US20040222276A1

US20040222276A1 - Material-saving blank and box

Info

Publication number: US20040222276A1
Application number: US10/431,984
Authority: US
Inventors: John Correll
Original assignee: CORRELL CONCEPTS LP
Current assignee: CORRELL CONCEPTS LP
Priority date: 2003-05-08
Filing date: 2003-05-08
Publication date: 2004-11-11

Abstract

A pizza box and blank comprising one or more of the features of (1) a unique end wall and corner panel structure for a box blank structure similar to that shown in Correll U.S. Pat. No. 6,547,125; (2) a unique cover side flap structure for a box blank structure similar to that shown in Correll U.S. Pat. No. 6,547,125; and (3) a unique pressure-reducing crushed area in the bottom panel for a box blank structure similar to that shown in Correll U.S. Pat. No. 6,547,125.

Description

FIELD OF THE INVENTION

This invention relates to packaging in general and in particular to boxes and box blanks for food products such as pizza and the like.

DESCRIPTION OF THE PRIOR ART

Each year thousands of pizza businesses sell millions of hot pizzas for delivery and carry-out. The success of these businesses depends to an extent on the cost and functionality of the boxes used for packaging the product. Ideally, these boxes should be cost-effective and easy to use.

The instant invention pertains to a blank and box that contains several structural enhancements that are applicable to a prior invention of mine disclosed in Correll U.S. Pat. No. 6,547,125 granted Apr. 15, 2003, and entitled “Material-saving Food Carton.” The preferred embodiment of the invention disclosed in this prior patent happens to be a non-fastened, non-rectangular, some-slanting-wall box having a full-length cover panel. The disclosure, discussion, and terminology contained within this U.S. Pat. No. 6,547,125 is included herein by this reference thereto.

One of the ways of reducing the amount of material required for making a box blank is to design the blank so that it can be oriented 180 degrees to an adjacent similar blank and then mated (or nested) along the adjacent sides of the two blanks. This technique has been done for decades within the packaging industry. One example is disclosed in Lighter U.S. Pat. No. 2,435,283 granted Feb. 3, 1948. This patent shows a blank having a cover side flap that has a shorter height than the side wall of the blank, thereby allowing one blank to be oriented 180 degrees to a similar adjacent blank and then mated together for manufacture.

The prior art also discloses Deiger U.S. Pat. No. 4,919,326 granted Apr. 24, 1990; Philips et al. U.S. Pat. No. 5,702,054 granted Dec. 30, 1997; and Correll U.S. Pat. No. 6,206,277 granted Mar. 27, 2001. Each of these patents discloses a particular type of structure comprising a side wall attached to a bottom panel, a corner panel attached to an end of the side wall, a connector panel attached to a bottom edge of the corner panel, an end wall panel attached to the bottom panel, and an end flap attached to an end of the end wall panel and also to the connector panel.

Philips et al., in particular, depicts the structure of the pizza box and box blank currently in use by Domino's Pizza.

Each of the above-cited prior art has a particular drawback. Specifically, Lighter discloses how to mate adjacent blanks of a particular structure but does not disclose how to mate adjacent blanks having a structure similar to that of the Domino's Pizza pizza box blank (or Philips et al.)

Deiger, Philips et al., and Correll '277 disclose how to create a non-slanting end wall on a box having a structure similar to the Domino's Pizza pizza box, but do not disclose how to create a material-saving inward-slanting end wall. Further, they do not disclose how to save material by mating adjacent blanks having a structure similar to that of the Domino's Pizza pizza box blank.

In conclusion, it would be highly desirable to provide a pizza box and blank that overcomes the above-cited drawbacks and further enhances the box blank disclosed in Correll U.S. Pat. No. 6,547,125, and, thereby, satisfies the need for further material savings and ease of use. Nothing in the prior art does that. However, my invention does.

SUMMARY OF THE INVENTION

My invention is a box and/or blank that can incorporate one or more of the following features:

1) A unique end wall and corner panel structure constituting a structure similar to that shown in Correll U.S. Pat. No. 6,547,125 except with an end flap fold line (at the end of the end wall) being disposed at an obtuse angle to an end wall fold line (at the bottom of the end wall);

2) A unique cover side flap structure constituting a structure similar to that shown in Correll U.S. Pat. No. 6,547,125 except with the height of the cover side flaps being substantially less than the height of the rear wall and/or side walls of the box blank, thereby providing a possible way to mate two adjacent blanks during the manufacturing process; and

3) A unique pressure-reducing crushed area in a structure similar to that shown in Correll U.S. Pat. No. 6,547,125, the crushed area being disposed adjacent to intersecting first and second fold lines, with the first fold line attaching a connector panel to a bottom panel and the second fold line connecting a wall to a bottom panel.

My invention typically would be used for packaging relatively flat food products such as pizza; however, it could take other forms for other packaging purposes, as well.

A complete understanding of the invention can be obtained from the detailed description that follows.

OBJECT AND ADVANTAGE

A main object of the instant invention is to enhance the box and blank disclosed in Correll U.S. Pat. No. 6,547,125 entitled “Material-saving Food Carton” and make it more material-efficient and easier to use.

