WO2006097683A1

WO2006097683A1 - Improvements in and relating to padded boxes

Info

Publication number: WO2006097683A1
Application number: PCT/GB2006/000810
Authority: WO
Inventors: Christopher Hallam
Original assignee: Concept Packaging Services Ltd; Concept Packaging Ltd
Current assignee: Concept Packaging Services Ltd; Concept Packaging Ltd
Priority date: 2005-03-12
Filing date: 2006-03-07
Publication date: 2006-09-21
Anticipated expiration: 2007-09-12
Also published as: EP1885605A1; GB0505170D0

Abstract

According to the present invention, there is provided a construction for a padded box comprising an inner board layer (60) and an outer board layer (2), the inner layer (60) comprising a base (62) and a first upstanding wall (64), the outer layer (2) comprising a base (4) and a first upstanding wall (6), which outer layer first upstanding wall (6) at least partly sandwiches the inner layer first upstanding wall (64).

Description

Improvements in and Relating to Padded Boxes

Field of the Invention

The present invention relates to constructions for padded boxes and to padded boxes comprising such carton constructions .

Background to the Invention

Padded boxes are known comprising an inner relatively rigid board layer, an intermediate relatively flexible board layer and an outer glued paper layer covering the intermediate layer and acting to obscure the layers from visibility. Padding, such as a foam material, is sandwiched between the two board layers to provide a bowing of the outer layer in the region of the padding to achieve an aesthetically pleasing curved shape of the box. The inner layer comprises side walls of an open-topped box, over which side walls; the paper outer layer is folded to secure the two board layers relative to one another .

It is, however, desirable to reduce the complexity of the box structure, make it more suitable for machine manufacture and further enhance its appearance.

Preferred embodiments of the present invention aim to obviate or overcome a disadvantage of the prior art, whether such prior art or disadvantage is referred to herein or otherwise. Summary of the Invention

According to the present invention in a first aspect, there is provided a construction for a padded box comprising an inner board layer and an outer board layer, the inner layer comprising a base and a first upstanding wall, the outer layer comprising a base and a first upstanding wall, which outer layer first upstanding wall at least partly sandwiches the inner layer first upstanding wall.

The outer layer need not be the outside layer, but is outer, relative to the inner layer.

Suitably, the outer layer first upstanding wall is hingedly connected to the base of the outer layer.

Suitably, the inner layer first upstanding wall is hingedly connected to the base of the inner layer.

Suitably, the inner layer first upstanding wall comprises a first flap hingedly connected to the base of the inner layer .

Suitably, the outer layer first upstanding wall comprises a first flap and a second flap, the first flap being hingedly connected to the base of the outer layer and the second flap being hingedly connected to the first flap. Suitably, the first flap lies on the outside of the box and the second flap lies on the inside of the box.

Suitably, a flange is hingedly connected to the second flap of the outer wall. Suitably, the flange extends the full length of the respective outer wall. Suitably, the flange abuts the base of the inner layer.

Suitably, the inner layer comprises a second upstanding wall, the outer layer comprises a second upstanding wall and the outer layer second upstanding wall at least partly sandwiches the inner layer second upstanding wall.

Suitably, the outer layer second upstanding wall is hingedly connected to the base of the outer layer.

Suitably, the inner layer second upstanding wall is hingedly connected to the base of the inner layer.

Suitably, the outer layer second upstanding wall comprises a first flap and a second flap, the first flap being hingedly connected to the base of the outer layer and the second flap being hingedly connected to the first flap. Suitably, the first flap lies on the outside of the box and the second flap lies on the inside of the box.

Suitably, the inner layer second upstanding wall comprises a first flap hingedly connected to the base of the inner layer.

Suitably, the first flap of the inner layer second upstanding wall comprises a cut-out portion and there is provided extending from a flap of the outer layer an infill portion for at least partly filling the space of the cut-out portion. Suitably, the in-fill portion comprises a web between the first wall of the outer layer and the first wall of the inner layer. Suitably, the web comprises a hinged connection. Alternatively, the in-fill portion comprises a tab extending from one of the first wall of the outer layer and the first wall of the inner layer.

Suitably, the box comprises an outer layer third upstanding wall, substantially similar to the outer layer first upstanding wall.

Suitably, the box comprises an outer layer fourth outstanding wall substantially similar to the outer layer second upstanding wall.

Suitably, the box comprises an inner layer third upstanding wall substantially similar to the inner layer first upstanding wall.

Suitably, the box comprises an inner layer fourth upstanding wall substantially similar to the inner layer second upstanding wall.

