US2770410A - Hollow-walled boxes - Google Patents

Description

1956 M. l. WILLIAM-SON 1.77 9

HOLLOW-WALLED BOXES 2 Sheets-Sheet 1.

Filed April 14, 1955 INVENTOR. Marhall l; Williamson W A TTORNEY 1956 M. 1. WILLIAMSON HOLLOW-WALLED BOXES 2 Sheets-Sheet 2 Filedc. April 14, 1953 INVENTOR. Marshall 1. Williamson L ATTORNEY United States Patent HOLLOW-WALLED BOXES Marshall I. Williamson, New Haven, Conn. Application April 14, 1953, Serial No. 348,739 Claims. (Cl. 229-34) This invention provides a novel and improved construction for boxes, cartons, trays, or other receptacles made from paperboard, cardboard, or other foldable sheet material, hereinafter collectively referred to, for convenience, as boxes or folding boxes.

This invention has particular reference to folding boxes having hollow walls of substantially triangular cross-section. Such boxes are sometimes referred to as bevel-edge boxes or bevel-edge trays.

Hollow walled boxes of the aforementioned type are particularly well suited for the visual display of merchandisc in an attractive and eye catching manner. The boxes must also meet exacting standards of strength and rigidity.

The dimensions of the bevel-edge boxes vary widely, in accordance with the merchandise to be packaged and displayed therein. In certain instances a group of re lated articles is packaged, for example a complete photo graphic outfit. As another packaging and display example may be mentioned a set of cutlery or a set of silverware. Naturally, considerable variations are encountered in the depth of the box as well as in the slope of the walls. The weight of the box contents may be considerable and it is readily seen that problems of strength and rigidity are encountered in boxes which are relatively shallow in relation to their size.

My prior Patents 2,605,953 and 2,605,954, disclose box constructions of extraordinary strength which is mainly derived from a particular construction of the box walls and corners.

It is often desirable to reinforce ;the box structure against twisting, which is encountered, for example, when a box with heavy contents, for example silverware, is picked up by one corner.

In other instances it may be desired to provide a cushioning or article retaining inner bottom panel, which may be provided with contents retaining recesses or projections.

This invention provides an improved box construction of the bevel-edge type characterized by great rigidity and twist resistance. The mechanical properties of the improved box make the box admirably suited for the packaging and display of merchandise which requires a relatively large but shallow box. However, the structural improvements according to the invention are equally advantageous for deep boxes or boxes of small size or boxes which, due to their particular use, require a double-ply bottom, or a liner panel.

My co-pending application, Serial No. 348,359, filed Aprill3, 1953, is directed to a box construction which permits ready assembly of the hollow box from a preglued flat blank so laid out that any desired slope and depth of the walls may be chosen without sacrifice of the assembly feature of using a pre-glued fiat, partially tubular blank. Such construction may advantageously be used in boxes incorporating the improvements which form the subject matter of this invention.

The aforementioned, and various other objects, features and advantages of the invention will appear more fully from the detailed description which follows, accompanied by drawings showing, for the purpose of illustration, a representative embodiment of the invention. The invention also consists in certain new and original features of construction and combination of elements hereinafter set forth and claimed.

Although the characteristic features of this invention which are believed to be novel will be particularly pointed out in the claims appended hereto, the invention itself, its objects and advantages, and the manner in which it may be carried out, may be better understood by referring to the following description taken in connection with the accompanying drawing in which:

Fig. 1 is a plan view of a modified fiat cut and scored box blank incorporating the present invention;

Fig. 2 is a plan view of a liner blank for use with the box shell blank of Fig. 1;

i Fig 3 is a perspective view of a box assembled from the box shell blank of Fig. l and the liner blank of Fig. 2, the box being shown before down-folding of a liner flap to illustrate the construction;

Fig. 4 is an elevational view of the end wall construction of the box of Fig. 3, the section being taken in plane 44 in Fig. 3;

Fig. 5 is a perspective view, partly in section of a box construction including a modified box shell blank and a corrugated liner; and

Fig. 6 is an elevational View of the side wall construction of the box of Fig. 5, a section being taken in plane 66.