A main advantage of my invention is cost savings for the box manufacturer and/or pizzeria owner without any attendant operational inconvenience or deterioration of package integrity. This results, in part, from the shortened-height cover side flaps and the ability to invert and mate adjacent blanks in manufacture.

Another advantage of my invention is improved ease of fold-up of the blank into a box. This is due, in part, to a unique end wall structure and a unique crush area in the blank.

Further objects and advantages of the inven-tion will become apparent from consideration of the following detailed description, related drawings, and appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a plan view of multiple units of a preferred embodiment of the box blank. [0020]
FIG. 2 is a perspective view of a box erected from the blank. [0021]
FIG. 3 is a plan view of an enlarged section of the blank. [0022]
FIG. 4 is a side sectional view of the box taken along line [0023] 4-4 of FIG. 2 (with the box holding a pizza).
FIG. 5 is a front sectional view of the box taken along line [0024] 5-5 of FIG. 2.
FIG. 6 is a plan view of an enlarged section of the blank.[0025]

LIST OF REFERENCE NUMERALS

Between drawings, like reference numerals designate corresponding parts. Within a drawing, closely related components have the same number but different alphabetic suffixes. [0026]
[0027] 10 blank of the preferred embodiment
[0028] 10 a blank of the preferred embodiment
[0029] 12 box of the preferred embodiment
[0030] 20 bottom panel
[0031] 22 rear end wall
[0032] 24 rear wall fold line
[0033] 26 end of rear end wall
[0034] 30 side wall structure
[0035] 32 side wall
[0036] 34 side wall fold line
[0037] 36 front corner panel
[0038] 37 fold line
[0039] 38 connector panel
[0040] 39 fold line (bottom edge of corner panel)
[0041] 40 front end of corner panel
[0042] 42 acute angle
[0043] 44 rear end of side wall
[0044] 46 obtuse angle
[0045] 47 acute angle
[0046] 48 top edge of side wall
[0047] 50 front wall structure
[0048] 51 obtuse angle
[0049] 52 front end wall
[0050] 53 acute angle
[0051] 54 front wall fold line
[0052] 55 end flap
[0053] 56 end flap fold line
[0054] 57 connector panel fold line
[0055] 58 top edge of front end wall
[0056] 59 crushed area
[0057] 60 cover
[0058] 62 cover panel
[0059] 64 cover panel fold line
[0060] 66 cover front flap
[0061] 68 cover front flap fold line
[0062] 69 bottom edge of cover front flap
[0063] 70 cover side flap structure
[0064] 72 cover side flap
[0065] 74 cover side flap fold line
[0066] 75 front end of cover side flap
[0067] 76 corner flap
[0068] 78 corner flap fold line
[0069] 80 oblique angle (obtuse angle)
[0070] 82 lower edge of corner flap
[0071] 82 a a section of lower edge 82
[0072] 82 b a section of lower edge 82
[0073] 82 c a section of lower edge 82
[0074] 84 lower edge of cover side flap
[0075] 90 front-to-rear length of bottom panel
[0076] 91 left-to-right width of bottom panel
[0077] 92 front-to-rear length of cover panel
[0078] 93 left-to-right width of cover panel
[0079] 94 left-to-right width of rear end wall
[0080] 95 height of rear end wall
[0081] 96 height of cover front flap
[0082] 97 height of front end wall
[0083] 98 height of cover side flap
[0084] 99 height of side wall
[0085] 101 pizza
[0086] 103 acute angle
[0087] 105 acute angle

DESCRIPTION OF A PREFERRED EMBODIMENT

The instant invention constitutes, in large part, improvements intended for use in the box and blank disclosed in Correll U.S. Pat. No. 6,547,125 granted Apr. 15, 2003, and entitled “Material-saving Food Carton.” As such, the structure of the instant invention is quite similar to that of Correll '125, with deviations occurring in the particular areas of structural improvement. Therefore, the discussion and terminology disclosed in Correll '125 is hereby included herein by this reference thereto. [0088]
The preferred embodiment is created from corrugated board; however, other foldable materials can be used, as well. The intended use for the embodiment is for erecting into a pizza box. However, it will be appreciated, as the description proceeds, that my invention may be realized in different embodiments and used in differing applications. [0089]
FIG. 1 shows a first blank [0090] 10 and a second blank 10 a oriented at 180 degrees to blank 10. Even though only a partial section of blank 10 a is depicted, this blank is of identical structure to that of blank 10. FIG. 2 shows a fully-erected pizza box 12 created from blank 10. Referenced components are labeled in FIG. 1; selected components are labeled in other Figures. Corresponding parts between drawings share a same reference numeral. It is noted that the invention is bilaterally symmetrical (i.e., having identical left and right sides). Therefore, pairs of opposing like components are to be found, with one item of the pair on each side of the blank or box. For simplicity of labeling, each component of the opposing pair will have the same reference numeral. Also, a pair may be indicated by a numeral on one side of the drawing only. Where this occurs, it is to be understood that the discussion also applies to the corresponding component on the other side, even though that component may not be numerically labeled.