Suitably, the outer layer is substantially more flexible than the inner layer, whereby the outer layer is relatively more deformable. Suitably, the outer layer is thinner than the inner layer.

According to the present invention in a second aspect, there is provided a padded box comprising a construction according to the first aspect of the present invention and further comprising a padding material between the first layer and the second layer.

Suitably, the padded box further comprises a lid. Suitably, the padding material comprises a foam layer.

According to the present invention in a third aspect there are provided blanks for a padded box construction according to the first aspect of the present invention, comprising a blank for the inner layer and a blank for the outer layer.

Brief Description of the Drawings

The present invention will now be described, by way of example only, with reference to the drawings that follow; in which:

Figure 1 is a plan view of an outer layer of a padded box construction according to the present invention in an unfolded configuration.

Figure 2 is a plan view of an inner layer of a padded box construction according to the present invention in an unfolded configuration.

Figure 3 is a plan view of the inner layer of Figure 2 laid over the outer layer of Figure 1 as part of the assembly process.

Figure 4 is a cross sectional elevation through an assembled first wall.

Figure 5 is a plan view of an alternative outer layer construction . Figure β is a perspective view of a padded box construction according to the present invention.

Figure 7 is an enlarged plan view of part of an outer layer in an alternative embodiment of the present invention .

Description of the Preferred Embodiments

Figure 1 shows an outer layer 2 for a padded box. The outer layer 2 comprises a rectangular base portion 4, and first through fourth walls 6, 8, 10 and 12, respectively. First wall 6 is connected to second wall 8 by a first connecting web 14. Second wall 8 is connected to third wall 10 by a second connecting web 16. Third wall 10 is connected to fourth wall 12 by a third connecting web 18. Fourth wall 12 is connected to first wall 6 by a fourth connecting web 20.

The construction of the first 6 and third 10 walls is substantially similar. The construction of the second 8 and fourth 12 walls is substantially similar. The construction of the first to fourth connecting webs 14, 16, 18 and 20, respectively is substantially similar. Only one of the relevant similar walls or webs is described in detail, the other (s) being similar.

First wall 6 comprises a rectangular first flap 22 hingedly connected to base 4 along a first crease 24. First flap 22 is hingedly connected to a rectangular second flap 26 along a second crease 28. Second flap 26 extends from the distal edge of first flap 22 (relative to the base 4) . A rectangular first flange 30 is hingedly connected to the second flap 26 along a third crease 32. First flange 30 extends from the distal edge of second flap 26.

Extending laterally from either end of second flap 26 are lateral flanges 34, 36, respectively.

Second wall 8 comprises a rectangular first flap 38 hingedly connected to base 4 along a first crease 40. First flap 38 is hingedly connected to a rectangular second flap 42 along a second crease 44. Second flap 42 extends from the distal edge of first flap 38.

Web 14 connects adjacent first flaps 22, 38 of the first and second walls 6, 8, respectively. Web 14 comprises a first panel 46 and a second panel 48. The first and second panels 46, 48, respectively are hingedly connected along a crease 50. First panel 46 is hingedly connected to first flap 22 of first wall 6 along a crease 52. Second panel 48 is hingedly connected to first flap 38 of second wall 8 along a crease 54. The crease 50 connecting the first and second panels, 46, 48, respectively bisects the angle between the perpendicular creases 52, 54.

Figure 2 shows an inner layer 60 for a padded box suitable for use with outer layer 2. Inner layer 60 comprises a rectangular base 62, from which extend first through fourth walls 64, 66, 68 and 70, respectively, each extending from edges of the base 62.

First and third walls 64, 68 are substantially similar. Second and fourth walls 66, 70 are substantially similar. Only one of the relevant similar walls is described in detail, the other being similar.

First wall 64 comprises a rectangular flange 72 hingedly connected to base 62 along a score 74.

Second wall 66 comprises a flange 76 hingedly connected to base 62 along a score 78. Flange 76 is shaped with first and second cut-outs 80, 82, respectively at either end thereof. The cut-outs 80, 82 are similar so only one will be described here. A lower portion 84 of the second cutout 82 extends from the junction with first wall 64 to form a generally U-shaped cut-out, with an upper portion 86 of a reduced width when compared with the corresponding side of base 62, but still extending for a substantial majority of the length of the corresponding side of base 62.

The upper portion 86 by extending to rear the ends of the respective side preventing the box from crushing when pressure is applied.

