GB2558641A

GB2558641A - A box and corresponding blank with a variable dimension

Info

Publication number: GB2558641A
Application number: GB1700602.4A
Authority: GB
Inventors: Firth David; John Wells Kelvin
Original assignee: DS Smith Packaging Ltd
Current assignee: DS Smith Packaging Ltd
Priority date: 2017-01-13
Filing date: 2017-01-13
Publication date: 2018-07-18
Also published as: WO2018130842A1; GB201700602D0

Abstract

A box has an unused fold line 12 which, had it been folded, would have made the box a different size. A blank 10 used to form the box can have a set of four parallel fold lines 16 perpendicular to a set of six parallel fold lines 12, 14. The blank can be corrugated cardboard and flutes adjacent a fold line can be crushed. The blank can have further fold lines arranged at 45 degrees to other fold lines. There can be partial cut lines to form tabs to construct the box. There can be adhesive tape 26 provided on a separable portion to seal the box. After opening the separable portion can be detached via a tear strip 30 and further tape can seal the box in a different region. A guide having three perpendicular walls with markings on them can be provided to indicate which lines to fold along for certain sizes of box.

Description

(71) Applicant(s):

DS Smith Packaging Ltd (Incorporated in the United Kingdom) 350 Euston Road, LONDON, NW1 3AX, United Kingdom (72) Inventor(s):

David Firth Kelvin John Wells (56) Documents Cited:

GB 2221896 U1 EP 0097022 A1 US 9174761 B1

GB 0371751 A FR 002987824 A1 US 4938413 A (58) Field of Search:

INT CL B65D Other: WPI, EPODOC (74) Agent and/or Address for Service:

Marks & Clerk LLP

Long Acre, LONDON, WC2E 9RA, United Kingdom (54) Title of the Invention: A box and corresponding blank with a variable dimension Abstract Title: Adjustable dimension box and blank for forming it (57) A box has an unused fold line 12 which, had it been folded, would have made the box a different size. A blank 10 used to form the box can have a set of four parallel fold lines 16 perpendicular to a set of six parallel fold lines 12, 14. The blank can be corrugated cardboard and flutes adjacent a fold line can be crushed. The blank can have further fold lines arranged at 45 degrees to other fold lines. There can be partial cut lines to form tabs to construct the box. There can be adhesive tape 26 provided on a separable portion to seal the box. After opening the separable portion can be detached via a tear strip 30 and further tape can seal the box in a different region. A guide having three perpendicular walls with markings on them can be provided to indicate which lines to fold along for certain sizes of box.

This print incorporates corrections made under Section 117(1) of the Patents Act 1977.

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A box and corresponding blank with a variable dimension

The present invention relates to a box and a blank for forming a box, wherein a single blank can be used to produce boxes of different dimensions. Specifically, the blank is arranged such that a user can select a box size most suitable for the intended purpose and erect a box of that size using only a single blank.

Boxes are used to transport and store countless different types of goods around the world. Typically, a box used to store or transport goods needs to be large enough to contain the goods, but not so large that the goods move around within the box during transportation or that space is wasted unnecessarily. Given the range of items with which boxes are used, this requires a wide variety of shapes and sizes of box. This can be particularly problematic for industries heavily involved in the storage, sale and transportation of goods of various sizes and packing requirements. Traditionally, such industries use a large number of different blanks and boxes to meet their packaging requirements. This can be costly and complex.

It would therefore be desirable for a single blank to be able to be erected to form a range of size of boxes, or for a box of certain dimensions to be reconfigurable into a box with different dimensions.

It should be noted that any reference to any of a first dimension, second dimension or third dimension can relate to any of a height, width or length of a box.

According to a first aspect of the present invention there is disclosed a blank for folding to make a box; wherein the box, once in a folded configuration, has a first, second and third dimension;

the blank comprising fold lines for forming edges of the box between adjacent sides of the box;

wherein the blank comprises fold lines arranged to form a box with a first dimension of a first length and fold lines arranged to form a box with a first dimension of a second length different to the first length.

A blank may be in the form of a flat piece of material suitable for being folded to make a box. It is generally made of a corrugated material for strength and lightweightness.

A box typically comprises at least 5 sides - a bottom, a front, a back and two ends. The box may optionally additionally comprise a top. A side of the box is adjoined to its adjacent side by an edge, defined by a fold. These are cuboid boxes. The present invention may also be applicable for other box forms with opposing sides that can have variable lengths.

Generally, a blank will be arranged to define a plurality of panels, wherein the panel forms one of the sides of the box. The top of the box may, instead of being defined by a single panel, be defined by a plurality of flaps which overlap to a degree in order to allow the flaps to cooperate to define a top.

Unless it is clear from the context, no limitation should be applied to any of the embodiments described herein by reference to any of these sides of the box since, generally speaking, any of the sides of the box may be considered to be any one of the front, back, top, bottom or ends, depending on the orientation of the box.

Likewise, a box will generally be defined by its three dimensions - its length, width and height. In the present disclosure, these dimensions are not directionally identified. Instead we defined a first dimension, second dimension and third dimension. Any of the first, second and third dimension can be used to describe any of the length, width and height for a particular orientation thereof. As such, a feature defined with respect to the first dimension may apply to the length, width or height, albeit not more than one at the same time.

In order to more easily facilitate the folding of the blank, the blank will be cut to a certain shape - most commonly a cross or rectangle. Additionally, the blank will comprise a plurality of fold lines - most commonly perpendicular to the arms of the cross or parallel and/or perpendicular to the length of the rectangle. A fold line, as used in the present disclosure, refers to any feature of the blank which either indicates visually the location of a possible fold to a user, or more commonly a predefined crease or perforation, score or impression, partial or full (along the full extent or partial length of the line), that is for facilitating a more easy fold along the line of that crease or perforation etc. so as to achieve a predetermined fold position along that line. As such, the term fold line may encompass a scored line, a reduced material thickness, a prefolded line, small cuts at either end of the line, a perforation line or markings to indicate a possible location of a fold. As such, a fold line is not necessarily a line where there is a fold, but a line which provides a clear reference of a line about which the blank is to be folded, as opposed to a location without a fold line.

The blank of the present disclosure is arranged to be folded into a box having a first dimension of one of at least two different lengths, at the user’s discretion, or in line with a suggestion provided by a wrapping guide, relative to the product or products to be wrapped. As such, the blank comprises a first set of fold lines which can be used to form a box with a first dimension of a first length, and a second set of fold lines which can be used to form a box with a first dimension of a second length (it is possible here that some individual fold lines may belong to both the first set and second set, but not essential).

The blank may comprise fold lines arranged to form a box with a first dimension of a third different length. Accordingly, a user may be able to make a box of a third different length from the same blank. The blank thus may comprise fold lines to form a box of three different lengths in the first dimension.

We limit here to three, although a fourth or more different length might be desirable, if precise wrapping is desirable. Typically, however, two or three are the preferred number of possible first dimensions.

The blank may comprise fold lines arranged to form a box with a second dimension of a first length and fold lines arranged to form a box with a second dimension of a second length different to the first length. These first and second lengths may be, but generally are not, the same length as the first and second lengths of the first dimension. By being the same, square boxes are achievable, and rectangular too from the same blank.

The second dimension may also have more potential lengths, as with the first dimension, but preferably there are two options, or perhaps three, for the length of the second dimension.

The blank may be provided with one or two variable dimensions. Fold lines may thus be provided to form a box with at least two different lengths in a first dimension and at least two different lengths in a second dimension. As such, a single blank may be configured to provide at least four different box sizes.

The blank may even comprise fold lines arranged to form a box with a third selectable dimension - a further first length, and fold lines arranged to form a box with an alternative third dimension of a further second length different to the further first length.

The blank may thus provide three variable dimensions, i.e. fold lines may be provided to form a box with at least two different lengths in a first dimension, at least two different lengths in a second dimension and at least two different lengths in a third dimension, whereby a single blank may be configured to provide up to 8 different sizes, or perhaps with three third dimensions, up to 12 different box sizes.

Other permutations can also be accommodated by changing the number of options for the various length dimensions.