In the following description and in the claims, various details will be identified by specific names for convenience. These names, however, are intended to be as generic in their application as the art will permit. Corresponding reference characters refer to corresponding parts in the several figures of the drawings.

In the drawings accompanying, and forming part of, this specification, certain specific disclosure of the invention is made for the purpose of explanation of broader aspects of the invention, but it is understood that details may be modified in various respects without departure from the principles of the invention and that the invention may be applied to other structures than the one shown.

Referring to the drawings, the blank A in Fig. 1 may be cut and scored in multiple from rolls or sheets of paperboard, cardboard, or other flexible sheet material. Only one side of the board need be imprinted or otherwise decoratively finished, since only one side of the blank is exposed to view, the inner bottom surface being covered by a liner in the finished box. In Fig. 1 the blank is shown in the position in which the unfinished surface faces the observer.

The blank is subdivided into panels and flaps by a plurality of score lines. A main panel 11 is bordered by outer side fold lines 12 and 13 and outer end fold lines 14 and 15. These fold lines intersect at the corners 16, 17, 18 and 19 of the main panel which, as will later be seen, become the outer corners of the box.

Outer side wall panels 20 and 21 are articulated to the main panel 11 along the outer side fold lines 12 and 13, respectively. Inner side wall panels 22 and 23 are articulated to the outer side wall panels along side ridge fold lines 24 and 25. Bottom side panels 26 and 27 are articulated to the inner side wall panels 22 and 23 along inner side fold lines 28 and 29, respectively.

In the same manner outer end wall panels 30 and 31 are articulated to the main panel 11 along the outer end fold lines 14 and 15, respectively. Inner end wall panels 32 and 33 are articulated to the outer end wall panels along end ridge fold lines 34 and 35, respectively. Bot- J31 torn end panels 36 and 37 are articulated to the inner end wall panels 32 and 33 along inner end fold lines 38 and 39, respectively.

A pair of side flaps 40 and 41 are articulated to the outer end wall panel 30 along oblique flap fold lines 42 and 43 extending at an angle with respect to the outer end fold line 14. A further pair of side flaps 44 and 45 is articulated to the outer end wall panel 31 along oblique flap fold lines 46 and 47, respectively.

The provision of the side flaps 40, 41, 44 and 45 is optional. However, as will later become apparent, the side flaps, besides performing a structural function, result in neater appearance, since no cut edges are exposed at the corners of the box, if the aforementioned side flaps are employed.

In the preferred form of the box according to my aforementioned prior patents the corner structure of the blank includes at least two panel portions bordered by at least three corner fold lines aimed at a common point of intersection on the side ridge fold lines. In the illustrated form of blank panel portions 48 and 49 are articula'ted to the inner side wall panel 22 along corner fold lines 50 and 51, respectively. These fold lines intersect the side ridge fold line 24 at 52 and 53. A pair of substantially triangular panel portions 54 and 55 is articulated to the outer side wall panel 29 along corner fold lines 56 and 57, respectively. It will be noted that these corner fold lines 56 and 57 are also aimed at the points of intersection 52 and 53, respectively. The panel portions 54 and 55 are further bordered by corner fold lines 58 and 59 towards the panel portions 48 and 49, respectively. The corner fold lines 58 and 59 are also aimed at the points 52 and 53, respectively.

Securing flaps 60 and 61 are articulated to the panel portions 54 and 55 along flap fold lines 62 and 63, respectively. These securing flaps perform their function in a variety of ways, as will later be seen. They may be secured to other portions of the blank by stapling or by adhesive or they may remain unattached in a position in which they abut one or more fold lines of the blank with their outer edges, such abutment edges being 64 and 65 on the securing flap 60, and edges 66 and 67 on the securing flap 61.

' In the same manner panel portions 68 and 69 are articulated to the inner side wall panel 23 along corner fold'lines 70 and 71, respectively. These fold lines intersect the side ridge fold line 25 at 72 and 73, respectively. A pair of substantially triangular panel portions 74 and 75 is articulated to the outer side wall panel 21 along corner fold lines 76 and 77, respectively. It will be notedthat these corner fold lines 76 and 77 are also aimed at the points of intersection 72 and 73, respectively. The panel portions 74 and 75 are further bordered bycorner fold lines 78 and 79 towards the panel portions 68 and 69, respectively. The corner fold lines 78 and 79 are also aimed at the points 72 and 73, respectively.