A plastics foam pad 88 (on the opposite side of base 62 and shown with a dashed line) is adhered to the underside of base 62.

Outer layer 2 is made from 350μm carton board.

Inner layer 60 is made from lOOOμm rigid box board.

Thus, the outer layer is relatively more deformable. Both layers are self-supporting. An example of the assembly of the outer and inner layers 2, 60, respectively, to a padded box will now be described.

Inner layer 60 is placed on outer layer 2 with the bases thereof overlapping as far as possible, i.e. in alignment substantially as shown in Figure 3 of the drawings. The foam material 88 is, therefore, sandwiched between the two bases 4, 62.

The first and third walls 6, 10, respectively of the outer layer 2 are first folded over the first and third walls 64, 66, respectively of the inner layer 60. The flanges 30 lie essentially flat against the base 62 helping to keep the first and third walls 6, 10, respectively, in place forming upstanding walls substantially perpendicular to the base 62. This forms a side wall construction with a cross section as shown in Figure 4 of the drawings. In Figure 4 the spacing between layers is exaggerated for clarity. In practice the layers will usually be in contact with each other, though the invention does include within its scope embodiments wherein the layers are not in contact .

Flanges 34 and 36 prevent the webs from unravelling and serve to strengthen their respective corners .

Next the second and fourth walls 8, 12, respectively of the outer layer 2 are folded over the second and fourth walls 66, 70, respectively of the inner layer 60. Referring to the second walls (the construction and assembly of the fourth walls being substantially similar) , the flange 42 of the outer layer 2 is folded over so as to cover the flange 76 of the inner layer 60.

As the second wall 8 is folded in, the webs 14 and 16 project into the internal open volume being formed as the inside of the box. As the flange 42 is folded down, the webs 14, 16 fold into the area of the cut out portions 80, 82 of the inner layer 60. It is noted that the webs 14, 16 do not entirely fill or align with their respective cut out portions 80, 82. However, they substantially fill the volume of the cut-out portions 80, 82 and so ensure there is minimal deformation in this region. The webs 14 and 16 provide an interengagement between the respective walls.

The lower portion 84 extending to the adjacent wall provides an abutment for alignment of the outer and inner layers 2, 62 respectively.

Referring to Figure 5, in an alternative outer layer construction, instead of webs 14, 16, 18, 20, there can be provided tabs 90, 92, 94, 96, which could extend from either adjacent wall. While the tabs 90, 92, 94, 96 do not conveniently locate as well as the webs 14, 16, 18, 20, they require less material and mean a less precise cut can be utilised.

The tabs or webs act as in-fill portions .

Figure 6 shows a box 100 manufactured using the layers shown in Figures 1 and 2.

For each of the walls, the outer layer at least partly sandwiches the walls of the inner layer whereby the walls of the inner layer lie at least partly between the layers of the outer layer. This provides a convenient construction for manufacture and assembly, whether by machine or person.

The cut-outs 80, 82 allow from easier erection of the box, whether used with a web and a flange. The web (and/or tab) and the flange together help to form a solid corner. The flange and the web can enter the cut-outs enabling an easier construction but with substantially similar strength, when constructed, as compared with a single layer carton.

The construction around the cut-outs therefore makes erection easier by hand or by machine, provides strengths and resistance to crush and evens out the number of layers .

In an alternative embodiment of the present invention, walls 64 and 68 (see figure 2) can be omitted. To provide the structural support that would then be missing, the outer layer 2 can be modified by providing a further layer extending from each of first and third walls 6, 10. Such an extension of wall 6 is shown in figure 7. In figure 7, the first flange 30 is truncated and another flap 200 is provided, hinged at 202 and 204. Flap 200 is folded down to lie between flaps 22 and 26. A corresponding structure is provided for wall 10.

The outer layer can be decorated externally if desired. Thus, preferred embodiments of the present invention provide a box which does not require the conventional outer paper layer to hold the two board layers together.

The box is generally used as a lid for a box, though it can be used as a padded base.

Optional^'ly, one wall of the outer layer can be affixed, for instance by an adhesive, to the corresponding wall of the inner layer, for instance first wall to first wall, along one surface so that during shipping of the product in the flat the inner and outer pairs do not become separated and are in approximate (at least) alignment for manufacture .

Although described in relation to a rectangular box with rectangular upstanding walls, it will be appreciated that the principles of the present invention can be extended to boxes and walls of different shapes.

Attention is directed to all papers and documents which are filed concurrently with or previous to this specification in connection with this application and which are open to public inspection with this specification, and the contents of all such papers and documents are incorporated herein by reference.

