BOX DESIGN FOR AUTOMATIC ASSEMBLY AND SEALING

Abstract

Embodiments are directed to the design, manufacturing, assembly and filling of a parcel container (i.e., box) cut from a single piece of material (e.g., corrugated cardboard). The parcel container is sealable without the use of tape as a sealing mechanism.

Description

FIELD

The present disclosure relates to the design, manufacturing, assembly and filling of a parcel container (i.e., box) cut from a single piece of material (e.g., corrugated cardboard). The parcel container is sealable without the use of tape as a sealing mechanism.

BACKGROUND

Corrugated paperboard boxes provide an exceptionally rugged, economical, and adaptable container for shipment and storage of goods. Because of the multi-ply construction of corrugated paperboard, the material is extremely lightweight for its stiffness. Through applied effort, ingenuity, and innovation, identified problems associated with the design, manufacture, assembly, filling, and sealing of corrugated paperboard boxes have been solved by developing solutions that are included in embodiments of the present disclosure, many examples of which are described in detail herein.

SUMMARY

According to embodiments, the present system is directed to a box assembly manufactured from a single continuous piece of material. In embodiments, the box assembly comprises a central bottom portion having a top surface, a bottom surface, a first central bottom portion side, a second central bottom portion side, a third central bottom portion side, and a fourth central bottom portion side.

In embodiments, the box assembly further comprises a first side piece extending from the first central bottom portion side. In embodiments, the first side piece has a first side piece alternating flap and a second side piece alternating flap extending therefrom. In embodiments, the first side piece alternating flap and the second side piece alternating flap extend from opposing sides of the first side piece and do not extend from the first central bottom portion side. In embodiments, the first side piece has a first top portion extending therefrom on a side of the first side piece opposing the first central bottom portion side.

In embodiments, the box assembly further comprises a second side piece extending from the second central bottom portion side. In embodiments, the second side piece has a third side piece alternating flap and a fourth side piece alternating flap extending therefrom. In embodiments, the third side piece alternating flap and the fourth side piece alternating flap extend from opposing sides of the second side piece and do not extend from the second central bottom portion side. In embodiments, the second side piece has extending therefrom a first pocket and a second pocket each extending from opposing sides of the second side piece and not extending from the second central bottom portion side.

In embodiments, the box assembly further comprises a third side piece extending from the third central bottom portion side. In embodiments, the third side piece has a fifth side piece alternating flap and a sixth side piece alternating flap extending therefrom. In embodiments, the fifth side piece alternating flap and the sixth side piece alternating flap extend from opposing sides of the third side piece and do not extend from the third central bottom portion side. In embodiments, the third side piece has a second top portion extending therefrom on a side of the third side piece opposing the third central bottom portion side.

In embodiments, the box assembly further comprises a fourth side piece extending from the fourth central bottom portion side. In embodiments, the fourth side piece has a seventh side piece alternating flap and an eighth side piece alternating flap extending therefrom. In embodiments, the seventh side piece alternating flap and the eighth side piece alternating flap extend from opposing sides of the fourth side piece and do not extend from the fourth central bottom portion side. In embodiments, the fourth side piece has extending therefrom a third pocket and a fourth pocket each extending from opposing sides of the fourth side piece and not extending from the fourth central bottom portion side.

In embodiments, the first top portion and the second top portion comprise a corrugated formed mechanical closure assembly.

In embodiments, the first pocket and the second pocket are folded and adhered to the second side piece during an assembly process.

In embodiments, the third pocket and the fourth pocket are folded and adhered to the fourth side piece during an assembly process.

In embodiments, the first top portion has extending therefrom a first friction clamp lock tab and a second friction clamp lock tab. In embodiments, the first friction clamp lock tab and the second friction clamp lock tab extend from opposing sides of the first top portion and do not extend from a side of the first top portion shared with the first side piece nor from a side extending from an opening mechanism.

In embodiments, the first top portion has extending therefrom a first ratcheting tab and a second ratcheting tab. In embodiments, the first ratcheting tab and the second ratcheting tab extend from opposing sides of the first top portion and do not extend from a side of the first top portion shared with the first side piece nor from a side extending from an opening mechanism.

In embodiments, the first top portion has extending therefrom an opening mechanism.

In embodiments, the first top portion comprises a first slot and a second slot for receiving a first folding tab and a second folding tab, respectively.

In embodiments, the first folding tab and the second folding tab extend from the second top portion.

In embodiments, a perforated strip is located between an adhesive location of the first top portion and a location of the first top portion wherefrom the opening mechanism extends.

