Pre-Folded File Bottom Box Form, and Method of Creating Same

Abstract

A pre-folded file bottom box form (80) created from a unitary blank (10) of corrugated material that is die cut and creased so as to form a series of panels and flaps arranged in three rows (A, B and C) of four panels or flaps each that define four columns (D, E, F and G). The blank (10) includes a first row (A) with four panels (32, 34, 36 and 38) that end up in the box as reinforcing sidewall and end wall panels, a middle row (B) contiguous with the first row (A) and having four panels (20, 24, 28 and 40) that end up in the box as sidewall and end wall panels, and a third row (C) coupled to the second row (B) and including first (16) and second (18) panels and two flaps (12, 14), the first (16) and second (18) panels making up the bottom of the box and the two flaps (12, 14) contiguous with the first third-row panel (16) and making up portions of the two end-walls. The four panels of the first row (A) are folded onto the four panels of the second row (B). The blank is then folded along two of the fold lines (42, 44) located between columns, and the edges (24, 26) of the end panels (30, 20) of the middle row (B) are fastened together, to create the completed form (80).

Description

CROSS-REFERENCE TO RELATED APPLICATION

This application claims priority of Provisional Application Ser. No. 61/492,912 filed on Jun. 3, 2011, the disclosure of which is incorporated herein by reference.

FIELD

This disclosure relates to a form that is constructed and arranged to be folded into a cardboard box.

BACKGROUND

File bottom record/archive file storage boxes are historically made in a fashion that requires a great deal of complex, manual assembly by the consumer. The existing state of the art “file bottom” style, in which the bottom is created from flaps as the box form is folded into a box, requires more time and space than is desirable. The file bottom style boxes present a flat bottom that is best suited for storage on shelving, while other file box designs such as the automatic bottom style boxes have cutouts and rough edges along with creases in the bottom flap(s) that can catch on shelving, and thus typically are not well suited for use in situations in which the boxes are going to be stored on shelves.

There are at least two problems with the file bottom box design that are addressed by the present disclosure. For one, the design requires the user to read and follow fairly complex assembly instructions, taking time and labor to put the box together. This involves folding the bottom panels up in a specific sequence which forms the bottom structure. Then the top flaps need to be folded over and inward to form the double wall structure on the length panels and triple wall structure on the width panels. This is a time consuming and complicated process for the consumer.

A second problem is the size of the file bottom box: the box form (the intermediate form in which the blank has been partially folded and lies flat for shipping and storage, and is ready to be assembled into a functional box) is relatively large. The box in its flat form has all the folding flaps top and bottom sticking out, waiting for assembly. This makes the box in the knocked down flat position, a large footprint to handle when delivering to customers through passage ways, doorways, and in an office environment. Also, more area needs to be devoted to shipping and storage of these box forms. The disclosure reduces this footprint when in the flat (i.e., the box form before it is squared up) by 33%, a huge material handling and shipping savings, and an enormous increase in convenience.

SUMMARY

This disclosure features a box for file storage and the like. The box is made from a unitary blank of material. The box, when assembled, has four interconnected sidewalls that define an open storage area between them. The sidewalls are typically each rectangular in shape, to define a generally rectangular prism-shaped storage area.

In an example the pre-folded file bottom box form is made from a unitary blank of material comprising a blank of corrugated material that is die cut and creased so as to form a series of panels and flaps arranged in three rows of four panels or flaps each that define four columns, a first row comprising four panels that end up in the box as reinforcing sidewall and end wall panels, a middle row contiguous with the first row and comprising four panels that end up in the box as the box sidewall and end wall panels, and a third row coupled to the second row and comprising first and second panels and two flaps, the first and second panels making up the bottom of the box and the two flaps contiguous with the first third-row panel and making up portions of the two end-walls. The four panels of the first row are folded onto the four panels of the second row. The blank is then folded along two of the fold lines located between columns, and the edges of the end panels of the middle row are glued together, to create the completed form. The disclosure includes a box created from this pre-folded file bottom box form.

The four panels of the first row may be separated from one another by slots. The slots may be skip slots that comprise a small region of material that spans the slots such that two panels separated by a slot are connected by the small region. The four panels of the first row may lie against but are not fixed to the four panels of the second row. The four panels of the first row may be glued to the four panels of the second row. The edges of the end panels of the middle row may be fastened together by gluing, stitching or stapling.

