SUSPENSION PACK BOX DESIGNS, BLANKS AND METHODS

Box designs, blanks for forming boxes, boxes formed thereby, and manufacturing methods therefor are disclosed. Preferably the boxes are formed from cardboard or other corrugated material and include suspension packs for securely shipping items such as, for example and not by way of limitation, wine bottles, candles, and cell phones. Each box includes suspension panels that extend from a top panel of the lid of the box. The ends of the suspension panels are bound such that on or more items placed between the suspension panels through a top opening of the box when the lid is open are contained between the suspension panels in a suspended location above a bottom panel of the box and at spaces to the end and side panels of the box. The suspension panels may include hinges defined by perforated lines or fold lines for conforming to shapes of and thereby cradling the items.

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Description
CROSS-REFERENCE TO RELATED APPLICATION

The present application is a U.S. nonprovisional patent application of, and claims the benefit of priority under 35 U.S.C. §119(e) to, U.S. provisional patent application 62/062,824, filed Oct. 10, 2014, which is incorporated by reference herein. The disclosure of the provisional patent application is contained in the Appendix, which is incorporated by reference herein. The present application further is a U.S. continuation-in-part patent application of, and claims the benefit of priority under 35 U.S.C. §120 to, U.S. patent application Ser. No. 14/881,132, filed Oct. 12, 2015, which is incorporated by reference herein, and which '132 application also is a U.S. nonprovisional patent application of, and claims the benefit of priority under §119(e) to, U.S. provisional patent application 62/062,824, filed Oct. 10, 2014.

COPYRIGHT STATEMENT

All of the material in this patent documents is subject to copyright protection under the copyright laws of the United States and other countries. The copyright owner has no objection to the facsimile reproduction by anyone of the patent document or the patent disclosure, as it appears in official governmental records but, otherwise, all other copyright rights whatsoever are reserved.

BACKGROUND OF THE INVENTION

The present invention generally relates to box designs, blanks for forming boxes by folding, collapsible and non-collapsible boxes formed thereby, and manufacturing methods therefor. Preferably boxes of the invention are formed from cardboard or other corrugated material and comprise suspension packs for securely shipping items such as, for example and not by way of limitation, wine bottles, candles, and cell phones.

Machines and methods for making collapsible boxes from blanks are well known. Exemplary such machines and methods are disclosed, for example, in U.S. patent application publication 2012/0238423, which is hereby incorporated by reference herein. A similar technique is disclosed in Westerman U.S. Pat. No. 6,837,420. Preferred embodiments of the invention comprising collapsible shipping packs formed from folded and glued blanks preferably—but not necessarily—are manufactured using such the machines and methods as disclosed and taught in the incorporated U.S. patent application publication 2012/0238423.

SUMMARY OF THE INVENTION

The present invention includes many aspects and features. Moreover, while many aspects and features relate to, and are described in, the context of shipping packs and, more particular, suspension packs for shipping items such as wine bottles, candles, and cell phones or smartphones, the present invention is not so limited and applies to other types and uses of boxes, as will become apparent from the following summaries and detailed descriptions of aspects, features, and one or more embodiments of the present invention.

Accordingly, a first aspect of the invention comprises a box comprising a shipping pack as shown and described herein.

Another aspect of the invention comprises an assembled box as shown and described herein.

Another aspect of the invention comprises an assembled, collapsible box as shown and described.

Another aspect of the invention comprises a box in the form of a blank as shown and described.

Another aspect of the invention comprises a method of making any of the foregoing boxes.

Another aspect of the invention comprises a method of assembling any of the foregoing boxes. In features of this aspect, machines and methods as disclosed in U.S. patent application publication 2012/0238423, incorporated by reference herein, are adapted and used to assemble one or more of the foregoing boxes disclosed herein in order to form collapsible, assembled shipping packs. Each such shipping pack generally is collapsible even though in an assembled state preferably by folding along an axis bisecting a bottom panel and opposite end panels thereof.

Another aspect of the invention comprises a method of collapsing and storing any of the foregoing boxes.

In another aspect of the invention, a box is formed from folding a single sheet of material having fold lines and/or lines of perforations therein. When the box is assembled, it includes suspension panels that extend into an interior of the box, each suspension panel being connected to a top panel of the box along a fold line or line of perforations, the top panel forming part of the lid of the box, and distal subpanels of the suspension panels defining distal ends thereof being bound together such that the suspension panels form a receiving space for receiving one or more articles for suspended retention thereof within the interior of the box at spacings to end, side, and bottom panels forming defining the interior of the box.

In a feature, a fold line bisects each of the end panels and bottom panels and further comprising fold lines defined in the bottom panel such that the box is collapsible when in the assembled and bound stated.

In another aspect, a box blank comprises: a bottom panel; a first side panel; a second side panel; a first end panel; a second end panel; a first overlapping side panel; a second overlapping side panel; a third overlapping side panel; a fourth overlapping side panel; a first top panel; a second top panel; a first suspension panel; and a second suspension panel; wherein the panels of the box blank are integrally formed as part of a generally planar single sheet of material and are defined and separated by fold lines and lines of perforations; wherein a fold line extends between and delineates the bottom panel and the first side panel, a fold line extends between and delineates the bottom panel and the second side panel, a fold line extends between and delineates the bottom panel and the first end panel, a fold line extends between and delineates the bottom panel and the second end panel, a line of perforations extends between and delineates the first top panel and the first side panel, a line of perforations extends between and delineates the second top panel and the second suspension panel; wherein each of the first suspension panel and second suspension panel is defined by a plurality of subpanels, adjacent subpanels being delineated by a fold line or line of perforations extending therebetween; and wherein, when the box blank is folded along the fold lines into an assembled box for use and is in a closed position, (i) the first suspension panel extends from the first top panel into an interior space defined by the bottom panel, first and second side panels, and first and second end panels, (ii) the second suspension panel extends from the second top panel into the interior space defined by the bottom panel, first and second side panels, and first and second end panels, and (iii) ends of the suspension panels defined by distal most subpanels are adhered to one another and form a base for supporting one or more articles received between the suspension panels, subpanels of the suspension panels forming side support areas extending over and containing the one or more articles with the interior space in a suspended position relative to the bottom panel, first and second side panels, and first and second end panels.

In features, a double hinge is defined between the first top panel and the first suspension panel, and a double hinge is defined between the second top panel and the second suspension panel. A double hinge is defined by parallel lines of perforations extending in close proximity to each other; a double hinge is defined by a fold line extending in parallel and close proximity to a line of perforations; or a double hinge line is defined by parallel fold lines extending in close proximity to each other.