In embodiments, the first friction clamp lock tab, the second friction clamp lock tab, the third friction clamp lock tab, and the fourth friction clamp lock tab are employed for reuse of the apparatus subsequent an original assembly and use of the apparatus.

In embodiments, the first ratcheting tab, the second ratcheting tab, the third ratcheting tab, and the fourth ratcheting tab are employed for reuse of the apparatus subsequent an original assembly and use of the apparatus.

In embodiments, the material is corrugated cardboard (also referred to herein as corrugated board and corrugated paperboard).

In embodiments, a quick dry hot glue style adhesive is used in the automated assembly process described herein.

Embodiments of the present disclosure provide improvements over prior art designs that facilitate exact dimensioning to create a box with dimensions required for the contents on demand. In embodiments, dimensions of a box can be calculated on-demand dependent upon the items intended to fill the box. In embodiments, a box template can be generated according to the desired dimensions and the design herein prior to being cut and assembled.

Embodiments of the present disclosure relate to a box assembly that does not require tape as a sealing mechanism during initial assembly or subsequent uses. Such a feature lowers costs and eases recycling of the box assembly.

The box assembly disclosed herein requires a solid one-piece central bottom portion that is able to support more weight than conventional prior art designs. The box assembly is tamper evident and cannot be opened and resealed without knowledge of a recipient.

It will be appreciated that the box assembly of the present disclosure resists horizontal angular forces (i.e., forces applied to opposite vertical corners) from which prior art box designs experience structural weaknesses.

BRIEF DESCRIPTION

Having thus described the disclosure in general terms, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and wherein:

FIG. 1 provides an illustration of an exemplary embodiment of the present disclosure;

FIG. 2A provides an illustration of a first portion of a two portion exemplary embodiment of the present disclosure;

FIG. 2B provides an illustration of a second portion of a two portion exemplary embodiment of the present disclosure;

FIG. 3A illustrates a step of an exemplary automated assembly process according to embodiments of the present disclosure;

FIG. 3B illustrates a step of an exemplary automated assembly process according to embodiments of the present disclosure;

FIG. 3C illustrates a step of an exemplary automated assembly process according to embodiments of the present disclosure;

FIG. 3D illustrates a step of an exemplary automated assembly process according to embodiments of the present disclosure;

FIG. 3E illustrates a step of an exemplary automated assembly process according to embodiments of the present disclosure;

FIG. 4A illustrates an exemplary box manufacturing process according to embodiments of the present disclosure;

FIG. 4B illustrates an exemplary automated assembly process according to embodiments of the present disclosure;

FIG. 5 provides an illustration of an exemplary embodiment of the present disclosure;

FIG. 6A provides an illustration of a first portion of a two portion exemplary embodiment of the present disclosure; and

FIG. 6B provides an illustration of a second portion of a two portion exemplary embodiment of the present disclosure.

DETAILED DESCRIPTION

The present disclosure will now be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all embodiments of the disclosure are shown. Indeed, the disclosure may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. Like numbers refer to like elements throughout.

FIG. 1 provides an illustration of an exemplary embodiment of the present disclosure. In an exemplary embodiment, a box 100 is cut from a single piece of corrugated board. In embodiments, box 100 comprises a central bottom portion 101 having a top surface, a bottom surface, and four sides. Extending from each of the four sides is a side piece 102-1, 102A, 102-2, 102B. Each side piece 102-1, 102A, 102-2, and 102B has a top surface, a bottom surface, and four sides. Each side piece 102-1, 102A, 102-2, and 102B has extending therefrom two alternating flaps (103A-1-103A-4 and 103B-1-103B-4). Side pieces 102A and 102B also have extending therefrom two pockets (105A-1, 105A-2 and 105B-1, 105B-2). Side pieces 102-1 and 102-2 also have extending therefrom a top portion (104-1, 104-2).

In embodiments, side piece 102-1 has extending therefrom two alternating flaps 103A-1 and 103B-1, where the alternating flaps 103A-1 and 103B-1 are extending from opposite sides of the side piece 102-1, and to a side of the side piece 102-1 that is not shared with the extension from the central bottom portion 101 and is not shared with a top portion 104-1 of the box 100.

In embodiments, side piece 102A has extending therefrom two alternating flaps 103A-2 and 103A-3, where the alternating flaps 103A-2 and 103A-3 are extending from opposite sides of the side piece 102A, and to a side of the side piece 102A that is shared with two pockets 105A-1 and 105A-2 also extending from side piece 102A. Alternating flaps 103A-2 and 103A-3 as well as pockets 105A-1 and 105A-2 are also extending from a side of side piece 102A that is not shared with the side extending from the central bottom portion 101.