Securing fiaps'80 and 81 are articulated to the panel portions 74 and 75 along flap fold lines 82 and 83, respectively. These securing flaps 80 and 81 have abutmerit edges 84, 85, and 86, 87, respectively.

The side flaps 40, 41, 44 and 45 have cut bordering edges 88, 89, 90, 91, 92, 93, 94 and 95, respectively, which are preferably so disposed that these cut edges Iabut certain fold lines of other panels in the assembled Bottom tabs 100 and 181 are formed on the bottom endpanels' 36 and 37 by U-shaped cuts 102 and 103 beginning and ending at the inner end fold lines 38 and 39, respectively.

The assembly of the blank A shown in Fig. 1 into box form may proceed as follows:

In the event the securing flaps 60, 61, 80 and 81 are to be adhesively secured, adhesive a is first applied to them. However, as previously indicated, the gluing of A these flaps is optional and there is no material difference in strength or rigidity of the finished box, whether the securing flaps are glued or not. As will later be mentioned, the securing flaps may also be secured to the side flaps by stapling at a later stage of the assembly.

As a first folding operation, the side wall assemblies are folded over the inside surface of the main panel 11 along the outer side fold lines 12 and 13, respectively. The aforedescribed folding operation brings the securing flaps 68, 61, and 81 into overlying'position with respect to the outer end wall panels3t) and 31. If adhesive is employed, the securing flaps 60 and 80 are pressed to the outer end wall panel 38, and the securing flaps 61 and 81 are bonded to the outer end wall panel 31.

Even if no adhesive is employed, it becomes apparent that in the folded condition the abutment edges 64 and 84 are in substantial register with the flap fold lines 42 and 43. Similarly, the abutment edges 66 and 86 are in substantial register with the flap fold lines 46 and 47. Also, the abutment edges 65 and are in substantial register with the end ridge fold line 34 and the abutmerit edges 68 and 87 are in substantial register with end ridge fold line 35.

Next, the side flaps 40, 41, 44 and 45 are folded over the respective securing flaps 60, 80, 61 and 81, respec-' tively. After performance of this last described folding operation, the abutment edges 88 and 98 of the side flaps 40 and 41 lie in substantial coincidence with the abutment edges 65 and 85, and also with the end ridge fold line 34. The abutment edges 89 and 91 are in substantial coincidence with the corner fold lines 62 and 82.

At'the other end of the box, the abutment edges 92 and 94 of the side flaps 44 and 45 are in substantial coincidence with the abutment edges 67 and 87 and with the end ridge fold line 35. The abutment edges 93 and 95 of the side flaps 44 and 45 are in substantial coincidence with the corner fold lines 63 and 83, respectively.

In the event the securing flaps 60, 61 and 38, 81 are not glued they may be stapled to the overlying side flaps 48, 44 and 41, 45, respectively.

The folded blank may be shipped and stored in flat collapsed condition and requires a minimum of space for shipping and storing. it may easily be set up into hollow box form by a simple operation which will now be described.

In order to erect the box, the end wall assemblies are folded at the fold lines 14 and 15 with respect to the main panel 11. Substantially simultaneously the bottom side panels 26 and 27 are folded at their respective inner side fold lines 28 and 29 to underlie the inner side wall panels 22 and 23, respectively.

The folding operations cause the side Walls to assume hollow triangular crosssectional shape. The blank creases at the fold lines 62, 82, 63 and 83, as well as at the corner fold lines 50, 51, 70 and 71, respectively. The

points of intersection 52, 53, 72 and 73 rise as peaks and form four ridge corners. The panel portions 54, 55, 74 and 75 form end surfaces over which the outer end wall panels 30 and 31 are foldable and against which the end panels rest together with the flaps 40, 60, 41, 8t) and the flaps 44', 61, and 45, 81, which are folded over the outer end Wall panel 38 and 31, respectively. When the'folding of the outer end wall panels 30 and 31 is completed, the end ridge fold lines 34 and 35 extend l-between the peaks 52, 72 and 53, 73, respectively. 7

In order to complete the erection of the box shell it is only necessary to fold the inner end wall panels 32 and 33 into their required position.