A preferred arrangement of blank may comprise a pair of first fold lines each arranged to form an edge between a first side and a common second side of the box, thereby defining a first dimension of the first length when folded.

Preferably this fold also locks a length of a second dimension of the box - in the common second side.

A blank may additionally comprise one, or a pair or more of, second fold line(s) arranged to form an alternative edge between its first side and the common second side of the box when folded.

Preferably this fold also locks a length of a second dimension of the box - again in the common second side - but with a different width.

The second fold line may be parallel to and spaced from the first fold line, the space causing a first dimension of a length different to the first length when that second fold line is folded instead of one of the first fold lines.

The blank may comprise a first plurality of parallel fold lines arranged to define a first dimension of a plurality of different lengths and a second plurality of parallel fold lines, arranged to define a second dimension of a plurality of different lengths.

The second plurality of parallel fold lines may be parallel to the first plurality of parallel fold lines, it this providing different first dimensions, or perpendicular thereto to then produce various different sizes of cuboid box.

The blank may comprise a plurality of different fold lines for defining a single edge (e.g. an edge between the panel forming the bottom of the box and the panel forming the front of the box). The use of these different fold lines results in different sizes of panel, and thus different sizes of the corresponding side of the box. As such, the blank comprises panels for forming sides of the box, wherein the sizes of the panel are variable.

A panel for forming a side of the box (e.g. the bottom) may have a plurality of fold lines at one of its edges, two of its edges, three of its edge or four of its edges. Necessarily, a plurality of fold lines for providing a variable first dimension of the box may result in a variable second dimension of the box due to the knock-on effect on an adjacent panel. For example, where a plurality of fold lines are provided between panels for forming the bottom and the front of the box, a first fold line may define a first width of the base and a second fold line may define a second width of the base. However, increasing the width of the base may result in less material for the panel forming the front of the box. As such, increasing the length of the first dimension (increasing the width of the base) may reduce the length of the second dimension (reducing the height of the front).

The above may be counteracted by adjustments being made to flaps arranged to form the top of the box. Flaps may be provided adjacent the front, back and both ends which cooperate to form the top of the box. The flaps may be arranged to have variable sizes, all of which are large enough to allow the flaps to cooperate to form the top. As such, the length of a second dimension may not be impacted by the selection of the length of the first dimension. An increase in the size of a first panel does not necessarily result in a corresponding reduction in size of a second panel - instead the second panel “shifts” and uses material of the blank which may otherwise have formed a flap for the top. The flaps are designed such that - even when the first, second and third dimensions are at their maximum lengths - they can cooperate to form the top of the box. This means, however, that when the first, second and third dimension are not at their maximum lengths, the flaps may present some additional overlap on the top side of the box, but they can wrap further around the box.

As described above, the blank may comprise a panel comprising a plurality of fold lines on one of its edges and a plurality of fold lines on the opposite edge. The blank may comprise a plurality of flaps arranged to cooperate to form a top of the box. A flap may be arranged adjacent a panel arranged to form the front, back, or either end of the box. The flap may comprise a plurality of fold lines to define a plurality of lengths of flap. The flaps may be configured to cooperate to form a top of the box when the flap is at its maximum length and its minimum length.

The blank may comprise two parallel fold lines arranged to be folded in opposite directions to form a Z-fold, thereby reducing the length of the first dimension of the box when folded flat. Such a fold may be locked with the previously mentioned first or second fold pairs. This can be extended to other walls. Therefore, instead of having a plurality of fold lines, all of which are arranged for forming an edge of the box, a plurality of the fold lines may be arranged to fold in opposite directions to form a Z-fold, or flattened concertina arrangement, either to an edge or in a central area of a final box’s panel. The fold lines arranged to form a Z-fold may thus be arranged away from an edge of a panel of the blank, or near them, and may be used to reduce the length of a dimension of the box compared to the non-Z-folded length - i.e. when in a folded arrangement, the Z-fold contracts the length of a dimension of the box by creating an area of the box with a triple layer of blank.

The blank may comprise a second pair of parallel fold lines arranged to be folded in opposite directions to form a second Z-fold.

The second pair of parallel fold lines may be parallel to the first pair of parallel fold lines and may be separated from the first pair of parallel fold lines by a fold line arranged to form an edge of the box between a first side and a second side of the box. Thereby, the second pair of parallel fold lines may be arranged to reduce the length of the second dimension of the box, whereas the other may reduce the length of a first or third dimension of the box.

The second pair of parallel fold lines may be perpendicular to the first pair of parallel fold lines, whereby the second pair of parallel fold lines may be arranged to reduce the length of the third (or second) dimension of the box.

The set of parallel fold lines arranged to form a Z-fold may be arranged to extend across three sides of the box once in a folded configuration - it thus potentially being across a base and two sides, or an end and two sides.

The blank may be made from any material suitable for folding to make a box. The blank may comprise or be made from cardboard, for example corrugated cardboard or a different corrugate.

Wi a corrugate, the corrugations may be aligned with the fold lines arranged to define a first dimension of a first length, or arranged perpendicular to the fold lines arranged to define a first dimension of a first length. Preferably they run parallel to at least one set of fold lines as it is easier to fold along a corrugation than across them. For folding across them, deep creases on an inside of a fold, or partial perforations in an inside of a fold, may be preferred to substantially cut or crush the waveform of the corrugations along the fold line, but to leave an outer surface of the fold non-perforated or noncreased.

An area adjacent the parallel fold lines arranged to form a Z-fold may have a reduced thickness compared to the rest of the blank. As such, the area between the two fold lines arranged to form a Z-fold may be flattened, or have otherwise a reduced thickness compared to the rest of the blank. This assists with the flat folding of the Zfold with a resultant wall thickness no longer being 3x the thickness of the non-flattened material. The area either side of the two fold lines arranged to form a Z-fold may also or instead be flattened or have a reduced thickness compared to the rest of the blank to improve upon or replace that effect. The whole area of the blank arranged to form the Z-fold is preferably flattened, or has a reduced thickness compared to the rest of the blank, so that the final thickness of the Z-folded fold, with its three layers, is no thicker than double the thickness of the unfastened material.

In particular, the fold lines of a blank may comprise partial cut lines. The partial cut lines may be perforations, or deep scoring or lines which are designed to be torn or cut when erecting the box. The partial cut lines may be arranged to define, in combination with the fold lines, tabs. Tabs may be arranged adjacent the panels that are arranged to form a side of the box, the tabs being for aiding in erection and fixation/securement of the box in the folded/erected state. The tabs may be arranged to, when in a folded configuration, be perpendicular to the side to which they are attached, in order to fit abutting, and inside, an adjacent side. This can help the box maintain its shape.

The tab may be arranged to be the same length as a side of the box. Given that tabs may extend along the entire edge of a panel arranged to form a side of the box, the blank may comprise partial cut lines, cut lines and/or fold lines arranged to define a tab of a first length in the first dimension and a length different to the first length in the first dimension. As such, the blank may comprise partial cut lines, arranged to define tabs of a length corresponding to the available lengths for the first dimension.

The blank may comprise partial cut lines to define, in combination with the fold lines, a tab of the first length and partial cut lines to define, in combination with the fold lines, a tab of a length different to the first length, wherein when in a folded configuration the tab is integral with a side of the box to aid in securing the side to an adjacent side of the box.

The blank may comprise panels arranged to form tabs for aiding in erection of the box, wherein, when in a folded configuration, a tab is integral with a side of the box to aid in securing or locating the side with respect to an adjacent side of the box.

The blank may comprise partial cut lines arranged to form, in combination with the fold lines, a first tab for use with a box with a first dimension of a first length; and partial cut lines arranged to form, in combination with the fold lines, a second tab for use with a box with a first dimension of a length different to the first length; wherein the first tab and second tab have different dimensions.

The blank may comprise a substantially rectangular panel arranged to form a side of the box and two adjacent tabs.

The rectangular panel may be connected to the rest of the blank by a first fold line.

The panel may comprise: a first portion arranged to form the side of the box; and two tab portions, one on either side of the first portion, arranged to form tabs which are perpendicular to the side of the box when in the folded configuration.