In embodiments, side piece 102B has extending therefrom two alternating flaps 103B-2 and 103B-3, where the alternating flaps 103B-2 and 103B-3 are extending from opposite sides of the side piece 102B, and to a side of the side piece 102B that is shared with two pockets 105B-1 and 105B-2 also extending from side piece 102B. Alternating flaps 103B-2 and 103B-3 as well as pockets 105B-1 and 105B-2 are also extending from a side of side piece 102B that is not shared with the side extending from the central bottom portion 101.

In embodiments, side piece 102-2 has extending therefrom two alternating flaps 103A-4 and 103B-4, where the alternating flaps 103A-4 and 103B-4 are extending from opposite sides of the side piece 102-2, and to a side of the side piece 102-2 that is not shared with the attachment to the central bottom portion 101 and is not shared with a top portion 104-2 of the box 100.

In embodiments, alternating flaps 103A-1, 103A-2, 103A-3, 103A-4, 103B-1, 103B-2, 103B-3, and 103B-4 are perforated for ease in disassembling the box and for recycling purposes. It will be appreciated that disassembling the box 100 for mechanized or other recycling is made easier by the use of alternating flaps 103A-1, 103A-2, 103A-3, 103A-4, 103B-1, 103B-2, 103B-3, and 103B-4.

It will be appreciated that, in embodiments, top portion 104-1 is opposite top portion 104-2. In embodiments, top portion 104-1 and top portion 104-2 comprise a corrugated board formed mechanical closure assembly.

In embodiments, pockets 105A-1, 105A-2, 105B-1, and 105B-2 are folded and glued to respective side pieces 102A and 102B, in the assembly process.

In embodiments, top portion 104-1 has extending therefrom, on opposing sides of top portion 104-1, two friction clamp lock tabs 106A-1 and 106B-1. Friction clamp lock tabs 106A-1 and 106B-1 are extending from sides of top portion 104-1 that are not shared with each other nor with a side of top portion 104-1 that is extending from side piece 102-1 nor with a side of top portion 104-1 extending from opening mechanism 107 and slots 109A and 109B. In embodiments, opening mechanism is extending from a side of top portion 104-1 and consists of a perforated strip located between an adhesive location and a location where the opening mechanism 107 is extending from the top portion 104-1. Opening mechanism 107 is designed such that no sharp implement is necessary for opening box 100 after it has been sealed. This includes no requirement for strength or dexterity for opening box 100 after is has been sealed.

In embodiments, top portion 104-2 has extending therefrom, on opposing sides of top portion 104-2, two friction clamp lock tabs 106A-2 and 106B-2. Friction clamp lock tabs 106A-2 and 106B-2 are extending from sides of top portion 104-2 that are not shared with each other nor with a side of top portion 104-2 that is extending from side piece 102-2 nor with a side of top portion 104-2 extending from folding tabs 108A, 108B.

In embodiments, friction clamp lock tabs 106A-1, 106A-2, 106B-1, and 106B-2 enable reuse of box 100 as opposed to mechanized recycling. It will be appreciated that reuse of corrugated boxes is the greenest form of recycling possible.

It will be appreciated that top portion 104-2 comprises folding tabs 108A and 108B that can be inserted into slots 109A, 109B located on top portion 104-1 such that folding tabs 108A and 108B are unfolded after insertion into slots 109A and 109B thereby creating a sealing mechanism.

FIG. 2A provides an illustration of a first portion of a two portion exemplary embodiment of the present disclosure. FIG. 2B provides an illustration of a second portion of a two portion exemplary embodiment of the present disclosure. In embodiments, box 100 is manufactured as two sections 100A and 100B. Combining sections 100A and 100B results in two central bottom portions 101 stacked on top of one another. Having two central bottom portions 101 provides a sturdy double layer bottom and supports sizes unable to be obtained from prior art box designs using the same corrugated board stock.

In embodiments, assembly equipment for use herein may include a folding apparatus, a creasing apparatus, laser cutting equipment, a laser engraving and/or printing apparatus, and an adhesive application (i.e., gluing) apparatus.

FIG. 3A illustrates a step of an exemplary automated assembly process according to embodiments of the present disclosure. In embodiments, an exemplary automated assembly process begins with the box 100 being cut from a single piece of corrugated board and having all creases applied to one of a top surface or a bottom surface of the single piece of corrugated board. The automated assembly process also includes applying all printing to the same one of the top surface or bottom surface of the single piece of corrugated board. Applying the creases and printing to only one side of the corrugated board provides ease in manufacturing and assembly of the box 100.

