the box, the panels each having a flap extending from a side thereof for forming the bottom of the box, the blank having two glue-lap portions for joining together two sections of the blank by overlaying the glue-lap portions and joining them together, wherein the blank is made of a corrugated material and the material is crushed at the overlap between the two glue-lap portions such that the thickness of the join is substantially less than double the thickness of the non-crushed material of the blank.

30. The blank of claim 29, wherein the thickness of the join is substantially similar to the thickness of the non-crushed material of the blank.

31. The blank of claim 29, wherein the thickness of the join is between 180% and 80% of the thickness of the non-crushed material.

32. The blank of any one of claims 29 to 31, wherein the crush is provided before the joint is made.

33. The blank of any one of claims 29 to 32, wherein the panels include at least two whole panels for forming a corresponding number of sides of the box and a split panel formed of the two sections of the blank for forming a further side of the box, the two sections being a first end of the split panel, provided at one end of the blank and a second end of the split panel at the opposing end of the blank.

34. The blank of claim 33, wherein the two ends of the split panel are for forming a fourth whole panel when the ends of the split panel are joined together.

35. The blank of claim 34, wherein the box to be assembled with the blank is square or rectangular, so there are at least three whole panels and the split panel.

36. The blank of claim 33, claim 34 or claim 35, wherein the glue lap portions extend from edges of the ends of the split panel into flaps attached thereto, the crush extending through the hinge line between the flaps and the ends of the split panel.

37. The blank of any one of claims 29 to 36, also in accordance with any one of claims 1 to 28.

38. A blank substantially as hereinbefore described with reference to any one or more of the accompanying drawings.

39. A box formed using a blank of any one of the preceding claims.

40. A method of assembling a box, comprising folding a blank according to claim 6 or any one of the preceding claims when dependent upon claim 6, the folding being done such that the flap of the blank that extends from an edge of at least one of the panels, and having provided along its cut edge, a profile corresponding to an inside form of the assembled box, is used such that the flap’s cut edge profile is used as a mandrel for forming the general shape of the box.

41. A stack of blanks, the blanks being in accordance with any one or more of claims 1 to 38.

42. The stack of claim 41, wherein the blanks, before being stacked, have each been folded into a flattened ring.