The length of the first portion perpendicular to the first fold line may define the first length of the first dimension of the box and a second fold line extending through the first portion and both tab portions, parallel to the first fold line, may define a first dimension of a different length to the first length.

The two tab portions may have a further fold line arranged at 45 degrees to and intersecting the second fold line such that the tab portions can be arranged perpendicularly to the first portion when the panel is folded along the second fold line.

The blank may comprise a rectangular panel arranged to form a side of the box, the rectangular panel connected to an adjacent panel along a central section of its length, such that two tab portions, at either end of the panel are only connected to the rest of the blank via the first, central, portion.

The first, central, portion may be arranged to form an end of the box and the two tab portions may be arranged to form tabs for the end of the box.

The rectangular panel may comprise fold lines such that both the first portion and the two tab portions may selectively define a first dimension of a first length and a length other than the first length.

The rectangular panel may have a longitudinal fold line along its length, extending through the first and both tab portions.

Each of the two tab portions may comprise a fold line arranged at 45 degrees to the longitudinal fold line, extending from the intersection of the longitudinal fold line with the boundary between the first portion and the tab portion, to the edge of the tab portion.

The fold lines of the rectangular portion may be arranged such that, when the longitudinal fold line and two diagonal fold lines are used, the rectangular panel defines an end of the box and two perpendicular tabs, all connected to a mutually perpendicular flap arranged to form part of the top of the box.

In the above embodiment, the rectangular portion is substantially folded along its length, except for triangular portions defined by the diagonal line, which are folded back on themselves to form a triangular part of triple thickness.

Angles other than 45 degrees will be appropriate for non-perpendicular corners.

The blank may further comprise adhesive tape arranged to seal the box when in a folded configuration.

The adhesive tape may be attached on one side to a panel of the blank.

The adhesive tape may be arranged at an end portion of a flap arranged to form the top of the box, so as to, in use, be stuck to a further flap arranged to form the top of the box, or a side of the box.

The adhesive tape may comprise a strip of adhesive tape along one edge of a panel, e.g. arranged to form a flap.

The blank may comprise a tear strip arranged to, once used, separate the part of the blank with the adhesive tape from the rest of the blank. The tear strip may be arranged towards an edge of a panel so that, once used, a strip of panel on which the adhesive tape is arranged is separated from the rest of the blank. The tear strip may then be used to unseal the box after it has been sealed using the adhesive tape.

The blank may comprise a further adhesive tape arranged to seal the box when in a folded configuration, after the tear strip has been used. The further adhesive tape may be arranged to reseal the box after it has been opened.

The further adhesive tape may be arranged on the same panel as the first adhesive tape, or on a different panel to the first adhesive tape.

Adhesive tape as used with the blank may comprise a double sided tape which, as part of the manufacturing of the blank, is attached on one side to the blank.

The blank may comprise a plurality of panels arranged to, when in a folded configuration, form each of a bottom, front, back and two ends of the box.

Each panel arranged to form an end of the box is connected to the rest of the blank by respective first fold lines.

Each panel arranged to form an end of the box comprises a first portion arranged to form the end of the box; and two tab portions, one on either side of the first portion, arranged to form tabs which are perpendicular to the end of the box when in the folded configuration; wherein the length of the first portion perpendicular to the first fold line defines the first length of the first dimension of the box and a second fold line extending through the first portion and both tab portions, parallel to the first fold line, defines the first dimension length which is different to the first length; and wherein each of the two tab portions have a further fold line arranged at 45 degrees to, and intersecting, the second fold line such that the tab portions can be arranged perpendicularly to the first portion when the panel arranged to form an end of the box is folded along the second fold line.

The blank may comprise two parallel fold lines on each of the panels arranged to form the front and back of the box, the two parallel fold lines arranged to define a first dimension of the first length and a first dimension of a length different to the first length; and a pair of parallel fold lines extending through the panels arranged to form the base, front and back of the box, the pair of parallel fold lines arranged to be folded in opposite directions to form a Z-fold, thereby selectively reducing the length of the second dimension of the box.

The blank may also comprise panels arranged to form flaps to cooperate to form a top of the box.

Another blank may comprise a plurality of panels arranged to, when in a folded configuration, define each of a bottom, front, back and two ends of the box; wherein the blank comprises: a first plurality of parallel fold lines on each of the panels arranged to form the front, back and both ends, the first plurality of parallel fold lines arranged to define a first dimension of a plurality of different lengths; a second plurality of parallel fold lines on each of the panels arranged to form the front, back and base, the second plurality of parallel fold lines arranged to define a second dimension of a plurality of different lengths; a pair of parallel fold lines extending through the panels arranged to form the base and both ends, the pair of parallel fold lines arranged to be folded in opposite directions to form a Z-fold, thereby selectively reducing the length of the third dimension of the box.

The blank may comprise panels arranged to form tabs, located adjacent to the panels arranged to form the front and back of the box, wherein the blank comprises: partial cut lines arranged to form, in combination with the fold lines, a first tab for use with a box with a first dimension of a first length; and partial cut lines arranged to form, in combination with the fold lines, a second tab for use with a box with a first dimension of a length different to the first length; wherein the first tab and second tab have different dimensions.

The partial cut lines may be arranged to define a first tab of the first length, and a first tab of the length different to the first length.

Another blank may comprise a first flap panel arranged to be a first flap and a second flap panel arranged to be a second flap, wherein the first flap and the second flap are arranged to cooperate to form a top of the box when in a folded configuration; wherein the first flap panel comprises a first adhesive tape arranged to seal the box when in a folded configuration; the first flap panel additionally comprises a tear strip arranged to, once used, separate the part of the first flap panel with the adhesive tape from the rest of the blank; and one of the first flap panel and the second flap panel comprises a second adhesive tape arranged to seal the box when in a folded configuration; wherein the blank is arranged such that the box can be sealed using the first adhesive tape, unsealed by using the tear strip and then resealed using the second adhesive tape.

A preferred blank comprises four sections: a first section at a first end of the blank, comprising a panel arranged to, when in the folded configuration, define a first end of the box; a second section adjacent the first section, comprising a panel arranged to, when in the folded configuration, define a front of the box; a third section adjacent the second section, comprising a panel arranged to, when in the folded configuration, define a second end of the box; and a fourth section adjacent the third section and at a second end of the blank, comprising a panel arranged to, when in the folded configuration, define a back of the box; wherein each of the first, second, third and fourth sections comprises a top flap and a bottom flap; wherein the top and bottoms flaps are arranged to cooperate to form, when in a folded configuration, a top and bottom of the box, respectively; and each of the first, second, third and fourth sections comprises a pair of parallel fold lines extending through the top flap, bottom flap and respective side of the box, the pair of parallel fold lines arranged to be folded in opposite directions to form a Z-fold, thereby selectively reducing the length of a dimension of the box.

According to a further embodiment of the invention is a box made from a blank as described anywhere herein. It will have at least 5 sides, each formed from the blank and one or more fold.

The present invention also provides a method of forming a box using a blank as previously disclosed and folding it a previously described to result in a predetermined size.

In general, any features described with respect to a blank apply equally to a box and the method. As such, embodiments relating to a blank of the present invention may equally apply to a box according to an embodiment of the present invention and a method of the present invention. Disclosure relating to fold lines of a blank can, when construed in relation to a box, be interpreted as either folds, or unused fold lines, as if the fold lines are used they become folds, but if they aren’t they are referred to herein as unused fold lines. In practice, unused fold lines may be scores, perforations or markings on a side of the box, and will preferably be on an inside face of the box.

A box according to an aspect of the present invention may have a first dimension of a first length. The box may comprise an unused fold line, or a plurality of unused fold lines for forming an edge or a plurality of edges of the box, wherein the unused fold lines are arranged to form a box with a first dimension of a length different to the first length.

The box may have a second dimension of a second length. The box may comprise an unused fold line or unused fold lines arranged to form a box with a second dimension of a length different to the second length.

The box may have a third dimension of a third length, the box may comprise an unused fold line or unused fold lines arranged to form a box with a third dimension of a length different to the third length.

The unused fold lines may be arranged parallel to an edge of the box defining the first, second or third dimension.