In another aspect, a box comprises a folded and bound box blank, wherein the box blank comprises: a bottom panel; a first side panel; a second side panel; a first end panel; a second end panel; a first overlapping side panel; a second overlapping side panel; a third overlapping side panel; a fourth overlapping side panel; a first top panel; a second top panel; a first suspension panel; and a second suspension panel. The panels of the box blank are integrally formed as part of a generally planar single sheet of material and are defined and separated by fold lines and lines of perforations. Furthermore, a fold line extends between and delineates the bottom panel and the first side panel; a fold line extends between and delineates the bottom panel and the second side panel; a fold line extends between and delineates the bottom panel and the first end panel; a fold line extends between and delineates the bottom panel and the second end panel; a line of perforations extends between and delineates the first top panel and the first side panel; a line of perforations extends between and delineates the second top panel and the second suspension panel. Additionally, each of the first suspension panel and second suspension panel is defined by a plurality of subpanels, adjacent subpanels being delineated by a fold line or line of perforations extending therebetween; and when the box blank is folded along the fold lines into an assembled box for use and is in a closed position, (i) the first suspension panel extends from the first top panel into an interior space defined by the bottom panel, first and second side panels, and first and second end panels, (ii) the second suspension panel extends from the second top panel into the interior space defined by the bottom panel, first and second side panels, and first and second end panels, and (iii) ends of the suspension panels defined by distal most subpanels are adhered to one another and form a base for supporting one or more articles received between the suspension panels, subpanels of the suspension panels forming side support areas extending over and containing the one or more articles with the interior space in a suspended position relative to the bottom panel, first and second side panels, and first and second end panels.

In features of this aspect, a double hinge is defined between the first top panel and the first suspension panel, and a double hinge is defined between the second top panel and the second suspension panel.

In a feature, a fold line bisects each of the end panels and bottom panels and further comprising fold lines defined in the bottom panel such that the box is collapsible when in the assembled and bound stated.

In a feature, the box further comprises a first overlapping panel attached to the first end panel with a fold line extending between and delineating the boundary between the first overlapping panel and the first end panel; a second overlapping panel attached to the first end panel with a fold line extending between and delineating the boundary between the second overlapping panel and the first end panel; a third overlapping panel attached to the second end panel with a fold line extending between and delineating the boundary between the third overlapping panel and the second end panel; a fourth overlapping panel attached to the second end panel with a fold line extending between and delineating the boundary between the fourth overlapping panel and the second end panel; a first side, top flap panel attached to the first overlapping panel with a fold line extending between and delineating the boundary between the first side, top flap panel and the first overlapping panel; a second side, top flap panel attached to the second overlapping panel with a fold line extending between and delineating the boundary between the second side, top flap panel and the second overlapping panel; a third side, top flap panel attached to the third overlapping panel with a fold line extending between and delineating the boundary between the third side, top flap panel and the third overlapping panel; and a fourth side, top flap panel attached to the fourth overlapping panel with a fold line extending between and delineating the boundary between the fourth side, top flap panel and the fourth overlapping panel; wherein the side, top panels extend from sides of the box in partial covering over the interior space and support the top panels in the closed position. In further possible characteristics of this feature, the box further comprises a first end, top flap panel attached to the first end panel with a fold line extending between and delineating the boundary between the first end, top flap panel and the first end panel; and a second end, top flap panel attached to the second end panel with a fold line extending between and delineating the boundary between the second end, top flap panel and the second end panel; wherein the end, top panels extend in partial covering over the interior space and support the top panels in the closed position. Furthermore, each end, top flap panel may include a fold line dividing it into first and second subpanels, wherein the suspension panels abut one of the first and second subpanels of each end, top flap panel when the box blank is folded along the fold lines into an assembled box for use and is in a closed position.

In another feature of this aspect, the box further comprises a first overlapping panel attached to the first side panel with a fold line extending between and delineating the boundary between the first overlapping panel and the first side panel; a second overlapping panel attached to the second side panel with a fold line extending between and delineating the boundary between the second overlapping panel and the second side panel; a third overlapping panel attached to the first side panel with a fold line extending between and delineating the boundary between the third overlapping panel and the first side panel; a fourth overlapping panel attached to the second side panel with a fold line extending between and delineating the boundary between the fourth overlapping panel and the second side panel; a first end, top flap panel attached to the first overlapping panel with a fold line extending between and delineating the boundary between the first end, top flap panel and the first overlapping panel; a second end, top flap panel attached to the second overlapping panel with a fold line extending between and delineating the boundary between the second end, top flap panel and the second overlapping panel; a third end, top flap panel attached to the third overlapping panel with a fold line extending between and delineating the boundary between the third end, top flap panel and the third overlapping panel; and a fourth end, top flap panel attached to the fourth overlapping panel with a fold line extending between and delineating the boundary between the fourth end, top flap panel and the fourth overlapping panel; wherein the end, top panels extend from ends of the box in partial covering over the interior space and support the top panels in the closed position. In further possible characteristics of this feature, the box blank further comprises a first guide flange panel attached to the first overlapping panel with a fold line extending between and delineating the boundary between the first guide flange panel and the first overlapping panel; a second guide flange panel attached to the second overlapping panel with a fold line extending between and delineating the boundary between the second guide flange panel and the second overlapping panel; a third guide flange panel attached to the third overlapping panel with a fold line extending between and delineating the boundary between the third guide flange panel and the third overlapping panel; and a fourth guide flange panel attached to the fourth overlapping panel with a fold line extending between and delineating the boundary between the fourth guide flange panel and the fourth overlapping panel; wherein the first guide flange panel abuts the second flange panel to define a guide extending along a height of the first end panel and the third guide flange panel abuts the fourth guide flange panel to define a guide extending along a height of the second end panel; and wherein the base includes a slot on each end within which a respective said guide is received, whereby the base is guided in its descent into and ascent from the interior of the box. Preferably double hinges formed by closely located lines of perforations in the suspension panels define the slots in which the guides are received.

In another feature, the box blank further comprises a removable buffer insert positioned within the interior space adjacent the first end panel and extending around and receiving through a recess therein the base formed by the suspension panels, whereby a space between one or more articles suspended in the assembled box and the first end of the box is consumed.

The buffer insert may be in the shape of a folded “H”.

In another feature of this aspect, the suspension panels form a “V” or “U” shaped containment area extending from the top panels for suspending articles received therein.

In addition to the aforementioned aspects and features of the present invention, it should be noted that the present invention further encompasses the various possible combinations and subcombinations of such aspects and features. Thus, for example, any aspect may be combined with an aforementioned feature in accordance with the present invention without requiring any other aspect or feature.

BRIEF DESCRIPTION OF THE DRAWINGS

One or more preferred embodiments of the present invention now will be described in detail with reference to the accompanying drawings.

FIG. 1 is a schematic illustration in plan view of a preferred box blank in accordance with one or more aspects and features of the present invention.

FIG. 2 is a schematic illustration in plan view of another preferred box blank that is similar to the box blank of FIG. 1, but in which once assembled into a box, the assembled box is nonetheless collapsible into a generally flat state in accordance with the disclosure and teaching of U.S. patent publication 2012/0238423.

FIG. 3 is a schematic illustration in plan view of a preferred box blank in accordance with one or more aspects and features of the present invention.

FIG. 4 is a schematic illustration of another preferred box blank that is similar to the box blank of FIG. 3, but in which once assembled into a box, the assembled box is nonetheless collapsible into a generally flat state in accordance with the disclosure and teaching of U.S. patent publication 2012/0238423.

FIG. 5 is a schematic illustration in plan view of a preferred box blank in accordance with one or more aspects and features of the present invention.

FIG. 6 is a schematic illustration in plan view of another preferred box blank that is similar to the box blank of FIG. 5, but in which once assembled into a box, the assembled box is nonetheless collapsible into a generally flat state in accordance with the disclosure and teaching of U.S. patent publication 2012/0238423.