Structure of the Embodiment

Referring in particular to FIG. 1 which shows blank [0091] 10, there is a bottom panel 20, a rear end wall 22 hingedly attached to bottom panel 20 at a rear wall fold line 24, and opposing left and right side wall structures 30.
[0092] Rear end wall 22 has left and right ends 26.
Each [0093] side wall structure 30 comprises a side wall 32 hingedly attached to bottom panel 20 at a side wall fold line 34 and disposed substantially perpendicular to rear end wall 22, a front corner panel 36 hingedly attached to a front end of side wall 32 at a fold line, a connector panel 38 hingedly attached to a bottom edge 39 of corner panel 36 at a fold line (also depicted by numeral 39) and to bottom panel 20 at a fold line 37. Front corner panel 36 has a front end 40 that is obliquely disposed, or disposed at an acute angle 42, to bottom edge 39 (in the preferred embodiment angle 42 is approximately 68 degrees). Side wall 32 has a rear end 44 that is obliquely disposed, or at an obtuse angle 46, to a top edge 48 of the side wall (in the preferred embodiment angle 46 is approximately 112 degrees). It is also noted that at least a portion of rear end 44 is obliquely disposed, or disposed at an acute angle 47, to side wall fold line 34. This can be seen in FIG. 3 which shows an enlarged section of the left side of blank 10.
A [0094] front wall structure 50 comprises a front end wall 52 hingedly attached to bottom panel 20 at a front wall fold line 54 and left and right end flaps 55 hingedly attached to respective left and right ends of front end wall 52 at an end flap fold line 56 and to connector panel 38 at a connector panel fold line 57. Front end wall 52 has a top edge 58 that is free of attachment.
Several important features are noted regarding [0095] fold lines 56, 57. First, as can be seen in FIG. 6 which shows an enlarged section of the left front corner of blank 10, end flap fold line 56 is disposed at an obtuse angle 51 to front wall fold line 54. Second, end flap fold line 56 is disposed at an acute angle 53 to connector panel fold line 57. Third, connector panel fold line 57 is substantially aligned with front wall fold line 54. This particular configuration, especially that of obtuse angle 51, makes it easier to fold blank 10 into a box having front end wall 52 being in an inward-slanting disposition (as illustrated in FIGS. 2 and 4). The optimal disposition of these fold lines, or the sizes of these angles, depends on several factors, including the type of corrugated board used in making the blank and the degree of inward-slanting angle desired on front end wall 52 of the box. Therefore, the determination of the optimal disposition of the fold lines, or the degree of angle between fold lines, will likely need to be derived from testing, a function easily accomplished by any box designer skilled in the art.
Referring to FIG. 6, it is noted that a crushed [0096] area 59 exists in bottom panel 20 (indicated by hatching in the drawing). This area (59) is adjacent fold lines 54, 37 and is located where the two fold lines intersect. The crushing occurs during manufacture of the blank and results in the fluted (medium) layer of the corrugated board being flattened. This reduces the amount of pressure at the corner, or at the intersection of fold lines 54, 37, after blank 10 has been erected into box 12, thereby making it easier to erect and close up the box.
It is further noted that end [0097] flap fold line 56 comprises a slit within it. In the drawing, numeral “56” points to this slit (and also indicates the entire fold line 56). In the preferred embodiment, this slit is at least twelve millimeters long. It helps assure that when blank 10 is erected into box 12 that fold line 56 will “break” in the intended precise location. It can also help reduce the pressure along fold line 56 after the blank has been erected into the box.
A [0098] cover 60 comprises a full-length cover panel 62 hingedly attached to rear end wall 22 at a cover panel fold line 64, a cover front flap 66 hingedly attached to a front edge of cover panel 62 at a cover front flap fold line 68, and left and right cover side flap structures 70. Cover front flap 66 has a bottom edge 69.
Each cover [0099] side flap structure 70 comprises a cover side flap 72 hingedly attached to a side edge of cover panel 62 at a cover side flap fold line 74 that's disposed perpendicular to rear end wall 22. The cover side flap has a front end 75 that is free of attachment. The side flap structure further comprises a free-swinging corner flap 76 hingedly attached to a rear end of cover side flap 72 at a corner flap fold line 78. Corner flap fold line 78 is disposed at an oblique angle 80 to cover side flap fold line 74 (specifically, in the preferred embodiment angle 80 is an obtuse angle of approximately 112 degrees). As a general rule, this angle should be greater than 95 degrees and less than 115 degrees, although other degrees are possible. The exact angle of the slope is whatever is needed to retain cover side flap 72 in a proper (vertical) position after blank 10 has been folded into box 12. The determination of this angle may require testing, a function easily accomplished by any box designer skilled in the art. It is also noted that corner flap 76 has a lower edge 82 that is non-aligned with a lower edge 84 of cover side flap 72. The determination of the optimal angle of lower edge 82 also may require testing. It is further noted that lower edge 82 is disposed lower than lower edge 84. Finally, it is noted that lower edge 82 comprises a plurality of sections or edges. In the preferred embodiment there are first, second, and third sections 82 a, 82 b, and 82 c, respectively, which are numerically labeled in FIG. 3.