The box may comprise two unused fold lines which are parallel and arranged to be folded in opposite directions to form a Z-fold.

The box may comprise a second set of two unused fold lines which are parallel and arranged to be folded in opposite directions to form a Z-fold.

A first set of unused fold lines arranged to form a Z-fold may be arranged parallel or perpendicular to a second set of unused fold lines arranged to form a Z-fold.

The box may comprise a Z-fold in at least one of its sides.

The box may comprise a Z-fold extending around three of its sides.

The box may comprise a second Z-fold intersecting a first Z-fold.

The box may comprise corrugated card and an area adjacent the parallel fold lines arranged to form a Z-fold may have a reduced thickness compared to the rest of the box.

The box may comprise, or be made out of, any material suitable for making a box, e.g. a corrugate - plastic or paper/cardboard, but preferably corrugated cardboard.

The box may comprise adhesive tape arranged to seal the box.

The box may comprise a tear strip arranged to, once used, unseal the box.

The box may comprise a further adhesive tape arranged to seal the box after the tear strip has been used.

The box may comprise a first flap comprising a first adhesive tape arranged to seal the box; the first flap additionally comprising a tear strip arranged to, once used, separate the adhesive tape from the rest of the first flap; and a second flap comprising a second adhesive tape arranged to seal the box once the tear strip has been used.

According to a further aspect of the present invention is a guide for use with a blank as described anywhere herein, wherein the guide comprises three mutually perpendicular surfaces arranged to form a corner, and a marking on the inside of at least one of the surfaces arranged to correspond to the first dimension of the first length of the blank. It can also have lines corresponding to any of the other dimensions to allow appropriate fold lines to be chosen upon folding the blank for forming the desired box size.

The guide may thus be used in order to determine which size of box is most suitable to the task at hand, and which blank (if many blanks are available) or which fold lines thereof, can provide the required size of box.

The guide may comprise a marking on the inside of at least one of the surfaces arranged to correspond to the first dimension of a length different to the first length.

At least one of the surfaces of the guide comprises a shaded area arranged to indicate a maximum size box which can be made from the blank.

The guide may comprise a series of markings depicting the possible dimension of a box which can be made with a, or one of many, blanks. A user may place an item to be packed inside the guide and observe which of the markings (which may be in the form of a line or a shaded area) is closest to, but not too small for, the specific item. The markings may be accompanied by text, images or symbols which indicated which specific fold lines of the blank should be used to arrive at the desired size of box.

Preferably the guide has three walls, each with parallel lines thereon, one of which being an upright wall having horizontal and vertical lines, a second being a second upright wall having further horizontal and vertical lines and a base wall having lines perpendicular to the vertical lines of at least one of the upright walls.

The guide may also be provided in combination with a blank has defined above. Preferably the horizontal and vertical parallel lines are spaced apart by a corresponding distance to the fold lines of the blank.

According to a further embodiment of the present invention is a workstation for use with a blank as described anywhere herein, the workstation comprising: a guide as described anywhere herein, for determining which folds to use; a rotatable platform for supporting and rotating a blank or box; and a sliding support jig arranged adjacent the rotatable platform for abutting an edge or side of a box or blank.

The rotatable platform allows reorientation of a box between folds.

The sliding support jig - preferably two thereof - allows support to be provided to the sides of the folded blank for holding folds in position during the erection of the box.

The guide can be used by the operator by presenting the article(s) to be contained within the box therein and reading off the markings or lines on the guide as to which blank or box, or fold line on the blank or box, is appropriate - in other words and erected box just larger than the article(s) to be contained within the box.

The workstation may comprise a conveyor configured to transfer items to the workstation and/or transfer boxed items away from the workstation.

An assembly line may comprise multiple workstations located along the conveyor.

These and other features of the present invention will now be described in greater detail, purely by way of example, with reference to the accompanying drawings, in which:

Figure 1 is a schematic perspective view of a blank according to a first embodiment of the invention;

Figure 2 is a perspective view of a box made from the blank of figure 1;

Figure 3 is a perspective view of a different box made from the blank of figure 1;

Figure 4 is a more detailed view of a blank according to the present invention, showing sample dimensions and possible cuts, fold lines, tape, perforations and partial cut lines, purely as examples;

Figure 5 is a view of a different blank according to the present invention, again with possible dimensions and details;

Figure 6 is a view of another different blank according to the present invention, again with possible dimensions and details;

Figure 7 is a view of another different blank according to the present invention, again with possible dimensions and details;

Figures 8A to 8C schematically illustrate methods of folding a blank similar to the embodiments of figures 1 and 4 to 7, in each case to achieve different lengths;

Figures 9A to 9C schematically illustrate methods of folding a blank similar to the embodiments of figures 1 and 4 to 7, in each case to achieve different heights;

Figure 10 illustrates a method of folding a similar blank to achieve a different width to the unfolded width;

Figure 11 is a schematic to illustrate a sample blank for forming a dimensions guide for use with the blank of the preceding figures - when determining the folds to use;

Figure 12 is a view of a workstation beside a conveyor belt for use when packing products into a box formed with the blank of at least figures 1 and 4 to 7;

Figures 13A to 13G illustrate a method for opening a box made from the blank of, for example, figure 1 or 4 to 7;

Figures 14A to 14G illustrate a method for resealing a box made from the blank of figure 1 or 4 to 7;

Figure 15 is a view of 4 boxes formed from a blank in accordance with a further aspect of the present invention;

Figure 16 is a schematic view of a blank for making the boxes of figure 15;

Figure 17 is a partial schematic perspective view of a partially folded version of the blank of figure 16 during the assembly of the box of figure 15 - the central section can be seen to have been z-folded, and the angled fold line can be seen to be being folded under the blank for forming a shortened side height;

Figure 18 is a perspective view of a box according to a further aspect of the present invention;

Figure 19 is a perspective view of another box according to a further aspect of the present invention;

Figure 20 is a perspective view of the box of figure 19 in a partially folded state; and

Figure 21 is a view of a blank for making the box of figures 18 to 20, showing dimensions and compressed areas, purely as examples.

Referring first to figure 1, a blank 10 for making a box is shown in a flat configuration. The blank 10 comprises a plurality of fold lines 12, 14, 16. The blank 10 also comprises panels for forming each side of the box, that is: a bottom 18, front 20, back 22 and two ends 24 of the box. Although certain shapes are shown, as will be noted below, the exact boundaries and hence the extent of these panels is arranged to vary according to a user’s requirements - larger, smaller, taller, shorter, etc.

Flaps are defined adjacent the front 20, back 22 and both end 24 panels for cooperating to form the top of the box; additionally, various tabs are defined at the edges of certain sides of the box, in order to aid in alignment and fixation of the panels when the box is being erected.

The blank 10 also comprises a first adhesive tape 26 and a second adhesive tape 28 for sealing and resealing the box, respectively, as well as a tear strip 30, for unsealing the box. The blank 10 also comprises adhesive tape 32 for use during the process of erecting the box.

Generally speaking, fold lines 12 extending through the panels forming the bottom 18 and both ends 24 of the box allow a box with a plurality of different widths to be produced from the blank 10; fold lines 14 extending through the panels forming the front 20 and back 22 allow a box with a plurality of different heights to be produced from the blank 10; and fold lines 16 extending through the panels forming the bottom 18, front 20 and back 22 allow a box with a plurality of different lengths to be produced from the blank 10. It should be noted that the above is a generalisation and, as will be described later, further fold lines may be required in other panels in order to fully fold a box with certain dimensions. For example, in addition to the fold lines 14 extending through the panels forming the front 20 and back 22 for providing different heights, fold lines in the panels forming the ends 24 should also be provided to provide corresponding varying heights.

Figure 2 illustrates a box made from the blank 10 of figure 1. Figure 3 illustrates a smaller box made from the same blank 10, as illustrated in figure 1. Figures 2 and 3 illustrate how different sized boxes can be made by utilising different fold lines of the blank 10.

Figure 4 is a blank similar to the embodiment of figure 1. Figure 4 illustrates which lines are fold lines, cuts and partial cut lines, as well as where adhesive tape is located.

Figure 4 also illustrates exemplary dimensions for the box.