The addition of a liner panel imparts great resistance to twisting to the box. If the box is picked up by one corner and would tend to twist due to the weight of the contents of the box, the inner side panels and the inner end panels of the box depart from their right angular position with respect to one another in which they normally outline a rectangle on the main panel 11. If the box is twisted, the rectangle becomes a parallelogram.

T he inserted liner panel 107 engages the, wall panel structure, of the box shell with its bounding edges and resists such distortion of the box. This is particularly important in boxes for heavy merchandise, for example, silverware, and for boxes which are particularly shallow in relation to the size of the main panel 11.

A liner panel for the blank B is shown in Fig. 2.

The liner panel 107 is of a length substantially equal to the distance between the outer end fold lines 14 and 15, and its width is substantially equal to the distance between the outer side fold lines 12 and 13 of the blank B.

Substantially U-shaped cuts 108 and 109 form flaps 110 and 111 in the panel 107. These flaps have foldlines 112 and 113, respectively, along which the flaps remain connected to the panel 107.

The assembly of the lined box from the blank A and the liner panel 107 may proceed as follows:

At the beginning of the assembly operations, the panel 107 is placed on the main panel 11 of the blank A and the side walls of the box are then erected in the same manner as hereinbefore described in connection with blank A. It is evident, however, that the bottom side panels 26 and 27 of the blank Acome to rest on top of the liner panel 107 instead of on the main panel 11 proper.

Before the bottom end panels of the blank A are tucked in, the flaps 108 and 109 are folded up as illustrated in Fig. 3 at 108, and the bottom end panels are then tucked into the space between the liner panel 107 and the main panel 11 of the blank A. The marginal portions of the liner panel 107 which the bottom end flaps underlie are identified as 114 and 115. After the inner end walls 32 and 33 are in place, the flaps 110 and 111 are folded down onto the respective bottom tabs 100 and 101. In this position the flaps 110 and 111 lock the inner end panels 32 and 33 firmly in place. The liner panel 107 makes the box twist resistant, not only 'by engaging the wall structures adjacent the outer side fold lines and adjacent the outer end fold lines, but also by clamping the inner end panels 32 and 33 at the cut edges of the cuts 108 and 109. i

Fig. 4 shows the panels and flaps of the box end structure in their final position, and the broken lines indicate the position of the flap 111 prior to tucking in of the bottom end panel 36. The edge down as indicated by the arrow 116 Fig. illustrates a modified box construction including,

a box blank incorporating pre-glued side wall structures as disclosed in greater detail in my co-pending application, Serial No. 348,359, filing date April 13, 1953.

As shown in greater detail in Fig. 6, the illustrated side wall structure comprises a bottom panel 11, an outer side wall panel 20, an inner side wall panel 22', an upper bottom panel 117 and a bottom side panel 26 which may be adhesively or otherwise secured to the main panel 11'. The upper bottom panel 117 forms a return fold with the bottom side panel 26', which by reason of its location may also be called an intermediate bottom panel, and the liner panel 107 extends into thisreturn fold.

In the event the liner panel 107 is of substantial thickness, for example if made of corrugated stock, it is advisable to provide two closely spaced fold lines 118 and 119 at the return fold.

The shape of the liner panel 107' corresponds to the shape of the liner panel 107 shown in Fig. 2. However, the liner panel 107 is slightly narrower, since its outer edges extend to the return fold lines 118 and 119, and not to the outer side fold lines 12 and 13. i

The liner panel 107 is placed on the pre-glued box blank prior to erection of the side wall structures, and the side wall structures are then directed above, or around, the liner panel 107. The completion of the end wall structures takes place in the same manner as illustrated and described in connection with Fig. 3.