In embodiments, the exemplary automated assembly process includes applying adhesive (i.e., glue) to a surface of each of alternating flaps 103A-1, 103A-2, 103A-3, 103A-4, 103B-1, 103B-2, 103B-3, and 103B-4. In embodiments, adhesive is also applied to a surface of each of side pieces 102A and 102B as depicted in FIG. 3A. It will be appreciated that the adhesive is applied to the same surface side of the alternating flaps 103A-1, 103A-2, 103A-3, 103A-4, 103B-1, 103B-2, 103B-3, and 103B-4 and the side pieces 102A and 102B (as shown in FIG. 3A).

FIG. 3B illustrates a step of an exemplary automated assembly process according to embodiments of the present disclosure. In embodiments, pockets 105A-1 and 105A-2 are folded and secured, using the previously applied adhesive, to side piece 102A. Pockets 105B-1 and 105B-2 are folded and secured, using the previously applied adhesive, to side piece 102B.

FIG. 3C illustrates a step of an exemplary automated assembly process according to embodiments of the present disclosure. In embodiments, side pieces 102A, 102-1, 102B, and 102-2 are folded up towards each other to form the open box 100.

FIG. 3D illustrates a step of an exemplary automated assembly process according to embodiments of the present disclosure. In embodiments, the alternating flaps 103A-2 and 103B-2 are folded and secured to (using the previously applied adhesive) side piece 102-1. Alternating flaps 103A-1 and 103A-3 (not shown) are folded and secured (using the previously applied adhesive) to side piece 102A. Alternating flaps 103B-1 and 103B-3 are folded and secured (using the previously applied adhesive) to side piece 102B. Alternating flaps 103B-4 and 103A-4 (not shown) are folded and secured (using the previously applied adhesive) to side piece 102-2.

It will be appreciated that, at this point in the assembly process, box 100 can be removed from the automated assembly process and filled with contents. Once the box 100 has been filled with contents, it can reenter the assembly process to continue complete assembly.

FIG. 3E illustrates a step of an exemplary automated assembly process according to embodiments of the present disclosure. In embodiments, top portion 104-2 is folded in toward the opening of box 100 and adhesive is applied thereto prior to top portion 104-1 being folded in toward and secured to top portion 104-2.

In embodiments, friction clamp lock or ratcheting tabs 106A-1, 106A-2, 106B-1, and 106B-2 (or 506A-1, 506A-2, 506B-1, and 506B-2) are folded in toward the opening of box 100 (not shown) prior to sealing of the box 100. In embodiments, the friction clamp lock or ratcheting tabs are fed into the pockets 105A-1, 105A-2, 105B-1, 105B-2 (or 505A-1, 505A-2, 505B-1, and 505B-2) so that the top of box 100 can stay closed/sealed without adhesive or any other sealing mechanism.

In embodiments, folding tabs 108A and 108B and slots 109A and 109B are not used during the initial assembly process but are available for a second use after the box's initial purpose. In such embodiments, folding tabs 108A and 108B are inserted (not shown) into slots 109A and 109B to enable reuse of the box 100.

FIG. 4A illustrates an exemplary box manufacturing process according to embodiments of the present disclosure. According to embodiments, a method of manufacturing a box assembly from a single continuous piece of material comprises selecting the single continuous piece of material 401. In embodiments, the method of manufacturing further comprises cut 402, using one or more laser cutting modules, from the single continuous piece of material. In embodiments, step 402 provides for cutting of a plurality of different sized boxes on demand.

In embodiments, the box assembly comprises a central bottom portion having a top surface, a bottom surface, a first central bottom portion side, a second central bottom portion side, a third central bottom portion side, and a fourth central bottom portion side. In embodiments, the box assembly further comprises a first side piece extending from the first central bottom portion side, the first side piece having a first side piece alternating flap and a second side piece alternating flap extending therefrom, wherein the first side piece alternating flap and the second side piece alternating flap extend from opposing sides of the first side piece and do not extend from the first central bottom portion side, the first side piece having a first top portion extending therefrom on a side of the first side piece opposing the first central bottom portion side.

In embodiments, the box assembly further comprises a second side piece extending from the second central bottom portion side, the second side piece having a third side piece alternating flap and a fourth side piece alternating flap extending therefrom, wherein the third side piece alternating flap and the fourth side piece alternating flap extend from opposing sides of the second side piece and do not extend from the second central bottom portion side, the second side piece having extending therefrom a first pocket and a second pocket each extending from opposing sides of the second side piece and not extending from the second central bottom portion side.