Figure 5 is a plan view of another blank similar to the embodiment of figure 1.

The blank of figure 5 has a total size of 753mm x 650mm and may be made from cardboard or plastic, and preferably a corrugate with the flutes extending along the long axis of the blank. In a preferred embodiment the fluting is of an R-Flute® form.

The blank of figure 5 includes 1 tear strip, for example formed with Rippa Tape®; two strips of 24mm corrugator adhesive tape; and two lots of 15mm corrugator adhesive tape.

The blank of figure 5 can be folded to form boxes of a range of different sizes, as illustrated in table 1. To reduce the width from 200mm to 150mm, the fold lines 12 extending through the bottom panel 18 and both end panels 24 are folded in opposite directions (i.e. one away from the viewer and one towards the viewer) to form a Z-fold. This is referred to as a concertina in table 1. The fold lines 12 forming the Z-fold are either folded along their entire length, or unfolded along their entire length.

llillllllllllllllll	Uogth	Width	H&ifM
		lllllllll!	000	150	0000
		lllllllll	ooo	100	0000
			ooo	SO	\| 3000
		lllllllll	ooo	1111111111	/300
		200	ooo	iiiiiii	5000
		3:20013313:	200	lllllllll	:1:0001111111111111
		lllllllll	200	I:1O:®\|\|::\|	4000
	300	130.................	11111111	3230..............................
		lllllllll	130	11111111	::111111111111111
		2:10	1:50	lllllllll	3023
		lllllllll	ISO	1:00011111	::111111111111111
		lllllllll	ISO	lllllllll	14300
		11I011I1I	ISO	llllllli	sooo

Table 1 - range of possible box sizes which can be made from the blank of figure 5.

In order to illustrate how the use of different fold lines can result in the provision of 20 boxes of different sizes, the fold lines which must be used between the panels for forming the bottom 18, front 20, back 22, and both ends 24 for producing a box of dimensions 300mm x 200mm x 150mm are labelled with reference 34 and for producing a box of dimensions 250mm x 150mm x100 mm are labelled with reference

36. Note that in figure 5 fold lines for use to form tabs for aiding in erection and fixation of the box are not labelled, and multiple reference labels may be applied to what, in practice, is a single fold line, for clarity.

The blank according to the embodiment of figure 1 also comprises a number of partial cut lines. These are lines which are partially cut and which can either be torn to be a fully cut line, or can be left and used as a fold line, in each case depending on the size of the box required. For example, in figure 5, for a box measuring 300mm x 200mm x 150mm, partial cut lines which need to be torn to form a fully cut line are labelled 34A.

The tables do not necessarily show all possible combinations.

The shaded area extending through the bottom 18 and both end 24 panels is highlighted as it is preferred to be a flattened region, where the corrugated card from which the blank has been formed has a reduced thickness, perhaps through a rolling process - usually performed after the sheet exits a corrugator, e.g. in a piece of equipment downstream thereof in a factory. This flattening can prevent a Z-fold from creating an area in a panel of the box with an awkward thickness - i.e. three times that of the rest of the box. The flattened region involves two strips that overlie one another when Z-folded, and thus present perhaps an overall thickness of about 2 (uncompressed) sheet thicknesses.

Figure 6 illustrates a larger embodiment of the blank-type of figure 1. The size of the blank of figure 6 is 1129mm x 975mm and it may be made from the same materials as that of figure 5. Some of the possible sizes of box that can be made from this blank are illustrated in table 2.

(mm)		WHth	Height
Medium iMsmtt	553505555555555:	llllllllll!	225	lllllllllllllllll
	450	lllllllll!	lllllllll	lllllllllllllllll
	lllllllll	llllllllll	IIIIIIIIIIIIIIIIIIIIIIII	lllllllllllll!!!!!!
	lllllllll	lllllllll!	111111111111	lllllllllllllllll
	325	300	130	1502.5
	300	300	225	20250
	lllllllll	llllllllll	llllllllll!	llllllllll
	llllllllll	53330553555/	IIIBIIIIIIIl	IIIIIBIIIIIIIIIIIIIIIIIII
	lOOOllillll	225	11111111111	llllllllll!!
	lllllllll	lllllllllllllllll	llllllllll	lllllllllllllllll
	llllllllll!	llll'!i:!^!lllllllll!ll	llllllllll	5:11111!!!!!!!!!:
	llllllllll	llllllllll	iiiiiiiiiii!	lllllllllllllllll
	lllllllll	llllllllll M<<<<<<<<<<<<<<<<<<<<<<<<<<<<<A	150	lllllllllllllllll ................................................

Table 2 - range of possible box sizes which can be made from the blank of figure 6.

In Figure 6, the outline and fold lines used to create a box of 300mm x 225mm x 5 225mm are outlined in heavier lines and dashed lines, respectively.

Figure 7 illustrates an even larger embodiment of the blank of figure 1. The size of the blank in figure 7 is 1505mm x 1300mm and it again may be made out of the same material as the blank of figure 5. Some of the possible sizes of box that can be made from the blank of figure 7 are illustrated in table 3.

(msm)	length	WHtb
BUnk	llllllllll	4-00	000	22000
	iiiiiiiiii	llllllll	200	lllllillllllllllll
	111111111	21102222	llllllllll!!	llllllllllllllllll
	llllllllll	llllllll	llllllllll
	lllllllll/ll		llllllllllllllllll	1111111111111
	leiiiii!)	400	300	llllllllllllllllll
	400	400	\| 200	20000
with	soo	300	000	TOXOOOsssssssssssss
	iiiiiiiiii	llllllll	\| 200	C;2XOOC2CCCCCCCCi\|C
	1111111111	llllllllll	llllllllllllllllllll	llllllllllllllllll
	liiiiiii!)	llllllll!
		llllllll	lllllllllll	lllllljjjjjjjjjjl!
	llllllllll	300	200

Table 3 - range of possible box sizes which can be made from the blank of figure 7.

In Figure 7, the outline and fold lines used to create a box of 600mm x 400mm x

100mm are outlined in heavier lines and dashed lines, respectively.

The partially cut lines in these embodiments can be used to provide flexibility when forming tabs attached to the edges of the front 20, back 22 and top panels. A partially cut line may also be used as a full cut or a fold depending on the size of box required (and hence the set of fold lines used).

In figures 6 and 7, flaps 46 can be seen adjacent the front 20, back 22 and size 24 panels. The flaps 46 cooperate to form a top when in a folded arrangement. Additionally in figures 6 and 7, tabs 44 can be seen. Tabs 44 are included on blanks for boxes to aid in erection of the box and to help to keep the box in a folded configuration. Generally, tabs 44 are folded perpendicular to the panel to which they are attached, and are arranged to lie parallel and abutting the inside of a second panel when the box is in a folded configuration.

In figure 7, the partially cut lines which have been torn or cut to become full cuts for forming tabs 44 are labelled 40. The partially cut lines which have been left as partially cut and have been used as fold lines are labelled 42.

Figures 8A, 8B and 8C illustrate how a single blank according to figure 1 can be cut and folded to produce three difference lengths. In figure 8A, the length of the doubleheaded arrow is desired, so four of the partial cut lines must be fully cut, as illustrated in the figure. In figure 8B, a slightly increased length is required, and so a different fold line is used and only two partial cut lines must be cut, as illustrated. In figure 8C the largest length is required so a further different fold line is used and no partial cut lines are cut.

The pairs of numbers 1,2 and 3 illustrated on the figures relate to pairs of fold lines to be used (i.e. for the smallest length, both fold lines labelled 1 are used, for a medium length, both fold lines labelled 2 are used, for the largest length, both fold lines labelled 3 are used).

Figures 9A, 9B and 9C illustrate which fold lines are used for selecting certain heights of box. As with figures 8A to 8C, the numbers 1, 2 and 3 represent the smallest, medium and largest possible dimensions, respectively.

Figure 10 illustrates how the width of a box can be selected by using the two fold lines 12 to form a Z-fold across the bottom 18 and both end 24 panels.

