GB2441997A

GB2441997A - A mailing container formed from a blank

Info

Publication number: GB2441997A
Application number: GB0618497A
Authority: GB
Inventors: Ben Matthew Jarrett
Original assignee: Individual
Current assignee: Individual
Priority date: 2006-09-19
Filing date: 2006-09-19
Publication date: 2008-03-26
Anticipated expiration: 2026-09-19
Also published as: GB0618497D0; GB2441997B

Abstract

A mailing container in flat pack form formed from a blank comprises a base panel 108 and a securing flap 122 for securing the mailing container in a closed condition when the mailing container has been fully assembled around the product; the panel 108 and flap 122 extending from opposite ends of a wrap-around panel 110 via a first lateral fold line 106 and a lateral severable link 120. A pair of longitudinal edge strips 112 extend along opposed edges of the base panel and wrap-around panel and carry a pair of opposed side wall flaps 116 adjacent to the base panel, the side wall flaps being foldable to surround the product on respective opposed sides and parts of an upper surface of the product. The wrap-around panel is foldable over the product and securable to the base panel by means of the securing flap to close the mailing container. Longitudinal reinforced edge strips (115, Figure 3) can be formed by folding strips 112 inwardly about longitudinal fold lines 104 and securing such as by adhesive 109. The blank is T-shaped, a stem portion of the T-shaped blank providing the base panel and wrap-around panel, and arm portions of the T-shaped blank providing the side wall flaps.

Description

I

A MAILING CONTAINER

This invention relates to a mailing container, to a blank for making up into a mailing container and to a method of forming the mailing container Rackround of the Invention Various types of mailing containers for use in sending products such as musical and video disks and books through the post are known and these are typically formed of a cardboard material, often comigated cardboard, and comprise two or more panels and flaps that can be folded to enclose the product.

EP 0377375 (Chevalier) discloses a packaging design in the form of an L-shaped blank which can be cut, glued and folded to form a mailing container for books.

GB 2167043 (Sawley Packaging Company Limited) discloses a blank that can be formed into a variable depth container as a consequence of possessing multiple fold lines along various walls and flaps.

EP 0846070 (Chevalier) discloses a blank formed from cardboard that can be folded to give a container. * .

DE 20007888U (3 V GmbH) discloses the mailing container shown in Figure 1 * : herein and marketed under the trade name "Multiwell". The container has a base * panel 2, a wrap-around panel 4, a pair of side wall flaps 6, a securing flap 8 and pair of reinforced edge regions fonned by folding the edge strips 10 about fold lines 14 and then gluing the folded edge strips down. The side wall flaps 6 are formed from * a single panel which has a line of perforations to allow the two individual side wall flaps 6 to be separated. The individual side wall flaps 6 are hingedly attached to the base panel 2 along fold lines 15. In the commercial form of the "Multiwell" mailing container, the side wall flaps 6 are folded about fold lines 15 and glued in place on the base panel 2 by means of adhesive regions (not shown in Figure 1).

In order to use the mailing container of DE 20007888U, a product is placed on the base panel 2 and each side wall flap 6 is folded up and around the product, the additional fold lines 20 on each flap enabling it to be folded over so that it covers the sides and part of the upper surface of the product. The wrap-around panel 4 is then folded over the product and wrapped around the underside of the container and the adhesive strip on the securing flap is used to adhere the flap to the underside of the base panel and complete the package.

In order to open the package, the recipient of the package tears away the tear strip 22, thereby allowing the wrap-around panel 4 to be opened out for removal of the product.

Summary of the Invention

The present invention provides a mailing container in flat pack form that is similar in some respects to the container of DE 20007888U when fully assembled but which is formed from a significantly differently shaped blank and is manufactured differently. The differences in the shape of the blank give rise to substantial manufacturing advantages over the packaging container of DE 20007888U.

The mailing container of the present invention is formed from a T-shaped blank rather than a linear blank and, as described in more detail below, this minimises the number of tearing, folding and gluing steps required. This, in turn, means that manufacturing times can be shortened and the amount of glue and time spent in * folding are reduced. * e