In embodiments, the box assembly further comprises a third side piece extending from the third central bottom portion side, the third side piece having a fifth side piece alternating flap and a sixth side piece alternating flap extending therefrom, wherein the fifth side piece alternating flap and the sixth side piece alternating flap extend from opposing sides of the third side piece and do not extend from the third central bottom portion side, the third side piece having a second top portion extending therefrom on a side of the third side piece opposing the third central bottom portion side.

In embodiments, the box assembly further comprises a fourth side piece extending from the fourth central bottom portion side, the fourth side piece having a seventh side piece alternating flap and an eighth side piece alternating flap extending therefrom, wherein the seventh side piece alternating flap and the eighth side piece alternating flap extend from opposing sides of the fourth side piece and do not extend from the fourth central bottom portion side, the fourth side piece having extending therefrom a third pocket and a fourth pocket each extending from opposing sides of the fourth side piece and not extending from the fourth central bottom portion side.

FIG. 4B illustrates an exemplary automated assembly process 450 according to embodiments of the present disclosure. In embodiments, a method 450 of automatically assembling a box assembly manufactured from a single continuous piece of material comprises applying design creases to a top surface of the box assembly 410. In embodiments, the method 450 comprises applying printing to a bottom surface of the box assembly 412. In embodiments, the method 450 comprises applying adhesive 414 to the top surface of the box assembly at each of a first side piece alternating flap, a second side piece alternating flap, a third side piece alternating flap, a fourth side piece alternating flap, a fifth side piece alternating flap, a sixth side piece alternating flap, a seventh side piece alternating flap, and an eighth side piece alternating flap.

In embodiments, the method 450 comprises applying adhesive 416 to the top surface of the box assembly at each of a second side piece and a fourth side piece such that a first pocket and a second pocket extending from the second side piece are folded and adhered to the second side piece and such that a third pocket and a fourth pocket extending from the fourth side piece are folded and adhered to the fourth side piece.

In embodiments, the method 450 comprises folding 418 each of a first side piece, the second side piece, a third side piece, and the fourth side piece upward in towards each other to form an opening of the box assembly. It will be appreciated that the method 450 may be paused at this point to provide for contents to be manually or automatically inserted into the opening of the box assembly.

In embodiments, the method 450 comprises automatically folding 420 in to adhere two side piece alternating flaps to the first side piece, folding in to adhere two different side piece alternating flaps to the second side piece, folding in to adhere two further different side piece alternating flaps to the third side piece and folding in to adhere the two even further side piece alternating flaps to the fifth side piece. It will be appreciated that folding step 420 is achieved, in embodiments, through mechanical automation.

In embodiments, the method 450 comprises folding a second top portion in toward the opening of the box assembly and applying adhesive thereupon and folding a first top portion in toward the opening of the box assembly and adhering the first top portion to the second top portion 422.

FIG. 5 provides an illustration of an exemplary embodiment of the present disclosure. In an exemplary embodiment, a box 500 is cut from a single piece of corrugated board. In embodiments, box 500 comprises a central bottom portion 101 having a top surface, a bottom surface, and four sides. Extending from each of the four sides is a side piece 102-1, 102A, 102-2, 102B. Each side piece 102-1, 102A, 102-2, and 102B has a top surface, a bottom surface, and four sides. Each side piece 102-1, 102A, 102-2, and 102B has extending therefrom two alternating flaps (103A-1-103A-4 and 103B-1-103B-4). Side pieces 102A and 102B also have extending therefrom two pockets (505A-1, 505A-2 and 505B-1, 505B-2). Side pieces 102-1 and 102-2 also have extending therefrom a top portion (104-1, 104-2).

In embodiments, side piece 102-1 has extending therefrom two alternating flaps 103A-1 and 103B-1, where the alternating flaps 103A-1 and 103B-1 are extending from opposite sides of the side piece 102-1, and to a side of the side piece 102-1 that is not shared with the extension from the central bottom portion 101 and is not shared with a top portion 104-1 of the box 500.

In embodiments, side piece 102A has extending therefrom two alternating flaps 103A-2 and 103A-3, where the alternating flaps 103A-2 and 103A-3 are extending from opposite sides of the side piece 102A, and to a side of the side piece 102A that is shared with two pockets 505A-1 and 505A-2 also extending from side piece 102A. Alternating flaps 103A-2 and 103A-3 as well as pockets 505A-1 and 505A-2 are also extending from a side of side piece 102A that is not shared with the side extending from the central bottom portion 101.

In embodiments, side piece 102B has extending therefrom two alternating flaps 103B-2 and 103B-3, where the alternating flaps 103B-2 and 103B-3 are extending from opposite sides of the side piece 102B, and to a side of the side piece 102B that is shared with two pockets 505B-1 and 505B-2 also extending from side piece 102B. Alternating flaps 103B-2 and 103B-3 as well as pockets 505B-1 and 505B-2 are also extending from a side of side piece 102B that is not shared with the side extending from the central bottom portion 101.