Figure 11 depicts a blank for a dimensions guide 48 for use with a blank or box according to the embodiment of figure 1. Once folded, the guide 48 forms three mutually perpendicular surfaces 58 into which items to be packed can be placed. Items to be put in a box can thus be put in the assembled guide to determine which size box is required: A plurality of differently-shaded areas 52, 54, 56, on the inside surfaces 58 of the guide 48 indicate to a user whether a small, medium or large blank is required; A series of guidelines 50 located on the inside of the guide 48 indicate also which size of box is required, and the numbers of the lines to fold, and thus informs a user which of the fold lines of the blank must be used when folding the blank.

There can be colour coding for the different blank sizes.

In use, a user places an item to be packed in a box into the assembled guide 48, and ensures it is abutting all three internal surfaces 58 of the guide 48 (i.e. that it is located in the corner of the guide 48). A user then observes where the item extends on the internal surfaces 58 of the guide 48. Firstly, the user determines whether the item fits within the shaded area for the small or medium blank, or if a large blank is required. Then the user observes which of the guidelines 50 marked on the internal surfaces 58 of the blank 48 is closest to, but larger than, the item. This indicates which fold lines should be used to fold to make the box.

The appropriate folds from Figures 8 to 10, for example, can thus then be made for a first fold, and the remaining fold lines will follow suit as the box is folded around the item(s) to be packed. Of course, any cutting of required partially cut lines should also be undertaken before those lines are concealed.

Figure 12 shows a workstation 52 for use with a blank according to figure 1. The workstation 52 comprises a table 54 on which there is a guide 48 as described with reference to figure 11; packing instructions 56 for informing a user on how to erect the box and pack an item; a rotatable platform 58 - which may be in the form of a rotatable table top - on which a blank, box or item can be sat and rotated to facilitate easy folding of the blank/box; and two support jigs 60 which are arranged to slide towards and away from the rotatable platform 58 to provide a flat surface against which a side of the box can rest.

On one side of the table 54 is a blank storage area 62 where new, unfolded blanks can be stored. On the other side of the table 54 is a conveyor 64 comprising a moving track. Items to be packed can be put on the conveyor 64 to be transported to the workstation 52; and packed items 66 can be put on the conveyor 64 to be taken away from the workstation 52.

The conveyor can link multiple workstations.

In use, a user will be provided with an item to be packed, which they will put in the guide to determine which size blank is required and which fold lines should be used, as described above. A user will then select a blank from the blank storage area 62 and review the packing instructions 56, as or if necessary. The blank then will be put on the rotatable platform 58 - extending lengthwise across the desk (or over the jigs 60) and any required partial cut lines will be torn or cut to form fully cut lines, if required, for forming appropriately sized first flaps. The user then begins to fold the blank, initially folding up the long sides using the selected fold lines, to form the box (but having first folded the z- fold in the base if needed). The item can be placed inside the partially formed box and the support jigs 60 can be slid into position either side of this arrangement, so that their inner surfaces abut outside surfaces of the folded sides (ends) of the blank. This prevents the sides of the partially-folded box from unfolding while the user folds the released flaps, as appropriate, around the front and back of the item. The other forward and backward extending side flaps (extending transversely of the long length of the blank) can then be folded up and over the item to form a further layer on the side and then an inner top, whereafter the rest of the longitudinal length of the sides can then be folded on top of them. Finally any remaining side flaps can then be folded downward over the front and back of the resultant box.

During these folding steps, any fold may lock a previously made Z-fold - i.e. one that extends across the line of that fold, if such a z-fold has been made.

Adhesive tape, either formed as part of the blank, or added externally, may be used in order to secure the final flaps of the box in their folded arrangement.

Once the box is fully formed and sealed (taped), it is put on the conveyor 64 to be taken to the next stage of delivery or storage.

Figures 13A to 13G next illustrate an opening process for a box formed from a blank similar to that of figure 1. This is almost a reverse of the previously described steps.

In figures 13A and 13B a user cuts the tape that was applied to the external of the box to unseal the final flaps. A tear strip 30 that extends between those flaps at a top surface of the illustrated arrangement in the folded box, which strip 30 is also shown in the blank of figure 4, and which is preferably formed as a part of the blank, is then used to separate the two ends of the long side panels of the blank to allow them to fold outwardly from the now top of the box. This leaves the first adhesive tape 26 (which is also formed as part of the blank) on one of these flaps for later resealing of the box, if needed (discussed further below). See figures 13C to 13E for this opening process, and 13F for the tape remaining on the far flap.

The unfolding of these panels/flaps reveal further flaps forming the top of the box, which can then be opened to expose the contents of the box, as illustrated in figures 13F and 13G.

Turning now to figures 14A to 14G, a process for resealing a box made from the blank of figure 1 is shown.

The resealing process may be used as part of a returns procedure if, once the box is opened, the user then decides to return the item using the same box.

In figure 14A, the user folds in the flaps attached to the two end 24 panels of the box. In figures 14B and 14C, the user removes a protective covering from the second strip of adhesive tape 28. A user can then fold in the remaining flaps to form the top of the box, using the second adhesive tape 28 to seal the top of the box, as illustrated in figures 14D and 14E. It should be noted that the second adhesive tape 28 is attached to the opposite flap to the first adhesive tape 26. As such, if the first adhesive tape 26 and the tear strip 30 are attached to a flap adjacent the front 20 of the box, the second adhesive tape 28 is attached to the back 22 of the box. This, however, may not be the case in all embodiments according to the invention - in some embodiments the second adhesive tape 26, used to reseal a box after opening, may be located on the same flap or tab as the first adhesive tape, separated by the tear strip.

Finally, in figures 14F and 14G, the user folds down the final edge portions of the flaps and secures them with further pieces of adhesive tape.

Referring next to Figure 15 there is shown four different boxes made from a blank according to a further embodiment of the present invention. All four boxes have been produced from the same blank.

Figure 16 shows a blank 70 for forming the boxes illustrated in figure 15. The blank 70 can be made of corrugated card. In this embodiment the corrugations align as shown in the small triangle 72 - transverse the long axis of the blank. This is helpful for the central folds as they extend parallel to the flutes.

The blank 70 comprises panels for forming a bottom 74, front 76, back 78 and two ends 80 and flaps for cooperating to form a top 82 of the box.

The blank 70 has fold lines for folding to define edges of the box, connecting adjacent panels.

The blank 70 of figure 16 has additional fold lines such that it can produce a box of two different lengths and of two different heights.

Fold lines 84 extend through the panels forming the bottom 74, front 76 and back 78 of the box and the flaps arranged to cooperate to form the top 82 of the box. These fold lines 84 are arranged perpendicular to the flutes. The fold lines 84 are arranged such that they can be folded in opposite directions to form a Z-fold, similar to the fold lines 12 of the blank of figure 1. The fold lines 84 allow boxes with two different lengths to be made from the blank 70, a longer length when the fold lines 84 are not used, and box with a reduced length when the fold lines 84 are used to form a Z-fold. As they extend parallel to the flutes, they fold more easily and with a tighter radius than if folded against the grain.

The shaded area 90 represents a portion of the surface of the blank 70 which will have a reduced thickness compared to the rest of the blank 70. This, in the case of corrugated materials, will be achieved by crushing that part of the blank 70. This is to ensure that, when fold lines 84 are used to form a Z-fold, the folded area is not of a triple thickness.

Fold lines 86 extending along the panels arranged to form the front 76 and back 78 of the box are arranged so that the blank can form a box with a front 76 and back 78 of two different heights. A first set of fold lines 86a are used when the larger height is required and a second set of fold lines 86b are used when the smaller height is required. Naturally, the heights of the two ends 80 must also be modified to correspond to that of the front 76 and back 78 and so fold lines 88 are arranged to allow ends 80 of two different heights to be provided. A first set of fold lines 88a are used when a large height is required and a second set of fold lines 88b are used in addition to the first set of fold lines 88a, when the small height is required.

Looking now at the panels arranged to form ends 80 of the box, it can be seen that the rectangular panels comprises three portions: a first portion 80a connected by a fold line to the bottom 74 panel, arranged in the centre of the panel and arranged to form the end 80 of the box; and two tab portions 80b, one on either side of the first portion. These tab portions 80b are arranged to form tabs which, when the blank is in a folded configuration, are arranged to be perpendicular to the end 80 of the box and to aid in erecting the box.

