Box assemblies and multi-ply units and methods for forming same
원문보기
IPC분류정보
국가/구분
United States(US) Patent
등록
국제특허분류(IPC7판)
B65D-005/24
B65D-005/22
B65D-005/30
B31B-003/60
B31B-003/26
B65D-005/68
B65D-065/40
B65D-005/62
출원번호
US-0162187
(2016-05-23)
등록번호
US-10150586
(2018-12-11)
발명자
/ 주소
Carden, Kevin B.
Royall, James F.
Worm, Steven Lee
출원인 / 주소
1540 Innovatus, LLC
대리인 / 주소
Myers Bigel, P.A.
인용정보
피인용 횟수 :
0인용 특허 :
6
초록▼
A blank for forming a carton includes a unitary substrate layer defining a primary axis and a secondary axis transverse to the primary axis. The substrate layer includes: a main panel having a side edge extending substantially parallel to the primary axis and an end edge substantially parallel to th
A blank for forming a carton includes a unitary substrate layer defining a primary axis and a secondary axis transverse to the primary axis. The substrate layer includes: a main panel having a side edge extending substantially parallel to the primary axis and an end edge substantially parallel to the secondary axis; an end outer panel connected to the end edge by a first fold line extending substantially parallel to the secondary axis; an end inner panel connected to the end outer panel by a second fold line extending substantially parallel to the secondary axis; a side outer panel connected to the side edge by a third fold line extending substantially parallel to the primary axis; a side inner panel connected to the side outer panel by a fourth fold line extending substantially parallel to the primary axis; a notch defined in a side edge of the end inner panel; and an integral tab extending from an end edge of the side inner panel adjacent the side edge of the end inner panel. The blank is configured to be erected into a carton by: folding the end outer panel relative to the main panel about the first fold line; folding the end inner panel relative to the end outer panel about the second fold line so that the end inner panel substantially faces the end outer panel and is deflectably spaced away from the end outer panel; folding the side outer panel relative to the main panel about the third fold line so that the side inner panel substantially faces the side outer panel, whereby a pocket is defined between the notch, the side outer panel, and the end outer panel; folding the side inner panel relative to the side outer panel about the fourth fold line so that the side inner panel substantially faces the side outer panel; and inserting the tab into the pocket to interlock the side inner panel and the end inner panel.
대표청구항▼
1. A reusable blank for forming a carton, the blank comprising: a unitary substrate layer defining a primary axis and a secondary axis transverse to the primary axis, the substrate layer including: a main panel having a side edge extending substantially parallel to the primary axis and an end edge s
1. A reusable blank for forming a carton, the blank comprising: a unitary substrate layer defining a primary axis and a secondary axis transverse to the primary axis, the substrate layer including: a main panel having a side edge extending substantially parallel to the primary axis and an end edge substantially parallel to the secondary axis;an end outer panel connected to the end edge by a first fold line extending substantially parallel to the secondary axis;an end inner panel connected to the end outer panel by a second fold line extending substantially parallel to the secondary axis;a side outer panel connected to the side edge by a third fold line extending substantially parallel to the primary axis;a side inner panel connected to the side outer panel by a fourth fold line extending substantially parallel to the primary axis;a notch defined in a side edge of the end inner panel; andan integral tab extending from an end edge of the side inner panel adjacent the side edge of the end inner panel;wherein the blank is configured to be erected into a carton by: folding the end outer panel relative to the main panel about the first fold line;folding the end inner panel relative to the end outer panel about the second fold line so that the end inner panel substantially faces the end outer panel and is deflectably spaced away from the end outer panel;folding the side outer panel relative to the main panel about the third fold line, whereby a pocket is defined between the notch, the side outer panel, and the end outer panel;following the steps of folding the end inner panel relative to the end outer panel and folding the side outer panel relative to the main panel, folding the side inner panel relative to the side outer panel about the fourth fold line so that the side inner panel substantially faces the side outer panel and the tab is thereby inserted through the notch and into the pocket to interlock the side inner panel and the end inner panel;wherein the step of folding the side inner panel relative to the side outer panel elastically deflects the end inner panel toward the end outer panel to permit the tab to pass over the end inner panel as the side inner panel is folded toward the side outer panel, and releases the end inner panel to spring away from the end outer panel after the tab has entered the notch;wherein when the carton is erected, the end inner panel is spaced apart from the end outer panel to provide a gap between the end inner panel and the end outer panel and a corresponding depth to the pocket, and the tab extends inwardly toward the end outer panel beyond the notch and into the depth; andwherein the blank is configured such that, when the carton is erected, the tab can be released from the pocket by deflecting the end inner panel toward the end outer panel, thereby permitting the carton to be collapsed. 2. The blank of claim 1 wherein the blank provides tactile and/or audible feedback when the end inner panel springs away from the end outer panel after the tab has entered the notch. 3. The blank of claim 1 wherein, when the carton is erected, the end inner panel and the side inner panel each exert a spring force on the other. 