In embodiments, side piece 102-2 has extending therefrom two alternating flaps 103A-4 and 103B-4, where the alternating flaps 103A-4 and 103B-4 are extending from opposite sides of the side piece 102-2, and to a side of the side piece 102-2 that is not shared with the attachment to the central bottom portion 101 and is not shared with a top portion 104-2 of the box 500.

In embodiments, alternating flaps 103A-1, 103A-2, 103A-3, 103A-4, 103B-1, 103B-2, 103B-3, and 103B-4 are perforated for ease in disassembling the box 500 and for recycling purposes. It will be appreciated that disassembling the box 500 for mechanized or other recycling is made easier by the use of alternating flaps 103A-1, 103A-2, 103A-3, 103A-4, 103B-1, 103B-2, 103B-3, and 103B-4.

It will be appreciated that, in embodiments, top portion 104-1 is opposite top portion 104-2. In embodiments, top portion 104-1 and top portion 104-2 comprise a corrugated board formed mechanical closure assembly.

In embodiments, pockets 505A-1, 505A-2, 505B-1, and 505B-2 are folded and glued to respective side pieces 102A and 102B, in the assembly process.

In embodiments, top portion 104-1 has extending therefrom, on opposing sides of top portion 104-1, two ratcheting tabs 506A-1 and 506B-1. Ratcheting tabs 506A-1 and 506B-1 are extending from sides of top portion 104-1 that are not shared with each other nor with a side of top portion 104-1 that is extending from side piece 102-1 nor with a side of top portion 104-1 extending from opening mechanism 107 and slots 109A and 109B. In embodiments, opening mechanism is extending from a side of top portion 104-1 and consists of a perforated strip located between an adhesive location and a location where the opening mechanism 107 is extending from the top portion 104-1. Opening mechanism 107 is designed such that no sharp implement is necessary for opening box 500 after it has been sealed. This includes no requirement for strength or dexterity for opening box 500 after is has been sealed.

In embodiments, top portion 104-2 has extending therefrom, on opposing sides of top portion 104-2, two ratcheting tabs 506A-2 and 506B-2. Ratcheting tabs 506A-2 and 506B-2 are extending from sides of top portion 104-2 that are not shared with each other nor with a side of top portion 104-2 that is extending from side piece 102-2 nor with a side of top portion 104-2 extending from folding tabs 108A, 108B.

In embodiments, ratcheting tabs 506A-1, 506A-2, 506B-1, and 506B-2 enable reuse of box 500 as opposed to mechanized recycling. It will be appreciated that reuse of corrugated boxes is the greenest form of recycling possible.

It will be appreciated that top portion 104-2 comprises folding tabs 108A and 108B that can be inserted into slots 109A, 109B located on top portion 104-1 such that folding tabs 108A and 108B are unfolded after insertion into slots 109A and 109B thereby creating a sealing mechanism.

FIG. 6A provides an illustration of a first portion of a two portion exemplary embodiment of the present disclosure. FIG. 6B provides an illustration of a second portion of a two portion exemplary embodiment of the present disclosure. In embodiments, box 500 is manufactured as two sections 500A and 500B. Combining sections 500A and 500B results in two central bottom portions 101 stacked on top of one another. Having two central bottom portions 101 provides a sturdy double layer bottom and supports sizes unable to be obtained from prior art box designs using the same corrugated board stock

In embodiments, assembly equipment for use herein may include a folding apparatus, a creasing apparatus, laser cutting equipment, a laser engraving and/or printing apparatus, and an adhesive application (i.e., gluing) apparatus. It will be appreciated that box 500 can be assembled according to methods described herein.

CONCLUSION

Many modifications and other embodiments of the inventions set forth herein will come to mind to one skilled in the art to which these inventions pertain having the benefit of the teachings presented in the foregoing description and the associated drawings. Therefore, it is to be understood that the inventions are not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation, unless described otherwise.