When the panels arranged to form ends 80 of the box are folded to have the largest height available only the first set of fold lines 88a are used such that first portion 80a and two tab portions 80b are unfolded, but are separated by fold lines.

When the panels arranged to form ends 80 of the box are folded to have the smaller height, fold lines 88b are additionally used. These include for each side of the box a horizontal line and an angled line - usually 45 degrees to the horizontal line. The horizontal fold lines 88b in the two tab portions 80b (herein parallel to the flutes) are folded up out of the plane of the page (as viewed in figure 17) and the angled fold line 88b is folded downwards therefrom and round past the horizontal line as the rest of the end of the blank lifts upwards. These then are both pushed against the sides of the box. The method of folding the end panels 80 can be seen more clearly in figure 17, which shows a partially folded blank 70.

Figures 18 to 21 show a third form of the present invention. Figure 18 shows a box made from the blank 100 of figure 21. The box of figure 18 is the largest box that can be made with the blank 100 of figure 21.

Figure 19 shows a box made from the blank 100 of figure 21. The box of figure 19 has a reduced length, caused by the use of a Z-fold, as seen in figure 19.

Figure 20 depicts the blank in a partially folded state, with the Z-fold visible.

Figure 21 shows the blank 100 for forming these boxes. It comprises substantially four sections: a first section 102 comprising a panel arranged to form a first end 103 of the box; a second section 104 comprising a panel arranged to form a front 105 of the box; a third section 106 comprising a panel arranged to form a second end 107 of the box; and a fourth section 108 comprising a panel arranged to form a back 109 of the box. Each section also comprises a top flap 110a, 110b, 110c, 110d arranged to cooperate to form, when in a folded configuration, a top side of the box. Each of the sections also comprises a bottom flap 112a, 112b, 112c, 112d arranged to cooperate to form, when in a folded configuration, a bottom of the box.

Each of the sections of the blank 100 of figure 21 comprises a set of fold lines 114a, 114b, 114c, 114d which are arranged to be folded in opposite directions to form a Zfold. In each section, the sets of fold lines 114a, 114b, 114c, 114d are arranged to extend through the top flap, centre panel (i.e. front, back or end) and bottom flap. The sections and fold lines are arranged such that the sets of fold lines 114a, 114c extending through the first and third section are arranged to allow a box of two different lengths to be made from the blank 100; and the fold lines 114b, 114d extending through the second and fourth section are arranged to allow a box of two different widths to be made from the blank 100.

The present invention therefore provides various forms of blank, and various forms of fold line to allow a single blank to form multiple box sizes and multiple box shapes herein all cuboid. Adding extra panels to the blanks can enable additional sides to be accommodated and likewise fewer panels can produce triangular or flat boxes especially easy with the third embodiment of Figure 21. The present invention further relates to the boxes formed therewith and the methods of folding these blanks to form the boxes, and the use of the guide or workstation for this purpose.

Where used herein, to seal a box is not to hermetically seal it, but is instead just to hold the box closed, as in taping it up. Likewise to unseal it is not to break a hermetic seal, but us instead just to release the tape or closure for allowing the box to be opened.

The present invention has been described above purely by way of example. Modifications in detail may be made to the present invention within the scope of the claims as appended hereto.

Claims

CLAIMS:

1. A blank for folding to make a box; wherein the box, once in a folded configuration, has first, second and third dimensions, the blank comprising fold lines for forming edges of the box between adjacent sides of the box, wherein the blank comprises fold lines arranged to form the box in a first configuration with the first dimension of a first length and further fold lines arranged to form the box with a different configuration with the first dimension of a length different to the first length.

2. A blank according to claim 1, further comprising fold lines arranged to form the box in a different configuration, with the first dimension of yet a further different length.

3. A blank according to any preceding claim, comprising fold lines arranged to form the box with the second dimension of a length referred to as the second length and fold lines arranged to form the box in a different configuration, with the second dimension having a length different to the second length.

4. A blank according to claim 3, the blank comprising fold lines arranged to form the box with the third dimension of a length referred to as the third length and additional fold lines arranged to form an alternative box configuration with the third dimension of a length different to the third length.

5. A blank according to any of the preceding claims, comprising a pair of first fold lines each arranged to form an edge between a first side and a second side of the box, thereby defining a first dimension of the first length; and one or more second fold line arranged to form an edge between the first side and the second side of the box; wherein the second fold line is parallel to and spaced from the first fold line, thereby defining for the first dimension a length different to the first length.

6. A blank according to any of the preceding claims, comprising a first plurality of parallel fold lines arranged to provide the first dimension with a selection of different lengths and a second plurality of parallel fold lines, arranged to provide the second dimension with a selection of different lengths.

7. A blank according to claim 6, wherein the second plurality of parallel fold lines are perpendicular to the first plurality of parallel fold lines.

8. A blank according to any of the preceding claims, comprising two parallel fold lines arranged to be folded in opposite directions to form a Z-fold, thereby reducing the length of the first dimension of the box.

9. A blank according to claim 8, comprising a second pair of parallel fold lines arranged to be folded in opposite directions to form a second Z-fold.

10. A blank according to claim 9, wherein the second pair of parallel fold lines are parallel to the first pair of parallel fold lines and are separated from the first pair of parallel fold lines by a fold line arranged to form an edge of the box between a first side and a second side of the box, wherein the second pair of parallel fold lines are arranged to reduce the length of the second dimension of the box.

11. A blank according to claim 9, wherein the second pair of parallel fold lines are perpendicular to the first pair of parallel fold lines and are separated from the first pair of parallel fold lines by a fold line arranged to form an edge of the box between a first side and a second side of the box, wherein the second pair of parallel fold lines are arranged to reduce the length of the third dimension of the box.

12. A blank according to any of claims 8 to 11, wherein at least one set of parallel fold lines arranged to form a Z-fold are arranged to extend across three sides of the box once the box is in an assembled configuration.

13. A blank according to any of claims 8 to 12, wherein the blank is made from corrugate and an area adjacent the parallel fold lines arranged to form a Z-fold has a crushed fluting.

14. A blank according to any of the preceding claims comprising panels arranged to form tabs for aiding in erection of the box; wherein, when in a folded configuration, a tab is integral with a side of the box to aid in locating the side with respect to an adjacent side of the box; wherein the blank comprises:

partial cut lines arranged to form, in combination with the fold lines, a first tab for use with a box with a first dimension of a first length; and partial cut lines arranged to form, in combination with the fold lines, a second tab for use with a box with a first dimension of a length different to the first length; and the first tab and second tab have different dimensions.

15. A blank according to any of the preceding claims comprising corrugated cardboard.

16. A blank according to any preceding claim, the blank comprising a substantially rectangular panel arranged to form a side of the box and two adjacent tabs; wherein the rectangular panel is connected to the rest of the blank by a first fold line; the panel comprising:

a first portion arranged to form the side of the box; and two tab portions, one on either side of the first portion, arranged to form tabs which are perpendicular to the side of the box when in the folded configuration;

wherein the length of the first portion perpendicular to the first fold line defines the first length of the first dimension of the box and a second fold line extending through the first portion and both tab portions, parallel to the first fold line, defines a first dimension of a different length to the first length; and the two tab portions have a further fold line arranged at 45 degrees to and intersecting the second fold line such that the tab portions can be arranged perpendicularly to the first portion when the panel is folded along the second fold line.

17. A blank according to any preceding claim comprising adhesive tape arranged to seal the box when in a folded configuration.

18. A blank according to claim 17, comprising a tear strip arranged to, once used, separate the part of the blank with the adhesive tape from the rest of the blank.

19. A blank according to claim 18, comprising a further adhesive tape arranged to re-seal the box when in a folded configuration, after the tear strip has been used.