It is noted that [0100] bottom panel 20 has a front-to-rear length 90 and a left-to-right width 91. Cover panel 62 has a front-to-rear length 92 and a left-to-right width 93. Rear end wall 22 has a left-to-right width 94 and a height 95. Cover front flap 66 has a height 96. Front end wall 52 has a height 97. Cover side flap 72 has a height 98. And side wall 32 has a height 99.
It is further noted that cover [0101] side flap height 98 is substantially less than side wall height 99 (and also less than rear wall height 95 and front wall height 97). This feature enables multiple adjacent blanks to be mated during manufacture for material savings.
In a five centimeter (two-inch) high pizza box in the format of the preferred embodiment, front-to-[0102] rear length 90 will be longer than left-to-right width 91 by approximately ten millimeters (three-eighths inch). Front-to-rear length 92 will be substantially shorter than front-to-rear length 90 by approximately thirty eight millimeters (one-and-a-half inch). Cover front flap height 96 will be shorter than front wall height 97 by approximately twelve millimeters (one-half inch). Cover side flap height 98 will be substantially less than side wall height 99 and rear end wall height 95.
Once blank [0103] 10 is set up into box 12 a number of special structural arrangements occur. As illustrated in FIG. 4 which shows a side sectional view of box 12 containing a recently-cooked round pizza 101 (this is the view taken along line 4-4 of FIG. 2), front and rear end walls 52/22 slant inward at substantially acute angles 103/105 to bottom panel 20. So the purpose in having bottom panel length 90 slightly longer than bottom panel width 91 is to create adequate space front-to-rear within the box cavity for accommodating a pizza having a diameter equivalent to width 91. As also seen in FIG. 4, the bottom panel's front-to-rear length 90 is slightly longer than the pizza's diameter (by at least six millimeters) and the cover panel's front-to-rear length 92 is substantially shorter than the pizza's diameter (by at least eight millimeters). This arrangement effects a material savings over a similarly-constructed box having all non-slanting walls (i.e., the box shown in Philips et al. U.S. Pat. No. 5,702,054).
As can be seen in FIG. 5, which shows a front sectional view of [0104] box 12 taken along line 5-5 of FIG. 2, side walls 32 are disposed at a non-acute angle to bottom panel 20 (specifically, in the preferred embodiment the non-acute angle is a 90 degree angle).
As can be seen in FIG. 2, end flaps [0105] 55 extend diagonally inward from front end wall 52 and contain cover front flap 66 between them. Corner panels 36 extend diagonally forward from side walls 32 and front end 40 of those panels abuts end flaps 55. Connector panels 38 overlie bottom panel 20. Cover side flaps 72 are disposed exterior to side walls 32 (hence they're sometimes called exterior cover side flaps) and corner flaps 76 are perpendicular to the cover side flaps and disposed between rear end 44 and rear end wall 22. A section of lower edge 82 of corner flap 76 contacts bottom panel 20, thereby holding cover side flaps 72 in vertical or erected disposition. It is noted that this configuration is accomplished in spite of the fact that height 98 of cover side flaps 72 is substantially less than height 95 of rear wall 22. It is also noted that another two sections of lower edge 82 are free of contact with bottom panel 20.
Similarly-constructed boxes to the preferred embodiment (e.g., Philips et al. '054 box) are prone to collapsing when a rearward-pushing force is applied to the cover panel relative to the bottom panel. This occurs because the rear ends of the cover side flaps slide past the ends of the rear end wall. To overcome this problem with my invention, left-to-right width [0106] 94 of rear wall 22 is made at least six millimeters longer than left-to-right width 93 of cover panel 62, thereby extending end 26 of rear end wall 22 well outside of end 78 of cover side flap 72. An enlarged diagram of this section of blank 10 is provided in FIG. 3 for the purpose of clearly depicting a suggested configuration for the preferred embodiment.
Also, in the Philips et al. '054 box the height of the cover front flap is the same length as the height of the front end wall. However, in my invention, height [0107] 96 of cover front flap 66 is substantially shorter than height 97 of front end wall 52, thereby effecting a significant material savings.

