US 3027060 A
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Description (OCR text may contain errors)
March 27, 1962 s. L. BEDER BOX CONSTRUCTION 2 Sheets-Sheet 2 Filed Feb. 26, 1960 FIG.3
INVENTOR. Samuel L. Beder Alma-W ATTORNEY United States atent 3,027,060 BOX CONSTRUCTION Samuel L. Beder, Riverdale, N.Y., assignor to Toymaster Products Co., Inc., Garfield, N.J., a corporation Filed Feb. 26, 196i), Ser. No. 11,244 1 Claim. (131. 229-116) This invention relates generally to a box construction and method of making the same, and more specifically to an open end, reinforced cardboard box and method of making the same.
An object of this invention is to provide a sturdily constructed box which is open at one end and a method of making the same in a relatively simple and inexpensive manner utilizing a minimum number of components and operational steps.
Another object is to provide for making a reinforced, open end box of double wall thickness which is particularly adapted for use as an amusement for children.
A feature of this invention resides in the provision that the reinforced box is formed primarily of only two component parts, and a covering of ornamental wrap.
The various features of novelty which characterize the invention are pointed out with particularity in the claims annexedto and forming a part of this specification. For a better understanding of the invention, its operating advantages and specific objects attained by its use, reference should be had to the accompanying drawings and descriptive matter in which there is illustrated and described a preferred embodiment of the invention.
In the drawings:
FIG. 1 is a plan view illustrating the inner surface of blank for forming the box in accordance with this invention.
FIG. 2 illustrates the outer surface of said blank with an ornamented wrap sheet glued thereto.
FIG. 3 illustrates the inner surface of the blank of FIG. 2, depicting an intermediate step of the box forming operation wherein the continuous flap overlies the centerfold of the blank.
FIG. 4 illustrates the arrangement of FIG. 3 folded along the transverse fold lines to define a four sided figure, with the bottom piece, shown in part, in position to square the sides of the box.
FIG. 5 is a detail view of the bottom piece.
FIG. 6 illustrates a perspective view of the box in almost complete form, having parts thereof broken away.
- FIG. 7 illustrates a perspective view of a nested set of boxes made in accordance with this invention.
FIG. 8 is a schematic view of a roller press to facilitate gluing of the outer wrap to the blank.
Referring to the drawings, the open end box in accordance with this invention is constructed principally from a blank 10 which is arranged to be folded in a predetermined fashion to form a reinforced, four-sided box closed at the bottom. An ornamental wrap or sheet is glued to the side panels of the box to give it an attractive appearance. In the particular instance the ornamented wrap is illustrated with art work that is appealing to small children. Preferably, the boxes in accordance with this invention are made in various sizes so that they may be nested one within the other to form a set of giant blocks to be utilized for the particular amusement of children.
Referring to FIG. 1, the blank 10, formed preferably in a die cutting machine, is formed of a sturdy cardboard material, e.g. a corrugated cardboard. As shown, the blank 10 is substantially rectangular in shape and is provided with a pair of longitudinally extending fold lines 11 and 12 to define a centerfold 13 and connected flaps 14, 15. In accordance with the illustrated embodiment flap 14 is continuous and it adjoins the lower edge of the centerfold 13 along fold line 12. A plurality of slotted perforations 16 spaced at substantially equal intervals and extending normal to the fold line 12, divide the continuous flap 14. into four panels 14A, 14B, 14C and 14D. Fold line 17 extends transversely of the centerfold 13 and divides it into four panels 13A, 13B, 13C and 13D, which have a width substantially equal to the panels 14A-D of the continuous flap 14. Connected to each of the centerfold panels 13A, B, C and D along fold line 11 are distinct flaps 15A, 15B, 15C and 15D, respectively. It is to be noted that fold line 11 has segments 11A and 11C which are spaced slightly above segments 11B and 11D thereof. Thus fold segments 11A, 11B, 11C and 11D faclitate alternate folding of opposed pairs of flaps 15A, 15B, 15C and 15D as will be hereinafter described.
Connected to one end of the centerfold 13 is an end flap 18. In accordance with this invention the outer surface of the continuous flap 14 is coated with a suitable dye or ink, to give it a solid color, such as blue, or other suitable color. As will be hereinafter described, this colored surface of the flap 14 will form the inside visible surface of the box. The outer surface of the box will comprise an ornamental wrap sheet 19 which circumscribes the four sides of the box, and a bottom wrap 29 to cover the bottom of the box. Thus in accordance with this invention the box is formed essentially of blank 10 folded to form the four sides of the box, a bottom piece 21 reinforced by flap 15, and ornamental wrap sheets 19 and 20.
The method of constructing the box and folding of the blank 10 in accordance with this invention is as follows:
The wrap sheet 19 which comprises a strip of paper printed on one side with attractive design, is coated on the other side thereof with a layer of glue. This wrap sheet 19 is sufficiently long to extend the length of the centerfold portion 13 of the blank 10. With the wrap sheet 19 coated with glue, it is placed in a suitable jig with the printed surface down. The die cut corrugated blank 10 is next placed in the jig on top of the wrap sheet 19 with the continuous flap 14 downward as viewed in FIG. 1. In this position the printed or colored surface of the continuous flap 14 is face down. The blank It is positioned on the wrap 19 in a manner so that the longitudinal edge of the wrap 19 overlies the fold lines 11 and 12 about inch as viewed in FIG. 2, one end of the wrap 19 coincides with the fold line 22 of the end flap 13 and the other end 19A of the wrap 19 extends beyond the opposite end of the centerfold about inch.