FIG. 7 is a schematic illustration in plan view of a preferred box blank in accordance with one or more aspects and features of the present invention.

FIG. 8 is a schematic illustration in plan view of another preferred box blank that is similar to the box blank of FIG. 7, but in which once assembled into a box, the assembled box is nonetheless collapsible into a generally flat state in accordance with the disclosure and teaching of U.S. patent publication 2012/0238423.

FIG. 9 is a schematic illustration in plan view of a blank for a buffer insert.

FIG. 10 a schematic illustration in plan view of the buffer insert assembled from the blank of FIG. 9 by folding the blank about the fold line seen in FIG. 9.

FIG. 11 is a schematic illustration in plan view of a preferred box blank in accordance with one or more aspects and features of the present invention.

FIG. 12 is a schematic illustration in plan view of another preferred box blank that is similar to the box blank of FIG. 11, but in which once assembled into a box, the assembled box is nonetheless collapsible into a generally flat state in accordance with the disclosure and teaching of U.S. patent publication 2012/0238423.

FIG. 13 is a schematic illustration in plan view of a preferred box blank in accordance with one or more aspects and features of the present invention.

FIG. 14 is a schematic illustration in plan view of another preferred box blank that is similar to the box blank of FIG. 13, but in which once assembled into a box, the assembled box is nonetheless collapsible into a generally flat state in accordance with the disclosure and teaching of U.S. patent publication 2012/0238423.

 DETAILED DESCRIPTION

As a preliminary matter, it will readily be understood by one having ordinary skill in the relevant art (“Ordinary Artisan”) that the present invention has broad utility and application. As should be understood, any embodiment may incorporate only one or a plurality of the above-disclosed aspects of the invention and may further incorporate only one or a plurality of the above-disclosed features. Furthermore, any embodiment discussed and identified as being “preferred” is considered to be part of a best mode contemplated for carrying out the present invention. Other embodiments also may be discussed for additional illustrative purposes in providing a full and enabling disclosure of the present invention. As should be understood, any embodiment may incorporate only one or a plurality of the above-disclosed aspects of the invention and may further incorporate only one or a plurality of the above-disclosed features. Moreover, many embodiments, such as adaptations, variations, modifications, and equivalent arrangements, will be implicitly disclosed by the embodiments described herein and fall within the scope of the present invention.

Accordingly, while the present invention is described herein in detail in relation to one or more embodiments, it is to be understood that this disclosure is illustrative and exemplary of the present invention, and is made merely for the purposes of providing a full and enabling disclosure of the present invention. The detailed disclosure herein of one or more embodiments is not intended, nor is to be construed, to limit the scope of patent protection afforded the present invention, which scope is to be defined by the claims and the equivalents thereof. It is not intended that the scope of patent protection afforded the present invention be defined by reading into any claim a limitation found herein that does not explicitly appear in the claim itself.

Thus, for example, any sequence(s) and/or temporal order of steps of various processes or methods that are described herein are illustrative and not restrictive. Accordingly, it should be understood that, although steps of various processes or methods may be shown and described as being in a sequence or temporal order, the steps of any such processes or methods are not limited to being carried out in any particular sequence or order, absent an indication otherwise. Indeed, the steps in such processes or methods generally may be carried out in various different sequences and orders while still falling within the scope of the present invention. Accordingly, it is intended that the scope of patent protection afforded the present invention is to be defined by the appended claims rather than the description set forth herein.

Additionally, it is important to note that each term used herein refers to that which the Ordinary Artisan would understand such term to mean based on the contextual use of such term herein. To the extent that the meaning of a term used herein—as understood by the Ordinary Artisan based on the contextual use of such term—differs in any way from any particular dictionary definition of such term, it is intended that the meaning of the term as understood by the Ordinary Artisan should prevail.

Regarding applicability of 35 U.S.C. §112(f), no claim element is intended to be read in accordance with this statutory provision unless the explicit phrase “means for” or “step for” is actually used in such claim element, whereupon this statutory provision is intended to apply in the interpretation of such claim element.

Furthermore, it is important to note that, as used herein, “a” and “an” each generally denotes “at least one,” but does not exclude a plurality unless the contextual use dictates otherwise. Thus, reference to “a picnic basket having an apple” describes “a picnic basket having at least one apple” as well as “a picnic basket having apples.” In contrast, reference to “a picnic basket having a single apple” describes “a picnic basket having only one apple.”

When used herein to join a list of items, “or” denotes “at least one of the items,” but does not exclude a plurality of items of the list. Thus, reference to “a picnic basket having cheese or crackers” describes “a picnic basket having cheese without crackers”, “a picnic basket having crackers without cheese”, and “a picnic basket having both cheese and crackers.” Finally, when used herein to join a list of items, “and” denotes “all of the items of the list.” Thus, reference to “a picnic basket having cheese and crackers” describes “a picnic basket having cheese, wherein the picnic basket further has crackers,” as well as describes “a picnic basket having crackers, wherein the picnic basket further has cheese.”

Additionally, as used herein, “pack” means a container and is intended to be synonymous with “package”, “box”, and “carton”.

Referring now to the drawings, twelve preferred box blanks are illustrated. It will be appreciated that each blank generally includes fold lines comprising score lines or areas of reduced thickness or weakness that facilitate folding of the blank during assembly of the box; such fold lines are illustrated in the drawings by dotted lines. Each blank also generally includes perforated lines that act as hinges during bending or curving of portions of the box in implementing suspension packaging in accordance with one or more aspects and features of the present invention; such perforated lines are illustrated in the drawings by dashed lines. It further is contemplated that, within the scope of the present invention, one or more illustrated fold lines may be interchanged with one or more illustrated perforated lines, and vice-versa; however, preferred arrangements of fold lines and perforated lines are illustrated in the drawings.

It also should be appreciated that boxes made from each of these blanks, and methods for making such boxes, all are considered to be preferred embodiments of boxes and methods, respectively, in accordance with one or more aspects and features of the present invention. Furthermore, in at least some preferred embodiments the boxes so formed are collapsible into a generally flat, assembled condition in accordance with the disclosure and teaching of U.S. patent publication 2012/0238423, as described in further detail below.

The Box Blank of FIG. 1

With regard to FIG. 1, a first preferred embodiment of a box blank 100 in accordance with one or more aspects and features of the invention is shown in FIG. 1 in plan view. The box blank 100 is flat in an unfolded generally planar form and can be efficiently stored until a box to be made using the blank is desired to be assembled, at which time the blank is glued and folded into the box to form an assembled state of the box. In this regard, the blank preferably is a single integral piece of corrugated material and includes a plurality of fold lines by which a box is folded from the blank, with panels and subpanels being defined between the fold lines.

As shown in FIG. 1, the box blank 100 comprises: a rectangular bottom panel 102 located generally centrally in the layout of the blank 100; side panels 104,106; and end panels 108,110. Fold lines extend between and define the boundaries between these panels.