Mating of Multiple Blanks During Manufacture

FIG. 1, which shows [0108] identical blanks 10 and 10 a oriented at 180 degrees to one another, depicts the configuration of multiple units of the preferred embodiment in a mated configuration for efficient manufacture. Even though only a partial section of blank 10 a is depicted, this blank is of identical structure to that of blank 10. Further, in the drawing a small gap exists between the blanks. This gap is provided for clarity of illustration. In the actual manufacture of these blanks this gap would likely not exist and, instead, the adjacent edges of the blanks would be in contact with one another. Specifically, lower edge 84 of cover side flap 72 of each blank contacts, or is disposed adjacent to, top edge 48 of side wall 32 of the other blank. It is further noted that the furthermost extremities at each end of each blank (constituted by bottom edge 69 of cover front flap 66 and top edge 58 of front end wall 52) are aligned with the furthermost extremities of the adjacent blank.

Method for Erecting the Blank into the Box

Any method used for erecting the blank of Philips et al. '054 patent or Correll '125 patent into a box can be used for erecting the preferred embodiment into a box. [0109]
Specifically, the following method can be used, which is highly efficient. [0110]
First, position the blank so that it's horizontal and with the inside surface up and cover [0111] front flap 66 next to the abdomen.
Second, with your hands placed near the rear end of cover side flaps [0112] 72, simultaneously fold cover side flaps 72 inward and, with your index fingers, fold rear corner flaps 76 inward.
Third, while keeping your hands in that position (i.e., at the rear end of cover side flaps [0113] 72) and while holding the cover side flaps upright, with your fingers pull rear end wall 22 upright.
Fourth, fold [0114] bottom panel 20 downward to about halfway closed.
Fifth, fold [0115] side walls 32 inward and position them interior to cover side flaps 72 and then fold bottom panel 20 down until the box is all the way, or almost all the way, closed.
Sixth, turn the partially-erected box to a vertical position with [0116] front wall structure 50 up.
Seventh, [0117] open cover panel 62 about three inches) and then, with your index fingers, push both front corner panels 36 inward. This will cause front wall structure 50 to assume an upright position.
Eighth, fold [0118] cover front flap 66 down and tuck it between end flaps 55 and close the box completely. This step can sometimes be most easily executed with the rear end of the box held against a surface. This can be accomplished by either (a) holding the box vertically with the rear end resting on a table or (b) holding the box horizontally with the rear end held against your abdomen.

Definition of Key Terms

Certain terms are used in the claims for describing the invention. To insure clarity of meaning those terms are now specifically defined as used herein. [0119]
A “front-to-rear length of a cover panel” is the distance between the cover panel fold line (connecting the cover panel to the rear wall) and the cover front flap fold line (connecting the cover front flap to the cover panel). The line of measurement is perpendicular to the cover panel fold line and is measured at the furthest distance between the two fold lines. [0120]
A “left-to-right width of a cover panel” is the distance between the left and right cover side flap fold lines (connecting the left and right cover side flaps to the cover panel), as measured parallel to the cover panel fold line. If it turns out that the left and right cover side flap fold lines are non-parallel, the measurement is taken along the rear edge of the cover panel (i.e., at the cover panel fold line). [0121]
A “front-to-rear length of a bottom panel” is the distance between the rear wall fold line (connecting the rear end wall to the bottom panel) and the front wall fold line (connecting the front end wall to the bottom panel). The line of measurement is perpendicular to the rear wall fold line and is measured at the furthest distance between the two fold lines. [0122]
A “left-to-right width of a bottom panel” is the distance between the left and right side wall fold lines (connecting the left and right side walls to the bottom panel), as measured parallel to the rear wall fold line. [0123]
A “substantially acute angle” is considered herein to be an angle of 85 degrees or less. [0124]
A “substantially non-acute angle” is considered herein to be an angle greater than 85 degrees. [0125]
A “full-length cover panel” is a cover panel that's hingedly attached to a wall of the box and extends from that wall substantially all the way to an opposing wall structure. [0126]
An “inward-slanting wall” is a wall disposed at an acute angle to a bottom panel. [0127]
A “perimeter edge of a cover panel” is one of the front, rear, left, or right side edges of a cover panel. [0128]
A “free-swinging” flap or panel is one that is attached to only one other flap or panel after the blank has been erected into a box. An example is [0129] corner flap 76.
The “fluted layer” of corrugated board refers to the layer of paper that is in a fluted, or corrugated, configuration. In double-face corrugated board, which is the type typically used to make pizza boxes, the fluted layer is the inside layer that's sandwiched between two flat outer layers. Often, the inner fluted layer is referred to as the “medium” and the two outer layers are referred to as “liners.” During manufacture, a portion of the corrugated board might be crushed for the purpose of reducing the rigidity provided by the fluted medium. Accordingly, a “crushed area” of a corrugated board is that area of the board that has been so crushed. [0130]
Within the drawing of blank [0131] 10, a fold line between component parts of the invention is depicted with a dashed line. Within the context of this invention, a fold line can be created by a number of means such as, for example, by a crease or score in the board, by a series of aligned spaced short slits in the board, by a combination of aligned spaced short and long slits, or by a combination of a slit and a score.
In some cases, when a longer slit is bounded on the ends by a series of shorter slits or a score, the longer slit may be slightly offset in alignment from the shorter slits or score for the purpose of creating a slot along the fold line when the blank is set up into a box. Such an offset slit may be referred to herein as a “slot-forming slit.” Nonetheless, the entire combination of long and short slits is considered to constitute a single fold line unless otherwise indicated. [0132]
In addition, to create a fold line where one panel is folded 180 degrees to lay parallel on another panel, the fold line may constitute two narrowly-spaced parallel scores or series of aligned slits. In this case, the two narrowly-spaced parallel scores or series of aligned slits constitute a single fold line unless otherwise indicated. [0133]
In conclusion, as referred to herein, a fold line is any line between two points on the blank or box along which the board is intended to be folded when the blank is being erected into a box or when the box is being manipulated as described herein. The type of fold lines shown in the drawings are presently preferred but it will be appreciated that other methods known to those skilled in the art may be used. [0134]
CONCLUSION, RAMIFICATIONS, AND SCOPE [0135]
I have disclosed a pizza box and blank embodying one or more of the following structural features: [0136]
1) A unique end wall and corner panel structure constituting a structure similar to that shown in Correll U.S. Pat. No. 6,547,125 except with an end flap fold line (at the end of the end wall) being disposed at an obtuse angle to an end wall fold line (at the bottom of the end wall); [0137]
2) A unique cover side flap structure constituting a structure similar to that shown in Correll U.S. Pat. No. 6,547,125 except with the height of the cover side flaps being substantially less than the height of the rear wall and/or side walls of the box blank, thereby providing a possible way to mate two adjacent blanks during the manufacturing process; and [0138]
3) A unique pressure-reducing crushed area in a structure similar to that shown in Correll U.S. Pat. No. 6,547,125, the crushed area being disposed adjacent to intersecting first and second fold lines, with the first fold line attaching a connector panel to a bottom panel and the second fold line connecting a wall to a bottom panel. [0139]
Within the foregoing discussion of the invention, the labeling of any components by a numerical adjective (i.e., “first,” “second,” etc.) is for reference purposes only and does not denote any particular location of the components within the blank or box. Further, the term “hingedly attached” refers to two panels (or a panel and a flap) joined together at a fold line, and does not imply any degree of movability of the panels in the erected box format. [0140]
The illustrated number, size, shape, type, and placement of components represent the preferred embodiment; however, many other combinations and configurations are possible within the scope of the invention. For example, Philips et al. '054 discloses a particular cover locking structure involving tabs on the ends of the cover front flap that engage with slits in the fold lines connecting the end flaps to the front end wall. This cover locking structure can easily be applied to the preferred embodiment. [0141]
The foregoing discussion has pertained mainly to packaging relatively flat food products such as pizza. However, it should be realized that my invention could be used for other purposes, as well. In conclusion, it is understood that the invention is not to be limited to the disclosed embodiments but, on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims, which scope is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures as is permitted under the law. [0142]