The disclosure also features a method of creating a pre-folded file bottom box form made from a unitary blank of material comprising providing a blank of corrugated material that is die cut and creased so as to form a series of panels and flaps arranged in three rows of four panels or flaps each that define four columns, a first row comprising four panels that end up in the box as sidewall and end wall panels, a middle row contiguous with the first row and comprising four panels that end up in the box as box sidewall and end wall panels, and a third row coupled to the second row and comprising first and second panels and two flaps, the first and second panels making up the bottom of the box and the two flaps contiguous with the first third-row panel and making up portions of the two end-walls. The four panels of the first row are folded onto the four panels of the second row. Then the blank is folded along two of the fold lines located between columns. Then the edges of the end panels of the middle row are glued together, to create the completed form.

The four panels of the first row may be separated from one another by slots. The slots may be skip slots that comprise a small region of material that spans the slots such that two panels separated by a slot are connected by the small region. The four panels of the first row may lie against but are not fixed to the four panels of the second row. The four panels of the first row may be glued to the four panels of the second row. The edges of the end panels of the middle row may be fastened together by gluing, stitching or stapling.

An open-top box may be created from the box form by squaring up the box form into an open rectangular box shape, pulling a first panel of the third row up inside the box shape, folding the two flaps of the third row onto the second panel of the third row, pushing the second panel of the third row down such that it lies generally at right angles to the four sidewalls, unfolding the two flaps of the third row against the two middle row panels that make up the end walls, and pushing the first panel of the third row down onto the second panels of the third row.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top inside view of a blank used to create an example of the box form, before folding.

FIG. 2 shows the top row folded down and glued to the middle row.

FIG. 3 shows the form in the state shown in FIG. 2, and then partially folded along vertical fold lines between columns.

FIG. 4 shows the fully assembled box form ready for shipment, storage and then folding into a box.

DETAILED DESCRIPTION OF EXAMPLES

An example of a box form is created from the unitary blank of material 10 shown in FIG. 1. Blank 10 may be constructed of any material that will form a stiff panel surface. Preferably, blank 10 is made from a single thickness corrugated material (corrugated paper or corrugated plastic), that is a material with two layers of linerboard separated by a single layer of fluted material. Such a corrugated material can be constructed from different substances, as is known in the art. The material can have several different constructions. Corrugated material is typically constructed from fiber materials or plastic materials.

Blank 10 is formed through die cutting and creasing of corrugated material as is known in the art. In one non-limiting example, blank 10 is about 75⅛ inches wide and about 32 7/16 inches high. FIG. 1 shows the blank from the side that will form the inside of the box. Lines 42-44 and 71-73 illustrate fold lines or creases where the form is adapted to be folded. In the example, blank 10 is pre-folded and glued such that the panels that make up the sidewall and end wall reinforcements are overlaid over and glued to the panels that make up two sidewalls and the two end walls. As a result, the form has an area that is only about two-thirds that of the typical form. This results in space savings in trucks, shipping containers and other means by which box forms are shipped, as well as warehouses, storage rooms and other locations where forms are stored by distributors or end-users before the forms are folded into boxes.

By pre-folding the top four panels (which become sidewall reinforcements) into position during the manufacturing process, the footprint of the box in the knocked down flat position is reduced by 33%. This is an important improvement because it allows for greater freight efficiencies, easier delivery through narrow doorways, hallways and within the office environment. From an ergonomic point of view, having a box foot print that is 33% smaller makes it easier for people to handle the box prior to assembly and reduces the risk of potential injury, especially when bundles of ten or more are being handled. Bundled units of ten or more are how these products are typically delivered. Having a third less width in the footprint allows people carrying the box forms to more easily handle them.

Blank 10 essentially defines three rows of panels and flaps labeled A, B and C, and four columns of panels and flaps labeled D, E, F and G. Panels 16 and 18 will eventually form the bottom of the box with panel 16 on the outside. Since panel 16 does not have any folds or creases in it, the resulting box will sit flat on shelves or other storage locations and is easier to handle than other boxes such as the automatic bottom style boxes in which the bottom panel has folds or creases in it and so does not present a flat outer surface.

The pre-folded file bottom box form 80 can be created as follows. Beginning with form 10, panels 34, 38, 32 and 36 are folded along horizontal crease 71 onto panels 24, 40, 28 and 20, respectively. Adhesive is applied before folding. This secures the panels of the double thickness sidewalls and end walls together, rather than relying on friction; this makes the construction more secure. As a result, the four panels of row A are now located on top of the four panels in row B, as shown in FIG. 2. The form is then folded along vertical fold lines 42 and 44 (as shown in FIG. 3), and extension 24 of panel 30 is glued to location 26 of panel 20; extension 24 is defined by score line 25 so it can fold relative to panel 30, thus allowing box form 80 to lie flat. This creates the pre-folded file bottom box form 80 shown in FIG. 4. This flat box form only occupies an area equal to that of rows B and C and columns D and G.