Obviously, the present invention is not restricted to the of the flap 111 swings particular form of box herein described, but may be incorporated in other forms of boxes with equal benefits.

tion, a main panel; a pair of side wall structures on oppo-' site sides of the main panel, a pair of end wall structures at opposite ends of the main panel; and corner structures between said side wall structures and said end Wall structures; each of said side wall structures comprising, an outer side wall panel articulated to said main panel along an outer side fold line; an inner side wall panel articulated to said outer side wall panel along a side ridge fold line; and a bottom side panel articulated to said inner side wall panel along an inner side fold line and extending outwardly toward said outer side fold line in the set-up box; each of said end wall structures comprising, an outer end wall panel articulated to said main panel along an outer end fold line; an inner end wall panel articulated to said outer end wall panel along an end ridge fold line; and a bottom end panel articulated to said inner end panel along an inner end fold line, said bottom end panel extending outwardly toward said outer end fold line in the set-up box; each of said corner structures comprising at least one corner panel articulated to one of the wall panels of one wall structure along a fold line aimed at the ridge fold line of said one wall structure, said corner panel lying, in the set-up box, between the outer wall panel and the inner wall panel of the other wall structure meeting said one wall structure at the respective corner; a liner panel of a width greater than the distance between the inl ner side wall panels and of a length greater than the distance between the inner end wall panels, considering the set-up box, said liner having internal flaps cut from its stock, said internal flaps pointing towards the proximate end edges of the liner and having a hinge line substantially parallel to, and spaced from, the inner end panel of the box, the end edges of the flaps being substantially parallel and spaced from each other a distance equal to the distance between the inner end panels of the box; and bottom tabs on the end wall structures, said bottom tabs extending at right angles to the inner end. wall panels and in the opposite direction as the bottom end panels, said liner underlying said bottom side panels and said bottom end panels, said tabs underlying said liner flaps at the end edges of said flaps.

2. A hollow walled folding box comprising, in combination, a main panel; a pair of side wall structures on opposite sides of the main panel, a pair of end Wall structures at opposite ends of the main panel; and corner structures between said side wall structures and said end wall structures; each of said side wall structures comprising, an outer side wall panel articulated to said main panel along an outer side fold line; an inner side wall panel articulated to said outer side wall panel along a side ridge fold line and a bottom side panel articulated to said inner side wall panel along an inner side fold line and extending outwardly toward said outer side fold line in the set-up box; each of said end wall structures comprising, an outer end wall panel articulated to said main panel along an outer end fold line; an inner end wall panel articulated to said outer endwall panel alongan end ridge fold line; and a bottom end panel articulated to said inner end panel along an inner end fold line, said bottom end panel extending outwardly toward said outer end fold line in the set-up box; each of said corner structures comprising at least one corner panel articulated to one of the wall panels of one wall structure along a fold line aimed at the ridge fold line of said one wall structure, said corner panel lying, in the set-up box, between the outer wall panel and the inner wall panel of the other wall structure meeting said one wall structure at the respective corner; a liner panel of a width greater than the distance between proximate end edges of the liner and having a hinge line substantially parallel to, and spaced from, the'inner end panel of the box, the end edges of the flaps being substantially'p'arallel and spaced from each other a distance equal to the distance between the inner end panels of the box;

and bo'ttorn' tabs on the end wall structures, said tabs being cut from the stock of the inner end wall panels, integral with, and lying in the same plane, but extending in the opposite direction as, the' bottom end panels, said liner underlying said bottom side'panels and said bottom end panels, said tabs underlying said liner flaps at the end edges of said flaps.

3 A hollow walled folding box comprising, in combination, a main bottom panel; a pair of side wall structitres on opposite sides of the main bottom panel; a pair of end w'all structures at opposite ends of the main bottom panel; and corner structures between said side wall structures and said end wall structures; each of said side wall structures comprising, an outer side wall panel articulated to said main bottom panel along an outer side fold'line;