20. A blank according to claim 1, comprising a plurality of panels arranged to, when in a folded configuration, form each of a bottom, front, back and two ends of the box; wherein:

each panel arranged to form an end of the box is connected to the rest of the blank by a first fold line;

each panel arranged to form an end of the box comprises a first portion arranged to form the end of the box, and two tab portions, one on either side of the first portion, arranged to form tabs which are perpendicular to the end of the box when in the folded configuration;

the length of the first portion perpendicular to the first fold line defines the first length of the first dimension of the box and a second fold line extending through the first portion and both tab portions, parallel to the first fold line, defines the first dimension length which is different to the first length;

each of the two tab portions have a further fold line arranged at 45 degrees to, and intersecting, the second fold line such that the tab portions can be arranged perpendicularly to the first portion when the panel arranged to form an end of the box is folded along the second fold line; and the blank further comprises:

two parallel fold lines on each of the panels arranged to form the front and back of the box, the two parallel fold lines arranged to define a first dimension of the first length and a first dimension of a length different to the first length; and a pair of parallel fold lines extending through the panels arranged to form the base, front and back of the box, the pair of parallel fold lines arranged to be folded in opposite directions to form a Z-fold, thereby selectively reducing the length of the second dimension of the box.

21. A blank according to any of the preceding claims, comprising a plurality of panels arranged to, when in a folded configuration, define each of a bottom, front, back and two ends of the box; wherein the blank comprises:

a first plurality of parallel fold lines on each of the panels arranged to form the front, back and both ends, the first plurality of parallel fold lines arranged to define the first dimension of a plurality of different lengths;

a second plurality of parallel fold lines on each of the panels arranged to form the front, back and base, the second plurality of parallel fold lines arranged to define the second dimension of a plurality of different lengths;

a pair of parallel fold lines extending through the panels arranged to form the base and both ends, the pair of parallel fold lines arranged to be folded in opposite directions to form a Z-fold, thereby selectively reducing the length of the third dimension of the box.

22. A blank according to claim 21, comprising panels arranged to form tabs, located adjacent to the panels arranged to form the front and back of the box, wherein the blank comprises:

partial cut lines arranged to form, in combination with the fold lines, a first tab for use with a box with a first dimension of a first length; and partial cut lines arranged to form, in combination with the fold lines, a second tab for use with a box with a first dimension of a length different to the first length;

wherein the first tab and second tab have different dimensions.

23. A blank according to claim 21 or claim 22, comprising a first flap panel arranged to be a first flap and a second flap panel arranged to be a second flap, wherein the first flap and the second flap are arranged to cooperate to form a top of the box when in a folded configuration; wherein the first flap panel comprises a first adhesive tape arranged to seal the box when in a folded configuration;

the first flap panel additionally comprises a tear strip arranged to, once used, separate the part of the first flap panel with the adhesive tape from the rest of the blank; and one of the first flap panel and the second flap panel comprises a second adhesive tape arranged to seal the box when in a folded configuration; and the blank is arranged such that the box can be sealed using the first adhesive tape, unsealed by using the tear strip and then resealed using the second adhesive tape.

24. A blank according to claim 1 comprising four sections:

a first section at a first end of the blank, comprising a panel arranged to, when in the folded configuration, define a first end of the box;

a second section adjacent the first section, comprising a panel arranged to, when in the folded configuration, define a front of the box;

a third section adjacent the second section, comprising a panel arranged to, when in the folded configuration, define a second end of the box; and a fourth section adjacent the third section and at a second end of the blank, comprising a panel arranged to, when in the folded configuration, define a back of the box; wherein each of the first, second, third and fourth sections comprises a top flap and a bottom flap; wherein the top and bottoms flaps are arranged to cooperate to form, when in a folded configuration, a top and bottom of the box, respectively; and each of the first, second, third and fourth sections comprises a pair of parallel fold lines extending through the top flap, bottom flap and respective side of the box, the pair of parallel fold lines arranged to be folded in opposite directions to form a Z-fold, thereby being able to selectively reduce the length of the first, second and third dimensions of the box.

25. A box made from a blank according to any of the preceding claims.

26. A box having a first dimension of a first length; the box comprising an unused fold line for forming an edge of the box in a different box configuration, wherein the unused fold line is arranged to form the box in a configuration with the first dimension of a length different to the first length.

27. A box according to claim 26, wherein the box has a second dimension of a second length, the box comprising an unused fold line arranged to form the box in a different configuration with the second dimension being of a length different to the second length.

28. A box according to claim 27, wherein the box has a third dimension of a third length, the box comprising an unused fold line arranged to form the box in a different configuration with the third dimension being of a length different to the third length.

29. A box according to any of claims 26 to 28, comprising two unused fold lines which are parallel and arranged to be folded in opposite directions to form a Z-fold.

30. A box according to claim 29, comprising a second set of two unused fold lines which are parallel and arranged to be folded in opposite directions to form a Z-fold.

31. A box according to any of claims 26 to 30, comprising a Z-fold in at least one of its sides bridging across an edge of the box.

32. A box according to claim 31, comprising a Z-fold extending around three of its sides, and thus across two of its edges.

33. A box according to any of claims 29 to 32, wherein the box comprises a corrugate and an area adjacent the parallel fold lines arranged to form a Z-fold has a reduced thickness compared to the uncompressed areas of the box to permit the z-fold to have a thinner form from its three layer thick arrangement than three full thicknesses of the uncompressed corrugate.

34. A box according to any of claims 26 to 32, mad substantially of corrugated cardboard.

35. A box according to any preceding claim comprising adhesive tape arranged to hold the box closed.

36. A box according to claim 35 comprising a tear strip arranged to, once used, release the box for opening.

37. A box according to claim 36, comprising a further adhesive tape pre-applied thereto and arranged to reseal the box after the tear strip has been used.

38. A box according to any of claims 26 to 36 comprising a first flap comprising a first adhesive tape arranged to seal the box; the first flap additionally comprising a tear strip arranged to, once used, separate the adhesive tape from the rest of the first flap; and a second flap comprising a second adhesive tape arranged to reseal the box once the tear strip has been used.

39. A combination of at least one blank according to any of claims 1 to 24 and a guide, wherein the guide comprises guide comprising three mutually perpendicular surfaces arranged to form a corner, and a marking on the inside of at least one of the surfaces arranged to correspond to the first dimension of the first length of the blank.

40. A combination according to claim 39, wherein the guide comprises a marking on the inside of at least one of the surfaces arranged to correspond to the first dimension of a length different to the first length.

41. A combination according to claim 39 or claim 40, wherein at least one of the surfaces comprises a shaded area arranged to indicate a maximum size box which can be made from the blank.

42. A guide comprising three mutually perpendicular walls, all arranged to form a corner effect for receiving an item to be packaged, each wall having parallel lines thereon, one of which being an upright wall having horizontal and vertical lines, a second being a second upright wall having further horizontal and vertical lines and a base wall having lines perpendicular to the vertical lines of at least one of the upright walls.

43. The guide of claim 42, wherein guide is formed from a blank and the corner is cut-out to avoid material bunching in the corner.

44. The guide of claim 42 or claim 43, provided for a predetermined blank in accordance with any one of claims 1 to 24, wherein the horizontal and vertical parallel lines are spaced apart by a corresponding distance to the fold lines of the blank.

45. A workstation for use with at least one size of blank according to any of claims 1 to 24, the workstation comprising:

a guide according to any of claims 39 to 44, for determining which folds to use on the blank;

a rotatable platform for supporting and rotating the blank during packing of an item within a box formed from the blank; and at least one sliding support jig arranged adjacent the rotatable platform for abutting a folded panel of the blank.

46. A workstation according to claim 45, further comprising a conveyor configured to transfer items to the workstation and/or transfer boxed items away from the workstation.

47. A method of using the workstation of claim 45 or claim 46, wherein the rotatable platform is rotated with the blank between certain folds carried out over different pairs of sides of the box being assembled.

5

48. A method of assembling a box from a blank in accordance with any of claims 1 to 24, using a combination or guide of any of claims 39 to 44, comprising presenting an article to be contained within the box within the guide and reading off from the markings or lines on the guide as to which blank or box, or fold lines on the blank or box, is or are appropriate and erected the box just larger than the article to be contained within the

10 box by folding the blank along those determined lines.

49. An assembly line comprising multiple workstations according to claim 45 or claim 46, located along a conveyor.

Intellectual

Property

Office

Application No: GB 1700602.4 Examiner: Mr Joe Cornfield