Accordingly, in a first aspect, the invention provides a mailing container in flat **** pack form, the mailing container comprising: a base panel upon which a product can be placed; a wrap-around panel; the base panel being connected via a first lateral fold line to the wrap-around panel; a securing flap for securing the mailing container in a closed condition when the mailing container has been fully assembled around the product; the wrap-around panel being connected to the securing flap at an end remote from the base panel via a severable link; a pair of longitudinal reinforced edge strips extending along opposed edges of the base panel and wrap-around panel; a pair of opposed side wall flaps secured to the base panel, the side wall flaps being foldable to surround the product on two opposed sides and part of an upper surface of the product; the wrap-around panel being configured in use to be foldable over the product and securable to the base panel by means of the securing flap to close the mailing container; wherein the mailing container is formed from a blank having a first pair of longitudinal fold lines positioned such that the longitudinal reinforced edge strips can be formed by folding opposed edges of the blank inwardly about the longitudinal fold lines and securing the opposed edges in a folded configuration; characterised in that: the blank is T-shaped, a stem portion of the T-shaped blank providing the base panel and wrap-around panel, and arm portions of the T-shaped blank providing the side wall flaps; and in that the opposed side wall flaps are integrally formed with the longitudinal reinforced edge strips and are connected thereto via a second pair of longitudinal fold lines.

The mailing container is typically formed from a cardboard or plastics material that * provides sufficient rigidity when assembled to protect the product inside from * .*** * 1 damage but is capable of being folded. A preferred material from which the containers are formed is corrugated cardboard. In order to assist folding and minimise the number of additional fold lines required, the corrugations preferably extend laterally with respect to the stem portion of the T-shape.

The term cardboard as used herein includes cardboard per se and also laminated paper boards of the type typically commonly known as corrugated cardboard. Such laminated paper boards can be of a sandwich structure comprising outer layers (liners) of a non-corrugated paper and an inner sandwich layer of a corrugated (fluted) paper.

The securing flap is used to close the container and hold it closed when the container has been assembled around a product. The securing flap may be provided with an area of adhesive (e.g. in the form of a strip of adhesive) which is preferably protected prior to use by means of a removable cover strip, for example a cover strip formed from a silicone treated paper. Alternatively, the securing flap may be left blank and glue or an adhesive tape subsequently applied by the user to secure the flap in place.

In order to assist the securing flap to be folded under the base panel, a second lateral fold line may be provided on the wrap-around panel adjacent the severable link (e.g. tear strip) to the securing panel. The second lateral fold line is particularly beneficial when the mailing container is filled to its maximum extent.

The term "fold line" as used herein refers to a crease or score in the surface of a panel that is created during the manufacture of the mailing container rather than during its use. The fold lines are typically created using a suitably profiled cutting tool during the cutting of the blank.

The mailing container has a pair of longitudinal reinforced edge strips extending along opposed edges of the base panel and wrap-around panel. The reinforced edge strips are formed by folding over the edges of the container blank so as to give a double thickness strip running down each edge of the container blank. The reinforced edges serve as buffers and protect the contents of the container.

* * The reinforced edges also serve to hold the side wall flaps in place by providing a * ..* : barrier to movement of the flaps when the container has been assembled around a product.

The reinforced edge strips preferably extend continuously along each side of the wrap-around panel and the base panel but, as an alternative, there may be breaks in the reinforced strips along their lengths. For example, there may be breaks in the reinforcing strips between the base panel and the wrap-around panel. Alternatively, or additionally, a notch may be provided on each longitudinal reinforced edge strip to assist folding of the mailing container, the notch being aligned with the first lateral fold line.

The side wall flaps are preferably each provided with a plurality of fold lines and this assists the container to accommodate products of differing thicknesses. For example, there may be 2, 3,4, 5 or more fold lines on each side wall flap.

In order that the container can be opened easily by a recipient, a severable link is provided between the securing flap and the wrap- around panel. The severable link can take the form of one or more rows of perforations, skip cuts or "zipper rule" cuts. For example, the severable link can be a tear strip defined by two rows of perforations, skip cuts or zipper rule cuts. The term "zipper rule" cuts as used herein is used in its conventional context to denote a row of elongate cuts in which each cut has an angled portion at one end thereof. The angled section can be oriented to the left or to the right. A pair of oppositely angled zipper rule cuts with their angled portions oriented towards each other can form a tear strip.

In another aspect, the invention provides a blank for making up into a fiat pack * mailing container as hereinbefore defined. **

In a further aspect, the invention provides a mailing container as hereinbefore defined in partially or fully assembled form.

**** S. * S The invention also provides a method of manufacturing a mailing container as hereinbefore defined, which method comprises: I...

: : (a) cutting the T-shaped blank from a sheet of corrugated cardboard and : impressing thereon the lateral and longitudinal fold lines; and (b) applying a pair of glue lines to the blank so that they are positioned inwardly of the first longitudinal fold lines, folding the opposed edges of the blank inwardly about the longitudinal fold lines and compressing the folded edges against the glue lines to secure the opposed edges in a folded configuration.