Specifically, a fold line extends and defines a boundary between the bottom panel 102 and side panel 104, whereby the bottom panel 102 is connected directly to—and is separated by such fold line from—the side panel 104; a fold line extends and defines a boundary between the bottom panel 102 and side panel 106, whereby the bottom panel 102 is connected directly to—and is separated by such fold line from—the side panel 106; a fold line extends and defines a boundary between the bottom panel 102 and end panel 108, whereby the bottom panel 102 is connected directly to—and is separated by such fold line from—the end panel 108; and a fold line extends and defines a boundary between the bottom panel 102 and end panel 110, whereby the bottom panel 102 is connected directly to—and is separated by such fold line from—the end panel 110.

Each of these panels further is generally rectangular, with the bottom panel 102 having a widthwise extent extending between the side panels 104,106 that generally defines the width W of the box that is assembled from the blank 100; and with the bottom panel 102 having a lengthwise extent extending between the end panels 108,110 that generally defines the length L of the box that is assembled from the blank 100.

The box blank 100 also includes top panel 112 and top panel 114. A fold line extends and defines a boundary between the side panel 104 and the top panel 112, whereby the side panel 104 is connected directly to—and is separated by such fold line from—the top panel 112; and a fold line extends and defines a boundary between the side panel 106 and the top panel 114, whereby the side panel 106 is connected directly to—and is separated by such fold line from—the top panel 114. It will be appreciated that when the box that is assembled from the blank 100 is in a closed configuration, top panel 112 and top panel 114 together close off a top opening of the assembled box. It thus will be appreciated that the combined widthwise extent w1 of each of the top panels 112,114 will approximately equal the width W of the assembled box.

The blank 100 further includes two pairs of overlapping end panels: a first pair of overlapping end panels 118,120; and a second pair of overlapping end panels 122,124. A fold line extends and defines a boundary between the end panel 108 and overlapping end panel 118, whereby the overlapping end panel 118 is connected directly to—and is separated by such fold line from—the end panel 108; and a fold line extends and defines a boundary between the end panel 108 and overlapping end panel 120, whereby the overlapping end panel 120 is connected directly to—and is separated by such fold line from—the end panel 108. Similarly, a fold line extends and defines a boundary between the end panel 110 and overlapping end panel 122, whereby the overlapping end panel 122 is connected directly to—and is separated by such fold line from—the end panel 110; and a fold line extends and defines a boundary between the end panel 110 and overlapping end panel 124, whereby the overlapping end panel 124 is connected directly to—and is separated by such fold line from—the end panel 110.

In order to maintain the box that is assembled from the blank 100 in an assembled state, adhesive preferably is applied to side panel 104 that binds side panel 104 to each of overlapping end panels 118,122; and adhesive preferably is applied to side panel 106 that binds side panel 104 to each of overlapping end panels 120,124. This is indicated, for example, by glue strips 116 that have been applied to the side panels 104,106 as illustrated in FIG. 1.

It further will be appreciated that each of panels 104,106,108,110 has an extent between opposed fold lines that defines an interior height H of the box that is assembled from the blank 100.

The blank 100 additionally includes side, top flap panels 126,128,130,132. A fold line extends and defines a boundary between side, top flap panel 126 and overlapping end panel 118, whereby the side, top flap panel 126 is connected directly to—and is separated by such fold line from—the overlapping end panel 118; a fold line extends and defines a boundary between side, top flap panel 128 and overlapping end panel 120, whereby the side, top flap panel 128 is connected directly to—and is separated by such fold line from—the overlapping end panel 120; a fold line extends and defines a boundary between side, top flap panel 130 and overlapping end panel 122, whereby the side, top flap panel 130 is connected directly to—and is separated by such fold line from—the overlapping end panel 122; and a fold line extends and defines a boundary between side, top flap panel 132 and overlapping end panel 124, whereby the side, top flap panel 132 is connected directly to—and is separated by such fold line from—the overlapping end panel 124.

An extent between an edge of the overlapping end panel 118 and the fold line extending between side, top flap panel 126 and overlapping end panel 118 generally corresponds to the defined interior height H of the box that is assembled from the blank 100. Similarly, an extent between an edge of the overlapping end panel 120 and the fold line extending between side, top flap panel 128 and overlapping end panel 120 generally corresponds to the defined interior height H; an extent between an edge of the overlapping end panel 122 and the fold line extending between side, top flap panel 130 and overlapping end panel 122 generally corresponds to the defined interior height H; and an extent between an edge of the overlapping end panel 124 and the fold line extending between side, top flap panel 132 and overlapping end panel 124 generally corresponds to the defined interior height H. Accordingly, when a box is assembled from the blank 100, each of the side, top flap panels 126,128,130,132 extends from a top edge of the assembled box over and into an interior space of the box as defined by the bottom panel 102; side panels 104,106; and end panels 108,110. These side, top flap panels 126,128,130,132 also serve to support the top panels 112,114 when folded over the top opening of the assembled box in closing off the opening.

Similarly, the box blank 100 includes end, top flap panels 134,136 that also serve to support the top panels 112,114 when folded over the top opening of the assembled box in closing off the opening. A fold line extends and defines a boundary between end, top flap panel 134 and end panel 108, whereby the end, top flap panel 134 is connected directly to—and is separated by such fold line from—the end panel 108; and a fold line extends and defines a boundary between end, top flap panel 136 and end panel 110, whereby the end, top flap panel 136 is connected directly to—and is separated by such fold line from—the end panel 110.

It will further be seen from FIG. 1 that end, top flap panel 134 is formed by two subpanels 138,140; and that end, top flap panel 134 is formed by two subpanels 142,144. A fold line extends and defines a boundary between subpanels 138,140, whereby subpanel 138 is connected directly to—and is separated by such fold line from—subpanel 140; and a fold line extends and defines a boundary between subpanels 142,144, whereby subpanel 142 is connected directly to—and is separated by such fold line from—subpanel 144.

Blank 100 further comprises first and second suspension panels 146,148. A line of perforations extends and defines a boundary between top panel 112 and suspension panel 146, whereby suspension panel 146 is connected directly to—and is separated by such line of perforations from—top panel 112. Suspension panel 146 is connected to top panel 112 only along such line of perforations and is not directly connected to any of the other panels, including bottom panel 102; side panels 104,106; end panels 108,110; top panel 114; overlapping panels 118,120,122,124; and flap panels 126,128,130,132,134,136.

Similarly, a line of perforations extends and defines a boundary between top panel 114 and suspension panel 148, whereby suspension panel 148 is connected directly to—and is separated by such line of perforations from—top panel 114. Suspension panel 148 is connected to top panel 114 only along such line of perforations and is not directly connected to any of the other panels, including bottom panel 102; side panels 104,106; end panels 108,110; top panel 112; overlapping panels 118,120,122,124; and flap panels 126,128,130,132,134,136.

Suspension panel 146 further comprises a set of additional perforated lines 150, and suspension panel 148 further comprises a set of additional perforated lines 152. The perforated lines 150 extend parallel to each other in a lengthwise direction, and the perforated lines 152 extend parallel to each other in a lengthwise direction. Furthermore, each perforated line preferably comprises a line of less rigidity and less resistance to bending or folding therealong compared to each of the aforementioned fold lines.