All of the features disclosed in this specification (including any accompanying claims, abstract and drawings), and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive. Each feature disclosed in this specification (including any accompanying claims, abstract and drawings) may be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features.

The invention is not restricted to the details of the foregoing embodiment (s) . The invention extends to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings) , or to any novel one, or any novel combination, of the steps of any method or process so disclosed.

Claims

1. A construction for a padded box comprising an inner board layer and an outer board layer, the inner layer comprising a base and a first upstanding wall, the outer layer comprising a base and a first upstanding wall, which outer layer first upstanding wall at least partly sandwiches the inner layer first upstanding wall.

2. A construction for a padded box according to claim 1, in which the outer layer first upstanding wall is hingedly connected to the base of the outer layer.

3. A construction for a padded box according to claim 1 or 2, in which the inner layer first upstanding wall is hingedly connected to the base of the inner layer.

4. A construction for a padded box according to any preceding claim, in which the inner layer first upstanding wall comprises a first flap hingedly connected to the base of the inner layer.

5. A construction for a padded box according to any preceding claim, in which the outer layer first upstanding wall comprises a first flap and a second flap, the first flap being hingedly connected to the base of the outer layer and the second flap being hingedly connected to the first flap.

6. A construction for a padded box according to claim 5, in which the first flap lies on the outside of the box and the second flap lies on the inside of the box.

7. A construction for a padded box according to any preceding claim, in which a flange is hingedly connected to the second flap of the outer wall.

8. A construction for a padded box according to claim 7, in which the flange extends the full length of the respective outer wall .

9. A construction for a padded box according to claim 7 or 8, in which the flange abuts the base of the inner layer .

10. A construction for a padded box according to any preceding claim, in which the inner layer comprises a second upstanding wall, the outer layer comprises a second upstanding wall and the outer layer second upstanding wall at least partly sandwiches the inner layer second upstanding wall .

11. A construction for a padded box according to claim 10, in which the outer layer second upstanding wall is hingedly connected to the base of the outer layer.

12. A construction for a padded box according to claim 10 or claim 11, in which the inner layer second upstanding wall is hingedly connected to the base of the inner layer.

13. A construction for a padded box according to any one of claims 10-12 , in which the outer layer second upstanding wall comprises a first flap and a second flap, the first flap being hingedly connected to the base of the outer layer and the second flap being hingedly connected to the first flap.

14. A construction for a padded box according to claim 13, in which the first flap lies on the outside of the box and the second flap lies on the inside of the box.

15. A construction for a padded box according to any one of claims 10-14, in which the inner layer second upstanding wall comprises a first flap hingedly connected to the base of the inner layer.

16. A construction for a padded box according to any one of claims 10-15, in which the first flap of the inner layer second upstanding wall comprises a cut-out portion and there is provided extending from a flap of the outer layer an infill portion for at least partly filling the space of the cut-out portion.

17. A construction for a padded box according to claim 16, in which the in-fill portion comprises a web between the first wall of the outer layer and the first wall of the inner layer.

18. A construction for a padded box according to claim 17, in which the web comprises a hinged connection.

19. A construction for a padded box according to claim 16, in which the in-fill portion comprises a tab extending from one of the first wall of the outer layer and the first wall of the inner layer.

20. A construction for a padded box according to any preceding claim, in which the box comprises an outer layer third upstanding wall, substantially similar to the outer layer first upstanding wall.

21. A construction for a padded box according to any preceding claim, in which the box comprises an outer layer fourth outstanding wall substantially similar to the outer layer second upstanding wall.

22. A construction for a padded box according to any preceding claim, in which the box comprises an inner layer third upstanding wall substantially similar to the inner layer first upstanding wall.

23. A construction for a padded box according to any preceding claim, in which the box comprises an inner layer fourth upstanding wall substantially similar to the inner layer second upstanding wall.

24. A construction for a padded box according to any preceding claim, in which the outer layer is substantially more flexible than the inner layer, whereby the outer layer is relatively more deformable.

25. A construction for a padded box according to any preceding claim, in which the outer layer is thinner than the inner layer.

26. A padded box comprising a construction according to any preceding claim, and further comprising a padding material between the first layer and the second layer.

27. A padded box according to claim 26, in which the padded box further comprises a lid.

28. A padded box according to claim 26 or 27, in which the padding material comprises a foam layer.

29. Blanks for a padded box construction according to any one of claims 1 - 25 comprising a blank for an inner board layer and a blank for an outer board layer.