This box form is then folded into a functional box as follows: The pre-folded file bottom box is squared up to form a rectangular shape. Panel 18 is pulled up inside the box against panel 20 to make room for the folding of panels 12, 16 and 14. Panel 16 is then pushed down such that it lies at right angles to the four sidewalls; flaps 14 and 12 are first folded flat against panel 16 to allow all three panels to fold inside the box. Once inside the squared up box, panel 16 forms the bottom outside of the box at a right angle to panel 40. Panel 12 then unfolds against panel 30 and panel 14 unfolds against panel 28. Panel 18 is pushed down onto panel 16. This forms a double thickness flat bottom to the box.

In an alternative example the panels that make up the sidewall and end wall reinforcements are not fastened (e.g., by gluing, stitching or stapling) to the panels that make up two sidewalls and the two end walls. Instead, they are held by friction. To accomplish this slots 101, 102 and 103 would be fashioned as “skip slots” (as known in the trade) wherein a small region of material would span the slots and directly interconnect the two adjacent panels, thus securing panels 34, 38, 32 and 36 as one unit. This allows the four panels in row A to be folded over all at once along fold line 71 against panels 30, 40, 28 and 20 making up row B. The tolerances (sizes) of the panels in row A would be adjusted so they would fit snugly and accomplish a friction fit when the box is folded over and sealed with the side seam 24 mating with area 26. The bottom of the box would be assembled as previously described.

Claims

1. A pre-folded file bottom box form, comprising:

a unitary blank of corrugated material that is die cut and creased so as to form a series of panels and flaps arranged in three rows of four panels or flaps each that define four columns, the blank comprising:

a first row comprising four panels that end up in the box as reinforcing sidewall and end wall panels;

a middle row contiguous with the first row and comprising four panels that end up in the box as sidewall and end wall panels; and

a third row coupled to the second row and comprising first and second panels and two flaps, the first and second panels making up the bottom of the box and the two flaps contiguous with the first third-row panel and making up portions of the two end-walls;

wherein the four panels of the first row are folded onto the four panels of the second row; and

wherein the blank is then folded along two of the fold lines located between columns, and the edges of the end panels of the middle row are fastened together, to create the completed form.

2. The box form of claim 1 wherein the four panels of the first row are separated from one another by slots.

3. The box form of claim 2 wherein the four panels of the first row are glued to the four panels of the second row.

4. The box form of claim 2 wherein the slots are skip slots that comprise a small region of material that spans the slots such that two panels separated by a slot are connected by the small region.

5. The box form of claim 4 wherein the four panels of the first row lie against but are not fixed to the four panels of the second row.

6. The box form of claim 1 wherein the edges of the end panels of the middle row are fastened together by gluing, stitching or stapling.

7. A box created from the box form of claim 1.

8. A method of creating a pre-folded file bottom box form made from a unitary blank of material, comprising:

i) providing a blank of corrugated material that is die cut and creased so as to form a series of panels and flaps arranged in three rows of four panels or flaps each that define four columns, a first row comprising four panels that end up in the box as reinforcing sidewall and end wall panels, a middle row contiguous with the first row and comprising four panels that end up in the box as sidewall and end wall panel, and a third row coupled to the second row and comprising first and second panels and two flaps, the first and second panels making up the bottom of the box and the two flaps contiguous with the first third-row panel and making up portions of the two end-walls;

ii) folding the four panels of the first row to the four panels of the second row;

iii) then folding the blank along two of the fold lines located between columns; and

iv) then fastening together the edges of the end panels of the middle row, to create the completed form.

9. The method of claim 8 wherein the four panels of the first row are separated from one another by slots.

10. The method of claim 9 wherein the four panels of the first row are glued to the four panels of the second row.

11. The method of claim 9 wherein the slots are skip slots that comprise a small region of material that spans the slots such that two panels separated by a slot are connected by the small region.

12. The method of claim 11 wherein the four panels of the first row lie against but are not fixed to the four panels of the second row.

13. The method of claim 8 wherein the edges of the end panels of the middle row are fastened together by gluing, stitching or stapling.

14. The method of claim 8 further comprising:

v) creating from the box form an open-top box.

15. The method of claim 14 wherein creating from the box form an open-top box comprises the following steps:

vi) squaring up the box form into an open rectangular box shape;

vii) pulling a first panel of the third row up inside the box shape;

viii) folding the two flaps of the third row onto the second panel of the third row and pulling the panel up inside the box shape;

ix) pushing the second panel of the third row down such that it lies generally at right angles to the four sidewalls;

x) unfolding the two flaps of the third row against the two middle row panels that make up the end walls; and

xi) pushing the first panel of the third row down onto the second panel of the third row.