The perforated lines 150 of suspension panel 146 extend and define boundaries between adjacent subpanels 154,156,158,160,162,164,166 of suspension panel 146, whereby adjacent subpanels of the suspension panel 146 are connected directly together and are separated by one of the perforated lines 150. Subpanel 154 is the proximal most subpanel and subpanel 168 is the distal most subpanel relative to the top panel 112, to which suspension panel 146 is connected. At least the distal most subpanel and, in some embodiments one or more additional, consecutively adjacent subpanels of the suspension panel 146, define a lower support area 180. As seen in FIG. 1, the lower support area 180 of suspension panel 146 is defined by subpanels 162,164,166. The other subpanels 154,156,158,160 of the suspension panel 146 define a side support area 182. Furthermore, as seen in FIG. 1, the lengthwise extent of these other subpanels 154,156,158,160 defining the side support area 182 is less than the lengthwise extent of the distal subpanels 162,164,166 defining the lower support area 180, whereby recesses 184,186 are defined on opposite sides of the suspension panel 146, with recess 184 extending between the top panel 112 and the foremost distal panel 162 and recess 186 extending between the top panel 112 and the foremost distal panel 162. Each recess is generally rectangular in profile, but other profiles are within contemplated embodiments of the invention.

The depth d1 of recess 184 preferably is less than lengthwise extent L1 of end, top flap panel 134, and the depth d2 of recess 186 preferably is less than the lengthwise extent L2 of end, top flap panel 136, such that opposite edges of the side support area 182 engages and bends subpanels 140,142 causing tension between end, top flap panels 134,136 and top panel 112 when top panel 112 is moved into the closed position in the assembled state of the box made from blank 100.

In like manner, the perforated lines 152 of suspension panel 148 extend and define boundaries between adjacent subpanels 168,1,170,172,174,176,178 of suspension panel 148, whereby adjacent subpanels of the suspension panel 148 are connected directly together and are separated by one of the perforated lines 150. Subpanel 168 is the proximal most subpanel and subpanel 178 is the distal most subpanel relative to the top panel 114, to which suspension panel 148 is connected. At least the distal most subpanel and, in some embodiments one or more additional, consecutively adjacent subpanels of the suspension panel 148, define a lower support area 188. As seen in FIG. 1, the lower support area 188 of suspension panel 148 is defined by subpanels 176,178. The other subpanels 168,170,172,174 of the suspension panel 148 define a side support area 190. Furthermore, as seen in FIG. 1, the lengthwise extent of these other subpanels 154,156,158,160 defining the side support area 190 is less than the lengthwise extent of the distal subpanels 168,170,172,174 defining the lower support area 188, whereby recesses 192,194 are defined on opposite sides of the suspension panel 148, with recess 192 extending between the top panel 114 and the foremost distal panel 178 and recess 194 extending between the top panel 114 and the foremost distal panel 176. Each recess is generally rectangular in profile, but other profiles are within contemplated embodiments of the invention.

The depth d3 of recess 192 preferably is less than lengthwise extent L1 of end, top flap panel 134, and the depth d4 of recess 194 preferably is less than the lengthwise extent L2 of end, top flap panel 136, such that opposite edges of the side support area 190 engages and bends subpanels 140,142 causing tension between end, top flap panels 134,136 and top panel 114 when top panel 114 is moved into the closed position in the assembled state of the box made from blank 100.

When a box is assembled from blank 100, the distal most subpanel of suspension panel 146 is bound to the distal most subpanel of suspension panel 148. Adhesive preferably is applied to subpanel 166 that binds the distal end of suspension panel 146 to the distal end of suspension panel 148 at subpanel 178 thereof. This is indicated, for example, by glue strips 196 that have been applied to subpanel 166 as illustrated in FIG. 1.

A box is assembled from blank 100 by folding side panels 104,106 and end panels 108,110 upwardly relative to bottom panel 102 to form a box-like space having a top opening opposite the bottom panel 102. In so folding, the overlapping panels 118,120,122,124 are extend within the box-like space in overlap to side panels 104,106 and are bound thereto. Additionally, the distal end of the suspension panel 146 is bound to the distal end of the suspension panel 148 and positioned within the box-like space such that the suspension panels 146,148 extend from the edges of the top panel 112,114 into the box-like space. Flap panels 126,128,130,132,134,136 are folded to extend over and partially cover the top opening. When used for storage and shipping, an item or article then is placed between the suspension panels 146,148 and the top panels 112,114 are closed to fully cover the top opening. The item placed between the suspension panels 146,148 is held in a suspended state from the top panels within the box-like space without being directly held to or in abutment against the bottom panel 102, side panels 104,106, or end panels 108,110. Such suspension of the article from the top panels at spaced distances to the bottom, side panels, and end panels is believed to insulate and protect the article within the assembled and closed box during storage and shipment.

It further will be appreciated that the greater the number of lines of perforation formed in the side support areas of the suspension panels, the better the suspension panels will conform to the sides of the article suspended within the box. In this regard, the suspension panels 146,148 of the blank 100 of FIG. 1 each includes three intermediate and two boundary lines of perforations enabling the side support areas 182,188 to conform to the shape of a bottle (such as a wine bottle) for storage and shipping.

Additionally, the suspension panel 146 includes two intermediate lines of perforations and one boundary line of perforations (which is shared with the side support area 182), and the suspension panel 148 includes one intermediate line of perforations and one boundary line of perforations (which is shared with the side support area 190). These lines of perforations in the lower support areas 180,188 enable one the lower support areas to overlap one another and form a base for supporting thereon an underside of the suspended article.

The Box Blank of FIG. 2

The box blank 101 of FIG. 2 is substantially similar to the box blank 100 of FIG. 1, with the exception that two sets 103 of additional fold lines are formed at opposite ends of the bottom panel and an additional fold line 105 bisects the end, top flap panels; the end panels; and the bottom panel. These additional fold lines 103,105 enable a box assembled from the box blank 101 to be collapsed while in the assembled condition—the use of such fold lines being a technique disclosed and taught, for example, in incorporated U.S. patent publication 2012/0238423.

The Box Blank of FIG. 3

The box blank 200 of FIG. 3 is similar to the box blank 100 of FIG. 1, with the above detailed description of the box blank of FIG. 1 generally applying to the box lank 200 of FIG. 3, as will be apparent from comparison and consideration of FIGS. 1 and 3. Accordingly, the following description will focus on differences in the box blank 200 over the box blank 100.

The box blank 200 includes the same types and layout of panels and primarily differs over the box blank 100 in edge profiles. In particular, the side support areas 282,290 of the suspension panels 246,248 include curved edge profiles unlike the straight edge profiles of the side support areas 182,190. The end, top flap panels 234,236 also have curved corners unlike the generally orthogonal corners of the end, top flap panels 134,136. The distal subpanels of the suspension panels 246,248 in the lower support area 280,288 also have different lengths and edge profiles so as to define a different base profile on which a suspended article is supported. An intermediate fold line also is included in the lower support area 288 of the suspension panel 248, in addition to an intermediate line of perforations; no corresponding fold line is shown in the lower support area 188 of the suspension panel 148 of blank 100.