Claims

1. A blank for a box having a unique end wall structure and corner panel, said blank being of foldable material cut and scored to define:

a bottom panel,

a side wall structure comprising a side wall attached to said bottom panel, a corner panel attached to said side wall and having an end edge and a bottom edge, and a connector panel attached to the bottom edge of said corner panel, and

an end wall structure comprising an end wall attached to said bottom panel at an end wall fold line and having an end flap attached to an end of said end wall at an end flap fold line and to said connector panel at a connector panel fold line;

wherein at least a portion of the end edge of said corner panel is obliquely disposed to the bottom edge and said end flap fold line is disposed at an obtuse angle to said end wall fold line.

2. The blank of claim 1 wherein:

said end flap fold line is disposed at an acute angle to said connector panel fold line.

3. The blank of claim 1 wherein:

said connector panel fold line is substantially aligned with said end wall fold line.

4. A blank for a box having a unique front wall structure and corner panel, said blank being of foldable material cut and scored to define:

a bottom panel,

a rear end wall attached to said bottom panel,

a cover comprising a cover panel attached to said rear end wall,

a side wall structure comprising a side wall attached to said bottom panel at a side wall fold line, a corner panel attached to said side wall and having a front end edge and a bottom edge, and a connector panel attached to the bottom edge of said corner panel, and

a front wall structure opposing said rear end wall and comprising a front end wall attached to said bottom panel at a front wall fold line and having an end flap attached to an end of said front end wall at an end flap fold line and to said connector panel at a connector panel fold line;

wherein at least a portion of the front end edge of said corner panel is obliquely disposed to the bottom edge and said end flap fold line is disposed at an obtuse angle to said front wall fold line.

5. The blank of claim 4 wherein:

said cover further comprises a cover side flap structure comprising a cover side flap attached to said cover panel at a cover side flap fold line and a corner flap attached to a rear end of said cover side flap at a corner flap fold line;

wherein said corner flap fold line is disposed at an obtuse angle to said cover side flap fold line.

6. The blank of claim 4 wherein:

said cover further comprises a cover side flap structure comprising a cover side flap attached to said cover panel and a free-swinging corner flap attached to a rear end of said cover side flap, and

said cover side flap and said rear end wall each have a predetermined height;

wherein the predetermined height of said cover side flap is substantially less than the predetermined height of said rear end wall.

7. The blank of claim 4 wherein:

said cover further comprises a cover side flap structure comprising a cover side flap attached to said cover panel and having a lower edge and a free-swinging corner flap attached to a rear end of said cover side flap and having a lower edge;

wherein the lower edge of said free-swinging corner flap is disposed in non-alignment to the lower edge of said cover side flap.

8. The blank of claim 4 wherein:

each of said cover panel and said rear end wall has a predetermined left-to-right width, and

said cover further comprises a cover side flap structure comprising a cover side flap attached to said cover panel and a corner flap attached to a rear end of said cover side flap;

wherein the predetermined left-to-right width of said rear end wall is at least six millimeters longer than the predetermined left-to-right width of said cover panel.

