Telescoping box construction

Abstract

A telescoping box is formed from two parts, a top part and a bottom part. The bottom part of the box has a bottom wall and a sidewall extending upwardly from the bottom wall. Likewise, the top part has a top wall and a sidewall depending from the sidewall. A collar is located to the interior sidewall and extends above the top edge of the bottom sidewall. When the box is closed, the bottom edge of the top sidewall rests upon the top edge of the bottom sidewall to result in a flush outer surface. The collar and bottom sidewall are formed from multiple panels. The collar and sidewall may te formed from a single blank. The sidewalls and collar are provided with fold lines to facilitate the sidewalls assuming an arcuate shape. When folded, the fold lines are hidden from view when the box is closed.

Description

CROSS-REFERENCE TO RELATED APPLICATION

[0001] This application is a divisional of application Ser. No. 09/643,397, filed Aug. 22, 2000.

FIELD OF THE INVENTION

[0002] The invention relates to a structure and method for making boxes of a complicated structure.

BACKGROUND OF THE INVENTION

[0003] Boxes are a very common way to package goods. Often, the goods sold in the boxes remain in the boxes after purchase so that the box serves as storage for the goods. For this reason, ornamental and sturdy boxes are desirable.

[0004] Boxes have been a popular form of container for a very long time. The light weight, strength and easy manufacture of boxes makes them a popular choice. The prior art has a great variety of available shapes, sizes, construction and features. One such prior art box is discloses in U.S. Pat. No. 1,678,958 (Schleicher). Schleicher discloses a round box having a sidewall 4 connected to the top wall 1 and bottom wall 3 by a series of tabs 7. Similarly, U.S. Pat. No. 1,772,878 (Schleicher) discloses a box having a sidewall 11 connected to bottom wall 2 by tabs 12. The sidewall is arcuate and provided with several fold lines 15, 18, 21, 22 to form bends in the sidewall.

[0005] Graves et al., U.S. Pat. No. 2,341,338 discloses a container having a bottom section with a lower wall 10 and an upper section having an upper wall 11 separated by pulling a string 13. A collar 2 extends above the lower wall 12 and is telescopicly received within the upper portion 9.

[0006] U.S. Pat. No. 2,457,198 (Bell) discloses a circular container having a crimped outer surface 13. Tabs 18 engage slots 19 to retain the container in a circular configuration.

[0007] Further, none of the prior art discloses a simplified method of forming complex boxes and none disclose a means of forming boxes with arcuate walls in which the bunching effect may be effectively hidden.

[0008] Further, none of the prior art patents discloses a telescoping box having an upper wall and a lower wall and a collar portion, the collar and lower portion being formed from multiple panels.

SUMMARY OF THE INVENTION

[0009] It is an object of the invention to provide a telescoping container having a smooth outer surface when closed.

[0010] It is another object of the invention to provide a multilayer box having a smooth, curved surface.

[0011] It is another object of the invention to provide a box having a strong construction.

[0012] It is yet another object of the invention to have fold lines with apertures to accommodate excess material caused by bending panels into an arcuate shape.

[0013] It is still another object of the invention to provide a box having curved sidewalls without any visible score lines.

[0014] It is yet another object of the invention to provide a box that is easy and inexpensive to manufacture.

[0015] These and other objects of the invention will become apparent after reading the detailed description of the invention that follows.

[0016] A telescoping box is formed from two parts, a top part and a bottom part. The bottom part of the box has a bottom wall and a sidewall extending upwardly from the bottom wall. Likewise, the top part has a top wall and a sidewall depending from the top wall. A collar is located interiorly of the sidewall and extends above the top edge of the bottom sidewall. When the box is closed, the bottom edge of the top sidewall rests upon the top edge of the bottom sidewall to result in a flush outer surface.

[0017] The collar and bottom sidewall are formed from multiple panels. The collar and sidewall may be formed from a single blank. The sidewalls and collar are provided with fold lines to facilitate the sidewalls assuming an arcuate shape. The fold lines are hidden from view when the box is closed.

[0018] Both the collar and upper sidewall are provided with tabs that extend along, and are secured to, the bottom or top wall. When the collar and bottom sidewall are formed from separate blanks, the bottom sidewall also has tabs securing it to the bottom panel. A strong, aesthetically pleasing box results that can be repeatedly used to store items.

[0019] Fold lines are formed on the interior panel of the multilayer construction. The fold lines have apertures. When the sidewalls are bent into an arcuate shape, the excess material that results from the bending process fits into the apertures. The result is a smooth exterior surface. When in the blank form, all the panels have the same length. When folded, the inner panel has the smallest radius of curvature of all the layers. The inner layer will have material that bunches while the outer layer will be stretched across the arc. The excess material of the inner layer fits into the apertures to result in a smooth surface.