In an optional step, during step (a), one or more lines of perforations or skip cuts are created between the securing flap and the wrap-around panel.

In a further optional step, an adhesive area can be created on the securing flap by applying adhesive thereto.

The mailing containers of the invention can be used to carry a variety of different types of product. Thus, for example, they can be used to carry individual CDs or DVDs or stacks of CDs or DVDs. They may also be used to carry books, pictures and other items of a generally flat fonn. They may be used to carry products of a more irregular fonn.

Brief Description of the Drawings

Figure 1 is a plan view of a mailing container blank of the type described in DE 20007888U.

Figure 2 is a plan view of a mailing container blank according to one embodiment of the invention.

Figure 3 is a scheme showing the sequence of folding and gluing steps starting from the blank of Figure 2 and progressing to the hilly assembled mailing container * 15 ready for mailing. * ***

I0** Figure 4 is a sectional view along line I-I in view 3H of Figure 3.

Detailed Description of the Invention

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The invention will now be illustrated but not limited by reference to the particular *.. : embodiment shown in Figures 2,3 and 4. S. * * S S

* 20 As shown in Figure 2, a mailing container according to one embodiment of the invention is formed from a T-shaped blank. In this embodiment, the blank is formed from corrugated board although other appropriate materials may be used.

The corrugated board is a sandwich material in which a layer of thick corrugated paper is bonded between two plain paper layers. The corrugations in the board are aligned laterally to assist folding of the blank.

The T-shaped blank has a pair of parallel longitudinal fold lines 104 and a first lateral fold line 106. The fold lines 104 and 106 divide the blank into a base panel 108, a wrap-around panel 110 and a pair of edge panels 112. Extending outwardly from edge panel 112 and delimited therefrom by means of fold lines 114 are side wall flaps 116. Each side wall flap 116 has a plurality of fold lines 118. A hole (not shown) is provided at the intersection between fold lines 104 and 106 on each side in order to assist folding of the blank.

Linked to the wrap-around panel 110 by means of a tear strip 120 is a securing flap 121 which is provided with a strip 122 of double sided adhesive tape bearing a rubber-based adhesive. The adhesive is protected by a silicone backed release strip which is removed during assembly of the mailing container. As an alternative to adhesive, the flap 121 can be left blank so that the user can apply glue or adhesive tape to secure the flap agarnst the base panel when assembling the container.

In order to assist folding when the container is filled to its maximum extent, a second lateral fold line (not shown) can be provided on the wrap-around panel 110 immediately adjacent the tear strip 120.

The blank shown in Figure 2 can be cut from a sheet of corrugated board using a cutting tool and the cutting tool is embossed so that the fold lines on the blank and * : the two rows of zipper rule cuts defining the tear strip 120 are created * :.: 20 simultaneously with the cutting step.

The method of assembly of the mailing container is illustrated schematically in Fi 3 in which stage 3A corresponds to the flat blank shown in Figure 2.

After the blank 3A has been formed, lines of glue 109 are applied to the blank just inside the fold line 104. The edge panels 112 on the flat blank are then folded along fold lines 104 and pressed down onto the glue lines to create double thickness reinforced edge strips or buffers 115. This gives the flat pack mailing container in form 3B which is the form in which it would typically be sold.

In order to use the mailing container, the side wall flaps 116 are lifted as shown in 3C to allow a product such as a stack of DVDs or a book to be positioned on the base panel 108. The side wall flaps 116 are then folded over the product so that they surround two sides and part of the top of the product as shown in 3D(except that the product has been omitted for clarity). The multiple fold lines 118 allow the side wall flaps to accommodate products of varying depths.

Once the product is in place and the side wall panels have been folded, the container is folded as shown in 3E, 3F, 3G and 3H and the adhesive tape on the securing flap used to adhere the securing flap to the underside (with respect to its original position) of the base panel 108. The mailing container is then ready for mailing.

The recipient of the mailing container can open the container by tearing out the tear strip 122 to release the wrap-around panel.

During transit, the reinforced edge strips 115 act as buffers and provide protection for the contents of the container. This is best illustrated by Figure 4 in which the product (e.g. a book or stack of DVDs) is indicated by means of the shaded area.