Claims

1. A box assembly manufactured from a single continuous piece of material, the box assembly comprising:

a central bottom portion having a top surface, a bottom surface, a first central bottom portion side, a second central bottom portion side, a third central bottom portion side, and a fourth central bottom portion side;

a first side piece extending from the first central bottom portion side, the first side piece having a first side piece alternating flap and a second side piece alternating flap extending therefrom, wherein the first side piece alternating flap and the second side piece alternating flap extend from opposing sides of the first side piece and do not extend from the first central bottom portion side, the first side piece having a first top portion extending therefrom on a side of the first side piece opposing the first central bottom portion side;

a second side piece extending from the second central bottom portion side, the second side piece having a third side piece alternating flap and a fourth side piece alternating flap extending therefrom, wherein the third side piece alternating flap and the fourth side piece alternating flap extend from opposing sides of the second side piece and do not extend from the second central bottom portion side, the second side piece having extending therefrom a first pocket and a second pocket each extending from opposing sides of the second side piece and not extending from the second central bottom portion side;

a third side piece extending from the third central bottom portion side, the third side piece having a fifth side piece alternating flap and a sixth side piece alternating flap extending therefrom, wherein the fifth side piece alternating flap and the sixth side piece alternating flap extend from opposing sides of the third side piece and do not extend from the third central bottom portion side, the third side piece having a second top portion extending therefrom on a side of the third side piece opposing the third central bottom portion side; and

a fourth side piece extending from the fourth central bottom portion side, the fourth side piece having a seventh side piece alternating flap and an eighth side piece alternating flap extending therefrom, wherein the seventh side piece alternating flap and the eighth side piece alternating flap extend from opposing sides of the fourth side piece and do not extend from the fourth central bottom portion side, the fourth side piece having extending therefrom a third pocket and a fourth pocket each extending from opposing sides of the fourth side piece and not extending from the fourth central bottom portion side.

2. The box assembly of claim 1, wherein the first top portion and the second top portion comprise a corrugated formed mechanical closure assembly.

3. The box assembly of claim 1, wherein the first pocket and the second pocket are folded and adhered to the second side piece during an assembly process.

4. The box assembly of claim 3, wherein the third pocket and the fourth pocket are folded and adhered to the fourth side piece during an assembly process.

5. The box assembly of claim 1, wherein the first top portion has extending therefrom a first friction clamp lock tab and a second friction clamp lock tab, the first friction clamp lock tab and the second friction clamp lock tab extending from opposing sides of the first top portion and not extending from a side of the first top portion shared with the first side piece nor from a side extending from an opening mechanism.

6. The box assembly of claim 1, wherein the first top portion has extending therefrom an opening mechanism.

7. The box assembly of claim 1, wherein the first top portion comprises a first slot and a second slot for receiving a first folding tab and a second folding tab, respectively.

8. The box assembly of claim 1, wherein the first folding tab and the second folding tab extend from the second top portion.

9. The box assembly of claim 6, wherein a perforated strip is located between an adhesive location of the first top portion and a location of the first top portion wherefrom the opening mechanism extends.

10. The box assembly of claim 5, wherein the second top portion has extending therefrom a third friction clamp lock tab and a fourth friction clamp lock tab, the third friction clamp lock tab and the fourth friction clamp lock tab extending from opposing sides of the second top portion and not extending from a side of the second top portion shared with the third side piece nor from a side extending from an opening mechanism.

11. The box assembly of claim 1, wherein the material is corrugated cardboard.

12. A method of manufacturing a box assembly from a single continuous piece of material, the method comprising:

selecting the single continuous piece of material; and

using mechanical means, cutting the box assembly from the single continuous piece of material, where the box assembly comprises:

a central bottom portion having a top surface, a bottom surface, a first central bottom portion side, a second central bottom portion side, a third central bottom portion side, and a fourth central bottom portion side;

a first side piece extending from the first central bottom portion side, the first side piece having a first side piece alternating flap and a second side piece alternating flap extending therefrom, wherein the first side piece alternating flap and the second side piece alternating flap extend from opposing sides of the first side piece and do not extend from the first central bottom portion side, the first side piece having a first top portion extending therefrom on a side of the first side piece opposing the first central bottom portion side;

a second side piece extending from the second central bottom portion side, the second side piece having a third side piece alternating flap and a fourth side piece alternating flap extending therefrom, wherein the third side piece alternating flap and the fourth side piece alternating flap extend from opposing sides of the second side piece and do not extend from the second central bottom portion side, the second side piece having extending therefrom a first pocket and a second pocket each extending from opposing sides of the second side piece and not extending from the second central bottom portion side;

a third side piece extending from the third central bottom portion side, the third side piece having a fifth side piece alternating flap and a sixth side piece alternating flap extending therefrom, wherein the fifth side piece alternating flap and the sixth side piece alternating flap extend from opposing sides of the third side piece and do not extend from the third central bottom portion side, the third side piece having a second top portion extending therefrom on a side of the third side piece opposing the third central bottom portion side; and

a fourth side piece extending from the fourth central bottom portion side, the fourth side piece having a seventh side piece alternating flap and an eighth side piece alternating flap extending therefrom, wherein the seventh side piece alternating flap and the eighth side piece alternating flap extend from opposing sides of the fourth side piece and do not extend from the fourth central bottom portion side, the fourth side piece having extending therefrom a third pocket and a fourth pocket each extending from opposing sides of the fourth side piece and not extending from the fourth central bottom portion side.