[0020] In accordance with the teachings of this invention there is provided a container, which comprises a bottom wall, a lower sidewall extending upwardly from the bottom wall, with the lower sidewall having an outer panel and an inner panel. There is also provided a collar located inside of the lower sidewall, the collar having a height greater than a height of the said lower sidewall, said collar having a first panel and a second panel.

[0021] In another aspect of this invention there is provided a method for forming a multilayer arcuate sidewall which comprises the steps of forming creases on an interior panel, forming apertures in the fold lines, bending the multilayer sidewall into an arcuate shape, and allowing excess material from an interior sidewall to enter said apertures in the middle sidewall.

[0022] In yet another aspect of this invention there is provided a curved sidewall which comprises an inner panel, an outer panel and a middle panel between the inner and outer panels. Apertures are formed in the middle panels, material from the inner panel entering the aperture.

[0023] In still another aspect of this invention there is provided a curved sidewall which comprises a first panel forming an interior of the sidewall, a second panel connected to the top of the first panel and extending downwardly, a third panel connected to the bottom of the second panel and extending downwardly, a fourth panel connected to the bottom of the third panel and extending upwardly, a fifth panel connected to the top of the fourth panel and extending downwardly, and a sixth panel extending from the bottom of the fifth panel and extending upwardly. Apertures are formed in the third and fifth panels. Material from the first panel enters the apertures when the sidewall is formed into a curved shape.

BRIEF DESCRIPTION OF THE DRAWINGS

[0024] FIG. 1 shows the preferred embodiment box constructed in accordance with the principles of the invention in an open condition.

[0025] FIG. 2 shows the preferred embodiment box constructed in accordance with the principles of the invention in a closed condition.

[0026] FIG. 3 shows a heart-shaped alternative embodiment of the invention.

[0027] FIG. 4 is a cross section of the bottom sidewall and collar.

[0028] FIG. 5 is a planned view of blank used to make the box depicted in FIG. 1.

[0029] FIG. 6 is a detailed view of the tabs.

[0030] FIG. 7 is a cross section of a second embodiment of the bottom wall and collar.

[0031] FIG. 8 is a view of a section of a blank that forms the box.

[0032] FIG. 9 is a cross section of the collar and bottom wall when it is formed from two pieces.

DETAILED DESCRIPTION OF THE INVENTION

[0033] The box of the invention has a bottom part 1 and top part 2, and can be seen in FIG. 1 in the open configuration. Seen in this figure is the bottom panel 3, a lower sidewall 4, and the collar 6 extending above the lower sidewall 4. A shoulder 5 is formed by the top of the lower sidewall 4. Creases on the interior side of the collar facilitate the bending of the collar into an arcuate shape. The top part 2 has a top panel 9 and a depending upper sidewall 8. The closed configuration shown in FIG. 2 is formed when the top part 1 and the bottom part 2 are joined to close the box. As can be seen in this view, the bottom of the upper sidewall 8 rests on the shoulder 5 of the lower sidewall to form a flush surface.

[0034] FIG. 3 shows an alternative form of the box. The box is heart shaped and has a bottom wall 13 with an upstanding lower sidewall 14. The top surface of the lower sidewall forms a shoulder 15. A collar 16 extends above the shoulder of the lower sidewall. Creases 17 are formed on the interior of the collar and creases 20 are formed on the outside of the collar 16. When the box is closed, the collar is covered by the upper sidewall and no creases are visible.

[0035] The structure of the collar and lower sidewall is seen in cross section in FIG. 4. The collar is formed by a first panel 29 and a second outer panel 30 connected to one another by a fold line 31. The second panel 30 has creases 32 to facilitate the bending of the panels into an arcuate shape. Tabs 23 attach the lower sidewall to the bottom panel. An inner panel 24 is connected to the tabs along a first fold line 19. A second fold line 25 connects the inner panel 24 to the outer panel 26. As can be seen, a space is created between the inner panel 24 and the outer panel 26. To create this space, the second fold line 25 can be a double fold line as is well known in the art. A middle panel 28 fits into the space between the inner panel 24 and outer panel 26. The middle panel 28 is connected to the outer panel 26 along third fold line 27. The inner panel 24, middle panel 28, outer panel 26, first panel 29 and second panel 30 can be adhered to one another with adhesive to maintain them in position and add to the structural integrity of the box.

[0036] The blank for forming the lower sidewall is shown in FIG. 5. Fold line 25 connects tabs 23 to the inner wall panel 24. Fold line 27 connects the inner wall panel 24 to an outer panel 26. The middle panel 28 is connected to the outer panel 26. The inner panel 24 is provided with creases 8 and the outer panel 26 is provided with creases 9. The middle panel has creases 10 formed on the outer surface that allow the pane to form a convex shape. Perforations 11 are also formed on the middle panel. In addition to the creases, cutouts 12 are formed in the middle panel 28.