The Box Blank of FIG. 4

The box blank 201 of FIG. 4 is substantially similar to the box blank 200 of FIG. 3, with the exception that two sets 203 of additional fold lines are formed at opposite ends of the bottom panel and an additional fold line 205 bisects the end, top flap panels; the end panels; and the bottom panel. These additional fold lines 203,205 enable a box assembled from the box blank 201 to be collapsed while in the assembled condition—the use of such fold lines being a technique disclosed and taught, for example, in incorporated U.S. patent publication 2012/0238423.

Suspension Packaging and Storage, Shipping, and Transport of Wine Bottles

Boxes assembled from the box blanks 100,101,200,201 can be used to store, ship and transport wine bottles and similarly shaped, fragile items. In this regard, dimensions for use in packing wine bottles are disclosed in the priority provisional application incorporated herein by reference, the disclosure of which is found in the Appendix hereto, also incorporated herein by reference. As seen in FIG. 1 of the Appendix, an exemplary box blank for assembling a box in which a wine bottle is suspended for storing, shipping, and transport has an overall dimension along the length of the assembled box of about 25.5 inches and overall dimension along the width of the assembled box of about 30.75 inches. Pictures of an exemplary box in which a wine bottle is suspended for storing, shipping, and transport are found in FIGS. 2-18 of the Appendix.

The Box Blank of FIG. 5

The box blank 300 of FIG. 5 is similar to the box blank 100 of FIG. 1, with the above detailed description of the box blank of FIG. 1 generally applying to this additional box blank as will be apparent from comparison and consideration of the drawings. Accordingly, the following description will focus on differences in the box blank 300 over the box blank 100.

The box blank 300 includes the same types and layout of panels as those of box blank 100 and primarily differs over the box blank 100 in the configuration of the suspension panels 346,348. In particular, the side support areas 382,390 of the suspension panels 346,348 are offset in the direction of the side of the blank that includes end panel 308, as seen in FIG. 5. Thus, the depth of the recess 384 is less than the depth of the recess 386, and the depth of the recess 392 is less than the depth of the recess 394, resulting in less interior space in a box assembled from this blank 300 between the suspension panels 346,348 and end panel 308 than that on the opposite side between the suspension panels 346,348 and end panel 310. The suspension panel 346 also includes closely spaced together lines of perforations forming a double hinge 397 at its connection to top panel 312, and suspension panel 348 includes closely spaced together lines of perforations forming a double hinge 399 at its connection to top panel 314.

The Box Blank of FIG. 6

The box blank 301 of FIG. 6 is substantially similar to the box blank 300 of FIG. 5, with the exception that two sets 303 of additional fold lines are formed at opposite ends of the bottom panel and an additional fold line 305 bisects the end, top flap panels; the end panels; and the bottom panel. These additional fold lines 303,305 enable a box assembled from the box blank 301 to be collapsed while in the assembled condition—the use of such fold lines being a technique disclosed and taught, for example, in incorporated U.S. patent publication 2012/0238423.

The Box Blank of FIG. 7

The box blank 400 of FIG. 7 is similar to the box blank 100 of FIG. 1, with the above detailed description of the box blank of FIG. 1 generally applying to this additional box blank as will be apparent from comparison and consideration of the drawings. Accordingly, the following description will focus on differences in the box blank 400 over the box blank 100.

The box blank 400 includes the same types and layout of panels as those of box blank 100 with the exception of side, top flap panels which are omitted from the box blank 400. Thus box blank 400 does not include panels corresponding to panels 126,128,130,132 found in the box blank 100 of FIG. 1. The edge profile of the end, top flap panels 434,436 is also trapezoidal rather than rectangular as seen in the edge profile of the end, top flap panels 134,136. The end, top flat panels of the blank 400 also do not each include a fold line defining two subpanels as found in the blank 100 of FIG. 1. The base formed by the lower support areas of the suspension panels also has a lesser extent d in a widthwise direction; and the side support areas of the suspension panels are greater in width than the width of the side support panels seen in the blank 100. The overall length of the box L when assembled from the blank 400 also is smaller, and the lower support area of the suspension panel 448 includes neither an intermediate fold line nor intermediate line of perforations facilitating bending or folding of the portion of the base formed thereby.

The Box Blank of FIG. 8

The box blank 401 of FIG. 8 is substantially similar to the box blank 400 of FIG. 7, with the exception that two sets 403 of additional fold lines are formed at opposite ends of the bottom panel and an additional fold line 405 bisects the end, top flap panels; the end panels; and the bottom panel. These additional fold lines 403,405 enable a box assembled from the box blank 401 to be collapsed while in the assembled condition—the use of such fold lines being a technique disclosed and taught, for example, in incorporated U.S. patent publication 2012/0238423.

Separate Buffer Inserts

In at least some embodiments, separate buffer inserts are used in connection with an assembled box for supporting a suspended article. In this respect, FIG. 9 is a schematic illustration in plan view of a blank 900 for a buffer insert, and FIG. 10 a schematic illustration of a buffer insert 902 assembled from the blank 900 of FIG. 9 by folding the blank about the fold line 904 seen in FIG. 9. Preferably two buffer inserts 902 are used with a suspended article in a box that is assembled, for example, from either blank 400 or blank 401. Each buffer insert preferably is used by positioning it adjacent an end panel with recess 906 extending around and receiving therethrough the base formed by the suspension panels. Further in this respect, a widthwise dimension d of the recess 906 is sufficient to receive the base of the suspension panels therethrough. The buffer inserts thereby are used to fill the space between one or more articles suspended in the assembled box and the ends of the box. This arrangement is perhaps best seen in the photograph of FIGS. 38-44 of the Appendix.

Suspension Packaging and Storage, Shipping, and Transport of Candles

Boxes assembled from the box blanks 300,301,400,401 can be used to store, ship and transport candles and similarly shaped, fragile items. In this regard, dimensions for use in packing candles are disclosed in the priority provisional application incorporated herein by reference, the disclosure of which is found in the Appendix hereto, also incorporated herein by reference. As seen in FIG. 19 of the Appendix, an exemplary box blank for assembling a box in which two candles are suspended together for storing, shipping, and transport has an overall dimension along a length of the assembled box of about 20.25 inches and overall dimension along a width of the assembled box of about 30.75 inches. Pictures of an exemplary box in which two candles are suspended for storing, shipping, and transport are found in FIGS. 20-46 of the Appendix.

The Box Blank of FIG. 11

The box blank 500 of FIG. 11 is similar to the box blank 100 of FIG. 1, with the above detailed description of the box blank of FIG. 1 generally applying to this additional box blank as will be apparent from comparison and consideration of the drawings. Accordingly, the following description will focus on differences in the box blank 500 over the box blank 100.

The box blank 500 includes the same types and layout of panels as those of box blank 100 with the exception that end, top flat panels 534,536 of the blank 500 do not each include a fold line defining two subpanels as found in the blank 100 of FIG. 1. The base formed by the lower support areas of the suspension panels also has a greater extent d in a widthwise direction that that in the blank 100; and the side support areas of the suspension panels are lesser in width than the width of the side support panels seen in the blank 100. The overall length of the box L when assembled from the blank 500 also is smaller. The suspension panels are also connected to the side panels by double hinge comprising a line of perforations and a fold line located very close together, as indicated in FIG. 11 at 597,599.