4. The blank of claim 1 wherein: the blank further includes an end foot panel connected to the end inner panel along a fifth fold line;the blank further includes a side foot panel connected to the side inner panel along a sixth fold line; andwhen the carton is erected, the side foot panel overlaps the end foot panel to capture the end foot panel between the side foot panel and the main panel and thereby inhibit the end inner panel from pivoting away from the end outer panel. 5. The blank of claim 1 further including an outer decorative sheet bonded to an outer surface of the substrate layer and covering at least a portion of each of the main panel, the end outer panel and the side outer panel. 6. The blank of claim 5 wherein the outer decorative sheet is loose wrap bonded to the substrate layer. 7. The blank of claim 5 wherein: the substrate layer includes a corner web connecting a side edge of the end outer panel to an end edge of the side outer panel;the outer decorative sheet includes a corner section extending beyond the end outer panel and the side outer panel and outwardly beyond the corner web; andthe corner section has a cross edge defining an oblique angle with each of the primary axis and the secondary axis. 8. The blank of claim 1 wherein at least some of the first, second, third, and fourth fold lines are of a first type and at least some of the first, second, third, and fourth fold lines are of a second type, wherein the fold lines of the first type exert a greater return spring force when folded than do the fold lines of the second type when folded. 9. The blank of claim 8 wherein the fold lines of the first type are creases in the substrate layer and the fold lines of the second type are lines of perforations in the substrate layer. 10. The blank of claim 1 wherein: the substrate layer includes: a first corner panel connected to the end outer panel by a first corner fold line; anda second corner panel connected to the side outer panel by a second corner fold line and to the first corner panel by a third corner fold line; andthe first corner panel is adhered to the end outer panel or the second corner panel is adhered to the side outer panel. 11. The blank of claim 1 wherein the end inner panel is not adhered to the end outer panel. 12. The blank of claim 1 wherein the blank is configured to be re-assembled into a second erected carton, after the carton has been disassembled by deflecting the end inner panel toward the end outer panel, by: again folding the side inner panel relative to the side outer panel about the fourth fold line so that the side inner panel substantially faces the side outer panel and the tab is thereby inserted through the notch and into the pocket to interlock the side inner panel and the end inner panel;wherein the step of folding the side inner panel relative to the side outer panel again elastically deflects the end inner panel toward the end outer panel to permit the tab to pass over the end inner panel as the side inner panel is folded toward the side outer panel, and releases the end inner panel to spring away from the end outer panel after the tab has entered the notch; andwherein when the second carton is erected, the end inner panel is again spaced apart from the end outer panel to provide a gap between the end inner panel and the end outer panel and a corresponding depth to the pocket, and the tab extends inwardly toward the end outer panel beyond the notch and into the depth. 13. The blank of claim 1 wherein: the end inner panel includes a second side edge opposite the side edge; andthe gap between the end inner panel and the end outer panel extends throughout an entire length from the side edge to the second side edge. 14. A method for using a blank and forming a carton, the method comprising: providing a reusable blank including a unitary substrate layer, the blank defining a primary axis and a secondary axis transverse to the primary axis, the substrate layer including: a main panel having a side edge extending substantially parallel to the primary axis and an end edge substantially parallel to the secondary axis;an end outer panel connected to the end edge by a first fold line extending substantially parallel to the secondary axis;an end inner panel connected to the end outer panel by a second fold line extending substantially parallel to the secondary axis;a side outer panel connected to the side edge by a third fold line extending substantially parallel to the primary axis;a side inner panel connected to the side outer panel by a fourth fold line extending substantially parallel to the primary axis;a notch defined in a side edge of the end inner panel; andan integral tab extending from an end edge of the side inner panel adjacent the side edge of the end inner panel; andforming a carton from the blank, including: folding the end outer panel relative to the main panel about the first fold line;folding the end inner panel relative to the end outer panel about the second fold line so that the end inner panel substantially faces the end outer panel and is deflectably spaced away from the end outer panel;folding the side outer panel relative to the main panel about the third fold line, whereby a pocket is defined between the notch, the side outer panel, and the end outer panel; thereafterfollowing the steps of folding the end inner panel relative to the end outer panel and folding the side outer panel relative to the main panel, folding the side inner panel relative to the side outer panel about the fourth fold line so that the side inner panel substantially faces the side outer panel and the tab is thereby inserted through the notch and into the pocket to interlock the side inner panel and the end inner panel;wherein the step of folding the side inner panel relative to the side outer panel elastically deflects the end inner panel toward the end outer panel to permit the tab to pass over the end inner panel as the side inner panel is folded toward the side outer panel, and releases the end inner panel to spring away from the end outer panel after the tab has entered the notch;wherein when the carton is erected, the end inner panel is spaced apart from the end outer panel to provide a gap between the end inner panel and the end outer panel and a corresponding depth to the pocket, and the tab extends inwardly toward the end outer panel beyond the notch and into the depth; andwherein the blank is configured such that, when the carton is erected, the tab can be released from the pocket by deflecting the end inner panel toward the end outer panel, thereby permitting the carton to be collapsed. 