[0037] The inner panel 24, middle panel 28, and outer panel 26 all have the same length when in the blank form. When they are folded into an arcuate shape of the box, however, the inner panel has the smallest rate of curvature. The arc length formed by the inner panel is shorter than that formed by the middle panel 28 or outer panel 26. When formed, the outer panel is stretched across the middle panel. When the inner panel is folded into the arcuate shape, the excess material formed by virtue of the tighter curvature of the panel fits into the cutouts in the middle panel. The cutouts form areas for the excess material to go and allow the three panels that form the sidewall to have a smooth surface.

[0038] A detailed view of an alternative embodiment is shown if FIG. 6. The lower sidewall is shown having tabs 122 connected along fold line 133 to a first panel 123. The first panel 123 is connected to the outer panel 124 along fold line 134 and to middle panel 125 along fold line 135. Creases 129 run along the height of the blank and cutouts 132 are formed within the middle panel 125.

[0039] An embodiment having the collar and lower sidewall formed from a single blank is shown in cross section in FIG. 7. The collar/sidewall has tabs 43 to attach the collar/sidewall to the bottom panel. A first panel 44 extends upwardly from the tabs and is connected to the tabs by fold 42. A fold line 45 at the top of the first panel 44 connects it to a second panel 46. The second panel 46 has a fold line 47 connecting it to a third panel 48 that extends upwardly. The third panel 48 is connected to a fourth panel 50 by fold line 49. The fourth panel 50 extends downwardly to terminate in a fifth fold line 51. The fifth fold line connects a fifth panel 52 to the fourth panel 50. The fifth panel extends upwardly and extends between the first panel 44 and the fourth panel 50. As in the earlier embodiment, adhesive is used between the panels that lay against one another to increase the structural integrity of the box.

[0040] Creases 64 are provided on the interior surface of the first panel 44 and protrude on the inside. Creases 65 are provided on the exterior of the second panel 46 that extends above the fold line 49 and protrude on the inside. On the exterior surface of the second panel 46 below the third fold line 48, creases 66 are cut to protrude outwardly. Lastly, creases 67 are formed on the interior surface of the third panel and protrude inwardly. When the cover is placed onto the lower part of the box, the fold lines are covered and not visible.

[0041] The section of the blank used to make the container is shown in FIG. 8. All of the various fold lines in the panels are seen. Also seen in this view is the locking tab 71 and 72 used to secure the sidewall to itself after folding. The locking tabs engage slits or are adhered to the opposite edge of the sidewall when assembled. In addition to the creases, there are slots 73, 74 and 78 that provide openings. When the blank is bent into an arcuate shape, the slots provide areas for material to move into.

[0042] In addition, there are a series of cuts 75 in the fifth panel 52. These cuts penetrate approximately half the thickness of the panel and make the material more pliable. The cuts can be replaced by perferations. Creases 76 and 77 traverse the fourth panel 50,. Creases 77 are colinear with the slot 74 on the fifth panel 52.

[0043] In FIG. 9, another embodiment of the invention is depicted. In this embodiment, the lower sidewall 81 is formed by a center panel 87 having a lower fold line 91 and an upper fold line 90. The upper fold line 90 forms a shoulder. A pair of wing panels 88 and 89 are attached to the center panel 87 by the upper and lower fold line. The wing panels are folded over against the center panel and are on the interior of the center panel. The collar 82 has tabs 83 for attaching the collar to a bottom panel. A fold line 80 attaches the tabs 83 to a first panel 84. A second panel 86 is connected to the first panel 84 by a fold line 85. The result is a two layer lower sidewall and two layer collar. The panels can be adhered to one another to improve their structural integrity.

[0044] While the invention has been described with reference to preferred embodiments, modifications and variations would be obvious to one very skilled in the art. The invention is not to be limited to the exact embodiments disclosed but encompasses variations that do not fall within the scope of the invention.

Claims

1. A method for forming a multilayer arcuate sidewall, comprising:

forming creases on an interior panel,

forming apertures in the fold lines,

bending the multilayer sidewall into an arcuate shape, and

allowing excess material from an interior sidewall to enter said apertures in the middle sidewall.

2. The method of claim 1, wherein said creases are formed on the interior side of the interior panel.

3. The method of claim 1, wherein said creases are formed on the exterior side of the interior panel.

4. A curved sidewall, comprising

an inner panel, an outer panel and a middle panel between said inner and outer panels, and

apertures formed in said middle panels, material from said inner panel entering said aperture.

5. The curved sidewall of claim 4 wherein said apertures are formed in fold lines in said middle panel.

6. The curved sidewall of claim 5, wherein said fold lines are vertical.

7. The curved sidewall of claim 4, wherein said outer panel is connected to said middle panel by a fold line and said middle panel is connected.

8. The curved sidewall of claim 4 further comprising perforations in said middle panel.

9. The curved sidewall of claim 8, wherein said perforations are spaced from said apertures.