9. The blank of claim 4 wherein:

each of said bottom panel and said cover panel has a predetermined front-to-rear length;

wherein the predetermined front-to-rear length of said cover panel is substantially shorter than the predetermined front-to-rear length of said bottom panel.

10. The blank of claim 4 wherein:

said front end wall has a predetermined height, and

said cover further comprises a cover front flap attached to a front edge of said cover panel and having a predetermined height substantially less than the predetermined height of said front end wall.

11. The blank of claim 4 wherein:

said side wall has a free rear end disposed at an obtuse angle to a top edge of said side wall.

12. The blank of claim 4 wherein:

13. The blank of claim 4 wherein:

said end flap fold line comprises a slit at least ten millimeters in length.

14. A blank for a box having a unique pressure-reducing crushed area, said blank being of corrugated board having a fluted layer, said blank being cut and scored to define:

a bottom panel,

a first wall structure comprising a first wall attached to said bottom panel, a corner panel attached to an end of said first wall, and a connector panel attached to a bottom edge of said corner panel and to said bottom panel at a first fold line, and

a second wall structure comprising a second wall attached to said bottom panel at a second fold line intersecting said first fold line and an end flap attached to an end of said second wall and to said connector panel;

wherein said corrugated board has an area of material disposed adjacent said first and second fold lines, said area of material having a crushed fluted layer.

15. A blank for a box having unique cover side flaps, said blank being of foldable material cut and scored to define:

a bottom panel,

a rear end wall attached to said bottom panel and having a predetermined height,

opposing left and right side wall structures comprising respective left and right side walls attached to said bottom panel at respective left and right side wall fold lines and each having a free rear end and a predetermined height, respective left and right corner panels attached to a front end of said left and right side walls and each having a front end and a bottom edge, and respective left and right connector panels attached to the bottom edge of said left and right corner panels,

a front wall structure opposing said rear end wall and comprising a front end wall attached to said bottom panel at a front wall fold line and left and right end flaps respectively attached to left and right ends of said front end wall at left and right end flap fold lines and to said left and right connector panels, and

a cover comprising a cover panel attached to said rear end wall and opposing left and right cover side flap structures comprising respective left and right cover side flaps attached to said cover panel at respective left and right cover side flap fold lines and respective free-swinging left and right corner flaps attached to a rear end of said left and right cover side flaps at respective left and right corner flap fold lines, said left and right cover side flaps having a predetermined height and said left and right corner flaps having a lower edge disposed in non-alignment to a lower edge of said left and right cover side flaps, respectively;

wherein the predetermined height of each of the left and right cover side flaps is substantially less than the predetermined height of at least one of the rear end wall and the left and right side walls.

16. The blank of claim 15 wherein:

the free rear end of each of said left and right side walls is disposed at an obtuse angle to a top edge of the same side wall.

17. The blank of claim 15 wherein:

the front end of each of said left and right corner panels is disposed at an acute angle to the bottom edge of the same corner panel and said left and right end flap fold lines are each disposed at an obtuse angle to said front wall fold line.

18. The blank of claim 15 wherein:

said left and right corner flap fold lines are disposed at an obtuse angle to said left and right cover side flap fold lines, respectively.

19. The blank of claim 15 wherein:

said front end wall has a predetermined height, and

20. The blank of claim 15 wherein:

21. The blank of claim 15 wherein:

the lower edge of each of said left and right corner flaps comprises a plurality of sections.

22. First and second box blanks formed from a single sheet of foldable material and disposed side-by-side, each of the blanks being cut and scored to define:

a bottom panel,

a rear end wall attached to said bottom panel,

opposing left and right side wall structures comprising respective left and right side walls attached to said bottom panel at respective left and right side wall fold lines and each having a free rear end, a top edge, and a predetermined height, respective left and right corner panels attached to a front end of said left and right side walls and each having a front end, and respective left and right connector panels attached to a bottom edge of said left and right corner panels,

a front wall structure opposing said rear end wall and comprising a front end wall attached to said bottom panel at a front wall fold line and left and right end flaps attached to respective left and right ends of said front end wall at left and right end wall fold lines and to said left and right connector panels at left and right connector panel fold lines, and

a cover comprising a cover panel attached to said rear end wall, a cover front flap attached to a front edge of said cover panel, and opposing left and right cover side flap structures comprising respective left and right cover side flaps attached to said cover panel at respective left and right cover side flap fold lines and each having a lower edge and a predetermined height and respective free-swinging left and right corner flaps attached to a rear end of said left and right cover side flaps at respective left and right corner flap fold lines and each having a lower edge, wherein the predetermined height of each of the left and right cover side flaps is substantially less than the predetermined height of said left and right side walls and the lower edge of said left and right corner flaps is disposed in non-alignment to the lower edge of said left and right cover side flaps, respectively;

said first and second blanks being oriented at one hundred eighty degrees from each other and with the top edge of one of the side walls of the first blank disposed adjacent the lower edge of one of the cover side flaps of the second blank.