13. A method of automatically assembling a box assembly, the box assembly manufactured from a single continuous piece of material, the method comprising:

applying design creases to a top surface of the box assembly;

applying printing to the bottom surface of the box assembly;

applying adhesive to the top surface of the box assembly at each of a first side piece alternating flap, a second side piece alternating flap, a third side piece alternating flap, a fourth side piece alternating flap, a fifth side piece alternating flap, a sixth side piece alternating flap, a seventh side piece alternating flap, and an eighth side piece alternating flap;

applying adhesive to the top surface of the box assembly at each of a second side piece and a fourth side piece such that a first pocket and a second pocket extending from the second side piece are folded and adhered to the second side piece and such that a third pocket and a fourth pocket extending from the fourth side piece are folded and adhered to the fourth side piece;

folding each of a first side piece, the second side piece, a third side piece, and the fourth side piece upward in towards each other to form an opening of the box assembly;

folding in to adhere two side piece alternating flaps to the first side piece;

folding in to adhere two different side piece alternating flaps to the second side piece;

folding in to adhere two further different side piece alternating flaps to the third side piece;

folding in to adhere the two even further side piece alternating flaps to the fifth side piece;

folding a second top portion in toward the opening of the box assembly and applying adhesive thereupon; and

folding a first top portion in toward the opening of the box assembly and adhering the first top portion to the second top portion.

14. The method of claim 13, wherein friction clamp lock tabs attached to each of the first top portion and the second top portion are folded in toward the opening of the box assembly prior to the first top portion being adhered to the second top portion.

15. The method of claim 14, wherein the friction clamp lock tabs are fed into each of the first pocket, the second pocket, the third pocket, and the fourth pocket.

16. The method of claim 13, wherein the box assembly is filled with contents prior to folding a second top portion in toward the opening of the box assembly and applying adhesive thereupon.

17. The method of claim 13, wherein the box assembly comprises:

a central bottom portion having a top surface, a bottom surface, a first central bottom portion side, a second central bottom portion side, a third central bottom portion side, and a fourth central bottom portion side;

a first side piece extending from the first central bottom portion side, the first side piece having a first side piece alternating flap and a second side piece alternating flap extending therefrom, wherein the first side piece alternating flap and the second side piece alternating flap extend from opposing sides of the first side piece and do not extend from the first central bottom portion side, the first side piece having a first top portion extending therefrom on a side of the first side piece opposing the first central bottom portion side;

a second side piece extending from the second central bottom portion side, the second side piece having a third side piece alternating flap and a fourth side piece alternating flap extending therefrom, wherein the third side piece alternating flap and the fourth side piece alternating flap extend from opposing sides of the second side piece and do not extend from the second central bottom portion side, the second side piece having extending therefrom a first pocket and a second pocket each extending from opposing sides of the second side piece and not extending from the second central bottom portion side;

a third side piece extending from the third central bottom portion side, the third side piece having a fifth side piece alternating flap and a sixth side piece alternating flap extending therefrom, wherein the fifth side piece alternating flap and the sixth side piece alternating flap extend from opposing sides of the third side piece and do not extend from the third central bottom portion side, the third side piece having a second top portion extending therefrom on a side of the third side piece opposing the third central bottom portion side; and

a fourth side piece extending from the fourth central bottom portion side, the fourth side piece having a seventh side piece alternating flap and an eighth side piece alternating flap extending therefrom, wherein the seventh side piece alternating flap and the eighth side piece alternating flap extend from opposing sides of the fourth side piece and do not extend from the fourth central bottom portion side, the fourth side piece having extending therefrom a third pocket and a fourth pocket each extending from opposing sides of the fourth side piece and not extending from the fourth central bottom portion side.

18. The method of claim 13, wherein the material is corrugated cardboard.

19. The box assembly of claim 10, wherein the first friction clamp lock tab, the second friction clamp lock tab, the third friction clamp lock tab, and the fourth friction clamp lock tab are employed for reuse of the apparatus subsequent an original assembly and use of the apparatus.

20. The method of claim 13, wherein assembly equipment employed to automatically assemble the box assembly comprises one or more of a folding apparatus, a creasing apparatus, laser cutting equipment, a laser engraving apparatus, a printing apparatus, and an adhesive application apparatus.