The Box Blank of FIG. 12

The box blank 501 of FIG. 12 is substantially similar to the box blank 500 of FIG. 11, with the exception that two sets 503 of additional fold lines are formed at opposite ends of the bottom panel and an additional fold line 505 bisects the end, top flap panels; the end panels; and the bottom panel. These additional fold lines 503,505 enable a box assembled from the box blank 501 to be collapsed while in the assembled condition—the use of such fold lines being a technique disclosed and taught, for example, in incorporated U.S. patent publication 2012/0238423.

The Box Blank of FIG. 13

The box blank 600 of FIG. 13 is similar to the box blank 100 of FIG. 1, with the above detailed description of the box blank of FIG. 1 generally applying to this additional box blank as will be apparent from comparison and consideration of the drawings. Accordingly, the following description will focus on differences in the box blank 600 over the box blank 100.

The box blank 600 includes mostly the same types and layout of panels as those of box blank 100 with the exception of the omission in the box blank 600 of overlapping end panels and flap panels. Thus box blank 600 does not include panels corresponding to panels 118,120,122,124,126,128,130,132,134,136 found in the box blank 100 of FIG. 1. Instead, overlapping side panels 618,620,622,624 with side, top flap panels 626,628,630,632 are provided, with the overlapping side panels being connected to side panels along a fold line, and the end, top flap panels being connected to the overlapping panels.

The box blank 600 further includes guide flange panels 623,625,627,629 connected along respective fold lines to the overlapping side panels as seen in FIG. 13. When assembled, guide flange panels 623,625 abut one another to define a guide extending along a height of an end panel, and guide flange panels 627,629 abut one another to define a guide extending along a height of an opposite end panel. The assembled box is maintained in this configuration by binding the overlapping panels to the end panels. This can be done by adhering the overlapping panels to the end panels using glue strips, for example, as illustrated in FIG. 13. Furthermore, when formed by binding the lower support areas of the suspension panels together, the base includes a slot on each end within which a guide is received, whereby the base is guided in its descent into and ascent from the interior of the box. The slots are facilitated by use of double hinges formed by closely located lines of perforations in the lower support areas of the suspension panels, as shown in FIG. 13. This is perhaps best seen, for example, in the photographs of FIGS. 54-59 of the Appendix.

The Box Blank of FIG. 14

The box blank 601 of FIG. 14 is substantially similar to the box blank 600 of FIG. 11, with the exception that two sets 603 of additional fold lines are formed at opposite ends of the bottom panel and an additional fold line 605 bisects the end panels and the bottom panel. These additional fold lines 603,605 enable a box assembled from the box blank 601 to be collapsed while in the assembled condition—the use of such fold lines being a technique disclosed and taught, for example, in incorporated U.S. patent publication 2012/0238423.

Suspension Packaging and Storage, Shipping, and Transport of Smartphones

Boxes assembled from the box blanks 500,501,600,601 can be used to store, ship and transport smartphones and similarly shaped, fragile items. In this regard, dimensions for use in smartphones are disclosed in the priority provisional application incorporated herein by reference, the disclosure of which is found in the Appendix hereto, also incorporated herein by reference. As seen in FIG. 47 of the Appendix, an exemplary box blank for assembling a box in which a smartphone may be suspended for storing, shipping, and transport has an overall dimension along the width of the assembled box of about 4.625 inches and overall dimension along the length of the assembled box of approximately 8 or 9 inches. Pictures of an exemplary box in which a article approximating the size of a small smartphone is suspended for storing, shipping, and transport are found in FIGS. 48-66 of the Appendix.

Based on the foregoing description, it will be readily understood by those persons skilled in the art that the present invention is susceptible of broad utility and application. Many embodiments and adaptations of the present invention other than those specifically described herein, as well as many variations, modifications, and equivalent arrangements, will be apparent from or reasonably suggested by the present invention and the foregoing descriptions thereof, without departing from the substance or scope of the present invention. Accordingly, while the present invention has been described herein in detail in relation to one or more preferred embodiments, it is to be understood that this disclosure is only illustrative and exemplary of the present invention and is made merely for the purpose of providing a full and enabling disclosure of the invention. The foregoing disclosure is not intended to be construed to limit the present invention or otherwise exclude any such other embodiments, adaptations, variations, modifications or equivalent arrangements, the present invention being limited only by the claims appended hereto and equivalents thereof.

Claims

1. A box formed from folding a single sheet of material having fold lines and/or lines of perforations therein, wherein, when the box is assembled, the assembled box includes suspension panels that extend into an interior of the box, each suspension panel being connected to a top panel of the box along a fold line or line of perforations, the top panel forming part of the lid of the box, and distal subpanels of the suspension panels defining distal ends thereof being bound together such that the suspension panels form a receiving space for receiving one or more articles for suspended retention thereof within the interior of the box at spacings to end, side, and bottom panels forming defining the interior of the box.

2. The box of claim 1, wherein a fold line bisects each of the end panels and bottom panels and further comprising fold lines defined in the bottom panel such that the box is collapsible when in the assembled and bound stated.

3. A box blank, comprising:

(a) a bottom panel;
(b) a first side panel;
(c) a second side panel;
(d) a first end panel;
(e) a second end panel;
(f) a first overlapping side panel;
(g) a second overlapping side panel;
(h) a third overlapping side panel;
(i) a fourth overlapping side panel;
(j) a first top panel;
(k) a second top panel;
(l) a first suspension panel; and
(m) a second suspension panel;
(n) wherein the panels of the box blank are integrally formed as part of a generally planar single sheet of material and are defined and separated by fold lines and lines of perforations;
(o) wherein a fold line extends between and delineates the bottom panel and the first side panel; a fold line extends between and delineates the bottom panel and the second side panel; a fold line extends between and delineates the bottom panel and the first end panel; a fold line extends between and delineates the bottom panel and the second end panel; a line of perforations extends between and delineates the first top panel and the first side panel; a line of perforations extends between and delineates the second top panel and the second suspension panel;
(p) wherein each of the first suspension panel and second suspension panel is defined by a plurality of subpanels, adjacent subpanels being delineated by a fold line or line of perforations extending therebetween; and
(p) wherein, when the box blank is folded along the fold lines into an assembled box for use and is in a closed position, (i) the first suspension panel extends from the first top panel into an interior space defined by the bottom panel, first and second side panels, and first and second end panels, (ii) the second suspension panel extends from the second top panel into the interior space defined by the bottom panel, first and second side panels, and first and second end panels, and (iii) ends of the suspension panels defined by distal most subpanels are adhered to one another and form a base for supporting one or more articles received between the suspension panels, subpanels of the suspension panels forming side support areas extending over and containing the one or more articles with the interior space in a suspended position relative to the bottom panel, first and second side panels, and first and second end panels.

4. The box blank of claim 3, wherein a double hinge is defined between the first top panel and the first suspension panel, and a double hinge is defined between the second top panel and the second suspension panel.

5. The box blank of claim 4, wherein each double hinge is defined by parallel lines of perforations extending in close proximity to each other.

6. The box blank of claim 4, wherein each double hinge is defined by a fold line extending in parallel and close proximity to a line of perforations.