23. The first and second box blanks of claim 22, wherein in each of the blanks:

24. The first and second box blanks of claim 22, wherein in each of the blanks:

each of said cover front flap and said front end wall has a predetermined height and the predetermined height of said cover front flap is substantially less than the predetermined height of said front end wall.

25. The first and second box blanks of claim 22, wherein in each of the blanks:

the free rear end of said left and right side walls is disposed at an obtuse angle to the top edge of the same side wall.

26. The first and second box blanks of claim 22, wherein in each of the blanks:

the free rear end of said left and right side walls is disposed at an acute angle to the side wall fold line of the same side wall.

27. The first and second box blanks of claim 22, wherein in each of the blanks:

the front end of said left and right corner panels is disposed at an acute angle to the bottom edge of the same corner panel.

28. The first and second box blanks of claim 22, wherein in each of the blanks:

said left and right end flap fold lines are each disposed at an obtuse angle to said front wall fold line.

29. The first and second box blanks of claim 22, wherein in each of the blanks:

30. The first and second box blanks of claim 22, wherein in each of the blanks:

31. A box having a unique cover side flap structure, said box comprising:

a bottom panel,

a rear end wall, a front end wall, and left and right side walls, each having a predetermined height, and

a cover comprising (a) a cover panel attached to said rear end wall and (b) a cover side flap structure comprising (i) a cover side flap attached to a side edge of said cover panel at a cover side flap fold line and disposed substantially parallel to one of the left and right side walls and having a predetermined height and (ii) a free-swinging corner flap attached to an end of said cover side flap at a corner flap fold line and having a lower edge;

wherein the predetermined height of said cover side flap is substantially less than the predetermined height of said one of the left and right side walls and at least a portion of the lower edge of said free-swinging corner flap is in contact with said bottom panel.

32. The box of claim 31 wherein:

the lower edge of said corner flap comprises a plurality of sections, at least one of the sections being free of contact with said bottom panel.

33. The box of claim 31 wherein:

at least one of said rear end wall and said front end wall is disposed at an acute angle to said bottom panel.

34. The box of claim 31 wherein:

35. The box of claim 31 wherein:

said corner flap fold line is disposed at an obtuse angle to said cover flap fold line.

36. The box of claim 31 further comprising:

respective left and right corner panels attached to a front end of said left and right side walls, left and right connector panels attached to a bottom edge of said left and right corner panels, and left and right end flaps attached to left and right ends of said front end wall at left and right end flap fold lines, respectively;

wherein said front end wall is attached to said bottom panel at a front wall fold line and each of said left and right end flap fold lines is disposed at an obtuse angle to said front wall fold line.

37. A box having a unique end wall structure, said box comprising:

a bottom panel,

a side wall structure comprising a side wall, a corner panel attached to said side wall, and a connector panel attached to a bottom edge of said corner panel, and

an end wall structure adjacent said side wall structure and comprising an end wall attached to said bottom panel at an end wall fold line and having an end flap attached to an end of said end wall at an end flap fold line;

wherein said end wall is disposed at an acute angle to said bottom panel and said end flap fold line is disposed at an obtuse angle to said end wall fold line.

38. The box of claim 37 wherein:

said corner panel has an end edge disposed at an acute angle to said bottom edge.

39. A blank for a box having a unique front wall structure comprising an inward-slanting end wall, said blank being of foldable material cut and scored to define:

a bottom panel having a predetermined front-to-rear length,

a rear end wall,

a cover comprising a full-length cover panel attached to said rear end wall and having a predetermined front-to-rear length,

a side wall structure comprising a side wall attached to said bottom panel, a corner panel attached to said side wall, and a connector panel attached to a bottom edge of said corner panel,

a front wall structure opposing said rear end wall and comprising a front end wall attached to said bottom panel at a front wall fold line and having an end flap attached to an end of said front end wall at an end flap fold line and to said connector panel at a connector panel fold line,

wherein the predetermined front-to-rear length of said cover panel is substantially shorter than the predetermined front-to-rear length of said bottom panel and said end flap fold line is disposed at a non-acute angle to said front wall fold line and at an acute angle to said connector panel fold line.

40. The blank of claim 39 wherein:

41. The blank of claim 39 wherein:

said cover side flap and said rear end wall each have a predetermined height;

42. The blank of claim 39 wherein:

43. The blank of claim 39 wherein:

said cover further comprises a cover side flap structure comprising a cover side flap attached to said cover panel and a corner flap attached to a rear end of said cover side flap, said corner flap having a lower edge comprising a plurality of sections.

44. The blank of claim 39 wherein:

said cover side flap and said side wall each have a predetermined height;

wherein the predetermined height of said cover side flap is substantially less than the predetermined height of said side wall.

45. The blank of claim 39 wherein:

46. The blank of claim 39 wherein:

said front end wall has a predetermined height, and

47. The blank of claim 39 wherein:

48. The blank of claim 39 wherein:

said corner panel has an end edge and at least a portion of said end edge is obliquely disposed to said bottom edge.