15. The method of claim 14 wherein the blank provides tactile and/or audible feedback when the end inner panel springs away from the end outer panel after the tab has entered the notch. 16. The method of claim 14 including: with the carton erected, deflecting the end inner panel toward the end outer panel to thereby release the tab from the pocket; andcollapsing the carton. 17. The method of claim 16 further including, following the step of disassembling the carton, re-assembling the blank into a second erected carton, after the carton has been disassembled by deflecting the end inner panel toward the end outer panel, by: again folding the side inner panel relative to the side outer panel about the fourth fold line so that the side inner panel substantially faces the side outer panel and the tab is thereby inserted through the notch and into the pocket to interlock the side inner panel and the end inner panel;wherein the step of folding the side inner panel relative to the side outer panel again elastically deflects the end inner panel toward the end outer panel to permit the tab to pass over the end inner panel as the side inner panel is folded toward the side outer panel, and releases the end inner panel to spring away from the end outer panel after the tab has entered the notch;wherein when the carton is re-assembled, the end inner panel is again spaced apart from the end outer panel to provide a gap between the end inner panel and the end outer panel and a corresponding depth to the pocket, and the tab extends inwardly toward the end outer panel beyond the notch and into the depth. 18. The method of claim 14 wherein, when the carton is erected, the end inner panel and the side inner panel each exert a spring force on the other. 19. The method of claim 14 wherein: the blank further includes an end foot panel connected to the end inner panel along a fifth fold line;the blank further includes a side foot panel connected to the side inner panel along a sixth fold line; andwhen the carton is erected, the side foot panel overlaps the end foot panel to capture the end foot panel between the side foot panel and the main panel and thereby inhibit the end inner panel from pivoting away from the end outer panel. 20. The method of claim 14 further including bonding an outer decorative sheet to an outer surface of the substrate layer such that the outer decorative sheet covers at least a portion of each of the main panel, the end outer panel and the side outer panel. 21. The method of claim 20 wherein bonding the outer decorative sheet to the outer surface of the substrate layer includes loose wrap bonding the outer decorative sheet to the substrate layer. 22. The method of claim 21 wherein bonding the outer decorative sheet to the outer surface of the substrate layer includes: adhering the outer decorative sheet to the outer surface of the substrate layer with a flowable adhesive while the substrate layer is in a first position; thereafterbending the substrate layer into a second position such that the outer decorative sheet and the outer surface of the substrate layer slide relative to one another; thereaftersetting the adhesive while the substrate is in the second position to thereby permanently affix the outer decorative sheet to the outer surface of the substrate layer with the set adhesive; and thereafterbending the substrate layer into a third position. 23. The method of claim 20 wherein, when the outer decorative sheet is bonded to the substrate layer: the substrate layer includes a corner web connecting a side edge of the outer end outer panel to an end edge of the side outer panel;the outer decorative sheet includes a corner section extending beyond the end outer panel and the side outer panel and outwardly beyond the corner web; andthe corner section has a cross edge defining an oblique angle with each of the primary axis and the secondary axis. 24. The method of claim 14 wherein at least some of the first, second, third, and fourth fold lines are of a first type and at least some of the first, second, third, and fourth fold lines are of a second type, wherein the fold lines of the first type exert a greater return spring force when folded than do the fold lines of the second type when folded. 25. The method of claim 14 wherein: the substrate layer includes: a first corner panel connected to the end outer panel by a first corner fold line; anda second corner panel connected to the side outer panel by a second corner fold line and to the first corner panel by a third corner fold line; andthe method includes adhering the first corner panel to the end outer panel or adhering the second corner panel to the side outer panel. 26. The method of claim 14 wherein the end inner panel is not adhered to the end outer panel. 27. The method of claim 14 wherein: the end inner panel includes a second side edge opposite the side edge; andthe gap between the end inner panel and the end outer panel extends throughout an entire length from the side edge to the second side edge.
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이 특허에 인용된 특허 (6)
Canning Timothy A. (5109 Sandlewood Dr. Raleigh NC 27609) Hartman Andrew F. (Elgarstraat 16 5653 AH Eindhoven NLX) Williams Ken (3523 Mill Run Raleigh NC 27612) Elliot Harry R. (325 Valley Green Rd. , Apparatus and method for erecting boxes.
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