7. A box comprising a folded and bound box blank, the box blank comprising:

(a) a bottom panel;
(b) a first side panel;
(c) a second side panel;
(d) a first end panel;
(e) a second end panel;
(f) a first overlapping side panel;
(g) a second overlapping side panel;
(h) a third overlapping side panel;
(i) a fourth overlapping side panel;
(j) a first top panel;
(k) a second top panel;
(l) a first suspension panel; and
(m) a second suspension panel;
(n) wherein the panels of the box blank are integrally formed as part of a generally planar single sheet of material and are defined and separated by fold lines and lines of perforations;
(o) wherein a fold line extends between and delineates the bottom panel and the first side panel; a fold line extends between and delineates the bottom panel and the second side panel; a fold line extends between and delineates the bottom panel and the first end panel; a fold line extends between and delineates the bottom panel and the second end panel; a line of perforations extends between and delineates the first top panel and the first side panel; a line of perforations extends between and delineates the second top panel and the second suspension panel;
(p) wherein each of the first suspension panel and second suspension panel is defined by a plurality of subpanels, adjacent subpanels being delineated by a fold line or line of perforations extending therebetween; and
(p) wherein, when the box blank is folded along the fold lines into an assembled box for use and is in a closed position, (i) the first suspension panel extends from the first top panel into an interior space defined by the bottom panel, first and second side panels, and first and second end panels, (ii) the second suspension panel extends from the second top panel into the interior space defined by the bottom panel, first and second side panels, and first and second end panels, and (iii) ends of the suspension panels defined by distal most subpanels are adhered to one another and form a base for supporting one or more articles received between the suspension panels, subpanels of the suspension panels forming side support areas extending over and containing the one or more articles with the interior space in a suspended position relative to the bottom panel, first and second side panels, and first and second end panels.

8. The box of claim 7, wherein a double hinge is defined between the first top panel and the first suspension panel, and a double hinge is defined between the second top panel and the second suspension panel.

9. The box of claim 8, wherein each double hinge is defined by parallel lines of perforations extending in close proximity to each other.

10. The box of claim 8, wherein each double hinge is defined by a fold line extending in parallel and close proximity to a line of perforations.

11. The box blank of claim 8, wherein a fold line bisects each of the end panels and bottom panels and further comprising fold lines defined in the bottom panel such that the box is collapsible when in the assembled and bound stated.

12. The box blank of claim 8, further comprising a first overlapping panel attached to the first end panel with a fold line extending between and delineating the boundary between the first overlapping panel and the first end panel; a second overlapping panel attached to the first end panel with a fold line extending between and delineating the boundary between the second overlapping panel and the first end panel; a third overlapping panel attached to the second end panel with a fold line extending between and delineating the boundary between the third overlapping panel and the second end panel; a fourth overlapping panel attached to the second end panel with a fold line extending between and delineating the boundary between the fourth overlapping panel and the second end panel; a first side, top flap panel attached to the first overlapping panel with a fold line extending between and delineating the boundary between the first side, top flap panel and the first overlapping panel; a second side, top flap panel attached to the second overlapping panel with a fold line extending between and delineating the boundary between the second side, top flap panel and the second overlapping panel; a third side, top flap panel attached to the third overlapping panel with a fold line extending between and delineating the boundary between the third side, top flap panel and the third overlapping panel; and a fourth side, top flap panel attached to the fourth overlapping panel with a fold line extending between and delineating the boundary between the fourth side, top flap panel and the fourth overlapping panel; wherein the side, top panels extend from sides of the box in partial covering over the interior space and support the top panels in the closed position.

13. The box blank of claim 12, further comprising a first end, top flap panel attached to the first end panel with a fold line extending between and delineating the boundary between the first end, top flap panel and the first end panel; and a second end, top flap panel attached to the second end panel with a fold line extending between and delineating the boundary between the second end, top flap panel and the second end panel; wherein the end, top panels extend in partial covering over the interior space and support the top panels in the closed position.

14. The box of claim 13, wherein each end, top flap panel includes a fold line dividing it into first and second subpanels, and wherein the suspension panels abut one of the first and second subpanels of each end, top flap panel when the box blank is folded along the fold lines into an assembled box for use and is in a closed position.

15. The box of claim 8, further comprising a first overlapping panel attached to the first side panel with a fold line extending between and delineating the boundary between the first overlapping panel and the first side panel; a second overlapping panel attached to the second side panel with a fold line extending between and delineating the boundary between the second overlapping panel and the second side panel; a third overlapping panel attached to the first side panel with a fold line extending between and delineating the boundary between the third overlapping panel and the first side panel; a fourth overlapping panel attached to the second side panel with a fold line extending between and delineating the boundary between the fourth overlapping panel and the second side panel; a first end, top flap panel attached to the first overlapping panel with a fold line extending between and delineating the boundary between the first end, top flap panel and the first overlapping panel; a second end, top flap panel attached to the second overlapping panel with a fold line extending between and delineating the boundary between the second end, top flap panel and the second overlapping panel; a third end, top flap panel attached to the third overlapping panel with a fold line extending between and delineating the boundary between the third end, top flap panel and the third overlapping panel; and a fourth end, top flap panel attached to the fourth overlapping panel with a fold line extending between and delineating the boundary between the fourth end, top flap panel and the fourth overlapping panel; wherein the end, top panels extend from ends of the box in partial covering over the interior space and support the top panels in the closed position.

16. The box of claim 15, further comprising a first guide flange panel attached to the first overlapping panel with a fold line extending between and delineating the boundary between the first guide flange panel and the first overlapping panel; a second guide flange panel attached to the second overlapping panel with a fold line extending between and delineating the boundary between the second guide flange panel and the second overlapping panel; a third guide flange panel attached to the third overlapping panel with a fold line extending between and delineating the boundary between the third guide flange panel and the third overlapping panel; and a fourth guide flange panel attached to the fourth overlapping panel with a fold line extending between and delineating the boundary between the fourth guide flange panel and the fourth overlapping panel; wherein the first guide flange panel abuts the second flange panel to define a guide extending along a height of the first end panel and the third guide flange panel abuts the fourth guide flange panel to define a guide extending along a height of the second end panel; and wherein the base includes a slot on each end within which a respective said guide is received, whereby the base is guided in its descent into and ascent from the interior of the box.

17. The box of claim 16, wherein double hinges formed by closely located lines of perforations in the suspension panels define the slots in which the guides are received.

18. The box of claim 8, further comprising a removable buffer insert positioned within the interior space adjacent the first end panel and extending around and receiving through a recess therein the base formed by the suspension panels, whereby a space between one or more articles suspended in the assembled box and the first end of the box is consumed.

19. The box of claim 18, wherein the buffer insert is in the shape of a folded “H”.

20. The box of claim 8, wherein the suspension panels form a “V” or “U” shaped containment area extending from the top panels for suspending articles received therein.

21-27. (canceled)

Patent History
Publication number: 20160101923
Type: Application
Filed: Oct 13, 2015
Publication Date: Apr 14, 2016
Inventor: Donn J. Costanzo, JR. (Fort Mill, SC)
Application Number: 14/882,432
Classifications
International Classification: B65D 81/07 (20060101); B65D 5/42 (20060101); B65D 5/50 (20060101); B65D 5/02 (20060101);