an" inner side Wall panel articulated to said outer side wall panel along a side ridge fold line; an upper bottom panel articulated to said inner side wall panel along an inner side fold line; an intermediate bottom panel articulated to said upper bottom panel along a foldline spaced from, and parallel to, said inner side fold line and said outer side fold line, said intermediate bottom panel being folded back with respect to said upper bottom panel and forming with the upper bottom panel a return fold underneath the side ridge fold line, said intermediate bottom' panel being adhesively secured to said main bottom panel of the box; each of said end wall structures comprising, an' outer end wall panel articulated to said main bottom panel along an outer end fold line; an inner end wall panel articulated to said outer end wall panel along an end ridge fold line; and a bottom flap articulated to said inner end panel along an inner end fold line; each ofsaid corner structures comprising at least one corner panel articulated to one of the side wall panels along a fold line aimed at said side ridge fold line, said corner panel lying, in' theYset-up box, between said outer end wall panel and said inner end wall panel; and a separate bottom liner panel having side edges, said liner panel extending with its side edges between the upper bottom panel and the intermediate bottom panel of each of said opposite s'ide wall structures, said liner panel having an internal flap cut from its stock, said internal flap pointing towards theproximate end edge and having a hinge line substantially parallel to the inner end panel of the box, the said bottom flap extending through the cut forming said internal flap, underneath said liner panel, the end edge of said internal flap bearing against said inner end wall panel in edge-to-surface position, thereby locking the end struc ture inset-up position.

4. A hollow walled folding box comprising, in com bination, a main panel; a pair of side wall structures on opposite sides of the main panel, a pair of end wall structures at opposite ends of the main panel; and corner structures between said side wall structures and said end wall structures; each of said side wall structures comprising, an outer side wall panel articulated to said main panel along an outer side fold line; an inner side wall panel articulated to said outer side wall panel along a side ridge fold line; an upper bottom panel articulated to said inner side wall panel along an inner side fold line, and an intermediate bottom panel articulated to the upper bottom panel at a return fold line, said intermediate bottom panel being folded back with regard to,-randunder, said upper bottom panel; each of said end wall structures comprising, an outer end wall panel articulated to said main panel along an outer end fold line; an inner end wall panel articulated to said outer end wall panel along an end ridge fold line; and a bottom end panel articulated to said inner end panel along an inner end fold li-ne; each of said corner structures comprising at' least one corner panel articulated to one of the side wall panels along a fold line aimed at the side ridge told line bordering said one wall panel, said corner panel :lying, in the set-up box, between the outer end wall panel and the inner end wall panel; and a separate liner panel larger than the space of the box between said inner wall panels, said liner panel overlying said main panel and extending with its marginal side portions underneath said side wall structures substantially to said return told lines, and extending with its marginal end portions under said end wall structures substantially to said outer end foldlines, said liner panel having two slits therethrough, said inner end panels extending through said slits so that each bottom end pa-nel lies in the space between said main panel and said liner panel underneath said end wall structure.

5, A hollow walled folding box comprising, in com- 'bination, a main panel; a pair of side wall structures on opposite sides of the main panel, a pair of end wall structures at opposite ends of the main panel; and corner structures between said side wall structures and said end wall structures; each of said side wall structures comprising, an outer side wall panel articulated to said main panel along an outer side fold line; an inner side wall panel articulated to said outer side wall panel along a side ridge fold line; and a bottom side panel articulated to said inner side wall panel along an inner side fold line and extending inwardly under the side wall structure in the set-up box; said end wall structures comprising, an outer end wall panel articulated to said main panel along an outer end fold line; an inner end wall panel articulated to said outer end wall panel along an end ridge fold line; and a bottom end panel articulated to said inner end panel along an inner end fold line, said bottom end panel extending inwardly under the end wall structure in the set-up box; said corner structure comprising at least one corner panel articulated to one of the wall panels of one wall structure along a fold line aimed at the ridge fold line of said one wall structure, said corner panel lying, in the set-up box, between the outer wall panel and the inner wall panel of the other wall structure liner panel of a width greater than the distance between said inner side wall panels and extending with its side edges substantially into contact with said side wall structures, considering the set-up box, said liner having two internal flaps cut from its stock, each said internal fl-ap pointing towards the proximate end edge and having a hinge line approximately parallel to the inner end panel of the box, said bottom end panel extending through the cut forming said internal flap, underneath said liner, the end edge of said internal flap bearing against said inner end wall panel in edge-to-surfa'ce position, thereby locking the end wall structure in a setup position.

References Cited in the file of this patent UNITED STATES PATENTS 1,331,009 Ford Feb. 17, 1920 2,148,048 Glray Feb. 2 1, 1939 2,465,169, OCon-nor Mar. 22, 1949 2,511,542 -Rau June 30, 1950 2,605,953 Williamson Aug. 5, 1952

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