Figure 4 also illustrates the manner in which the reinforce edge strips 115 hold the side wall flaps firmly in place as a result of the inner edge 1 15a of the edge strip :::: 115 acting as a stop to prevent lateral movement of the folded corner 11 6a of the side wall flap * The mailing container of the invention is of simple construction and requires only a * 20 small number of manufacturing steps. It has advantages over the mailing container disclosed in DE 20007888U in that it requires a smaller number of folding *: * : operations and a smaller number of gluing operations thereby giving rise to savings in time and materials. In addition, because the side wall flaps are arranged in a T-shape and extend outwardly from the initially formed blank, there is greater scope for increasing or reducing the height of the side wall flaps than is the case with DE 20007888U where the size of the flaps is constrained by the width of the mailing container. In the mailing containers of the invention, the side wall flaps could be varied in height resulting in a corresponding variation in the size of the gap between the innermost edges of the flaps in the folded form 3B in Figure 3. Side wall flaps of greater height can be accommodated simply by overlapping the innermost edges in the folded form B, an advantage that is absent from the mailing containers of DE 20007888U.

Equivalents It will readily be apparent that numerous modifications and alterations may be made to the specific embodiments of the invention described above without departing from the principles underlying the invention. All such modifications and alterations are intended to be embraced by this application.

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Claims

1. A mailing container in flat pack form, the mailing container comprising: a base panel upon which a product can be placed; a wraparound panel; the base panel being connected via a first lateral fold line to the wrap-around panel; a securing flap for securing the mailing container in a closed condition when the mailing container has been fully assembled around the product; the wrap-around panel being connected to the securing flap at an end remote from the base panel via a severable link; a pair of longitudinal reinforced edge strips extending along opposed edges of the base panel and wrap-around panel; a pair of opposed side wall flaps secured to the base panel, the side wall flaps being foldable to surround the product on two opposed sides and part of an upper surface of the product; the wrap-around panel being configured in use to be foldable over the product and securable to the base panel by means of the securing flap to close the mailing container; **.* wherein the mailing container is formed from a blank having a first pair of longitudinal fold lines positioned such that the longitudinal reinforced edge ..ss* * strips can be formed by folding opposed edges of the blank inwardly about I.....

* the longitudinal fold lines and securing the opposed edges in a folded : configuration; **. : characterised in that: * ** the blank is T-shaped, a stem portion of the T-shaped blank providing the base panel and wrap-around panel, and arm portions of the T-shaped blank providing the side wall flaps; and in that the opposed side wall flaps are integrally formed with the longitudinal reinforced edge strips and are connected thereto via a second pair of longitudinal fold lines.

2. A mailing container according to claim I wherein the blank is formed from a corrugated board material which has corrugations extending laterally with respect to the stem portion of the T-shape.

3. A mailing container according to claim I or claim 2 wherein the securing flap is provided with an area of adhesive for securing the flap to the base panel.

4. A mailing container according to claim 3 wherein the area of adhesive is in the form of a strip.

5. A mailing container according to claim 3 or claim 4 wherein the area of adhesive is covered with a removable protective cover.

6. A mailing container according to any one of the preceding claims wherein the longitudinal reinforced edge strips are formed by folding opposed edges of the blank inwardly about the longitudinal fold lines and gluing the opposed edges in a folded configuration.

* 15

7. A mailing container according to any one of the preceding claims wherein *.

* the side wall flaps are each provided with a plurality of fold lines to accommodate products of differing thicknesses.

*

8. A mailing container according to any one of the preceding claims wherein * the severable link is defined by one or more rows of perforations, skip cuts orzipperrulecuts. S. I

* .

9. A mailing container according to claim 8 wherein the severable link is a tear strip defined by two rows of perforations, skip cuts or zipper rule cuts.

10. A mailing container according to any one of the preceding claims wherein the longitudinal reinforced edge strips extend continuously from the wrap-around panel to the base panel.

11. A mailing container according to claim 10 wherein a notch is provided on an outer surface of each longitudinal reinforced edge strip to assist folding of the mailing container, the notch being aligned with the first lateral fold line.

12. A mailing container substantially as described herein with reference to the accompanying drawings.

13. A blank for folding to form a mailing container as defined in any one of the preceding claims.

14. A method of manufacturing a mailing container according to any one of the preceding claims, which method comprises: (a) cutting the T-shaped blank from a sheet of corrugated board and impressing thereon the lateral and longitudinal fold lines; and (b) applying a pair of glue lines to the blank so that they are positioned inwardly of the first longitudinal fold lines, folding the opposed edges of the blank inwardly about the longitudinal fold lines and compressing the folded edges against the glue lines to secure the opposed edges in a folded configuration.

15. A method according to claim 14 in which, during step (a), one or more lines of perforations or skip cuts are created between the securing flap and the wrap-around panel. * *

16. A method according to claim 14 or claim 15 wherein an adhesive area is created on the securing flap by applying adhesive thereto, for example in the **** form of a double sided adhesive tape.