Pressure is then applied to adhere the wrap sheet 19 to the die cut blank 10. This is attained by passing the blank 10 and connected wrap sheet 19 through a roller press 23. As shown in FIG. 8, the blank 10 and connected wrap sheet 19 are passed through rollers 23A and 23B with the blank 10 presented to the rollers along its longitudinal edge with the wrap 19 down. As shown, the upper roller 23A is somewhat shorter than that of the lower roller 23B. This is done to prevent the glue on the overhang portion 19A of the wrap sheet 19 from. contacting any part of the upper roller 23A.
The blank 10 and attached wrap sheet 19 are then picked up manually by an operator and run through an edge gluer to coat the inside surface of the four panels or distinct flaps 15A, 15B, 15C and 15D with glue. The blank 10 is then turned over and the outer surface of end flap 18 is coated with glue.
The blank 10 and connected wrap 19 are now laid on a table with the printed side of the continuous flap 14 down. The continuous flap 14 is then folded to overlie the centerfold portion 13 of the blank 10. In this position, as shown in FIG. 3, the color side of the continuous flap 14 is now in position to form the inner surface of the box.
The next operation is for the operator to fold the blank 10, as viewed in FIG. 3, inwardly along each of the transverse fold lines 17 to form a four-sided box, as seen in FIG. 4. The slotted opening 16 of the continuous flap 14 facilitates this operation. In this position the boX so formed is rested on a 45 jig (a wood form) and the end flap 18 inserted between the inside panel 14A and the corresponding centerfold portion or panel 13A. The end flap 13, previously coated with glue, is secured in position therebetween. The overhang 19A of the printed sheet 19 is then folded down onto that wrap portion covering panel 13A to finish the juncture corner.
The box is then taken off the 45 jig and placed by the operator on a mandrel which has substantially the inside dimension of the box. In the specific instance the mandrel is square. The operator then takes the bottom piece 21, which in this case is a square, as illustrated in FIG. 5, and places it in the box. Preferably one side of the bottom piece 21 is coated or printed with the same color ink as that of the continuous flap 14. The operator places the bottom piece within the box with its colored side down. In this position the bottom piece 21 rests on the edge of the inturned continuous flap 14 and aids to keep the walls of the box squared.
With the box in this form the next step resides in bending inwardly the two opposed flaps 15B'and 15D so that the glue coated surface thereof is brought to rest on the bottom piece 21 and adheres thereto. The other two opposed flaps 15A and 15C are next folded so that their glue coated surfaces rest on the outer side of closed flaps 15B and 15D. With the flaps down as seen in FIG. 6, a compressive force is applied to the bottom, the force being maintained until the glued flaps 15 are set. The glue applied is of a type which requires no external heat and will set by pressure alone.
After the bottom flaps 15 have been set, the box is removed from the mandrel. The bottom wrap 20 is then passed through a suitable gluing machine so that the under side thereof is coated with glue. The bottom wrap 20 is then placed over the top of flaps 15A and 15C, the wrap being sized so that its opposed edges 20A overlie the raw edges of the box. Thus the overhang portion 20A may be folded downwardly to finish off the opposite sides of the box. This completes the making of the box.
In accordance with this invention the box described may be made in various sizes adapted to nest in one another as viewed in FIG. 7, to form a set of blocks. It is to be further noted that the boxes formed in accordance with this invention constitute in fact a dobule wall box which gives it the rigidity and sturdiness necessary to withstand the abuse of children and the box is sufiiciently strong to withstand the weight of a relatively large child, e.g. an average four year old.
While in accordance with the provisions of the statutes there is illustrated and described herein the best form and mode of operation of the invention now known to the inventor, those skilled in the art will understand that changes may be made in the form of the apparatus disclosed without departing from the spirit of the invention covered by the claims, and that certain features of the invention may sometimes be used to advantage without a corresponding use of other features.
What is claimed is:
A toy double walled play-box having an open end and a closed reinforced bottom end comprising;
(a) a cardboard blank including a centerfold having longitudinal edges and a plurality of spaced transversely extending foldlines to define a plurality of side panels disposed in side by side relationship,
(1)) a decorative wrap sheet secured to the outer side of said centerfold,
(c) a continuous flap connected along a longitudinal edge of said centerfold,
(:1) said continuous fiap having a spaced transversely extending slotted foldlines to define a plurality of panels corresponding to the side panels defined by the foldlines of said centerfold, said slotted foldlines of the continuous flap being disposed in alignment with the transverse foldlines of said centerfold,
(e) said continuous flap being reversely folded degrees so as to overlap onto the inner surface of said centerfold,
(1) said continuous flap being proportioned with respect to the centerfold so that in the folded position thereof the longitudinal end of said continuous flap falls short of the longitudinal edge of said centerfold opposite the foldline between the centerfold and the connected continuous flap,
(g) an end flap connected to one end of said centerfold,
(h) said centerfold and connected reversely folded continuous flap being bent along the corresponding transverse foldlines of said centerfold and continuous flap to define a closed figure,
(i) said end flap securing the ends of said closed figure at the junction thereof,
(j) a separate and distinct bottom piece seated on the edge of said reversely bent flap within the periphery of said closed figure as defined by the centerfold,
(k) a distinct flap connected to each side panel of said centerfold,
(l) opposed pairs of said distinct flaps being alternately folded onto said bottom piece to close the bottom end of the box, and
(m) a bottom decorative wrap sheet secured to the closed bottom of the box.
References Cited in the file of this patent UNITED STATES PATENTS 850,490 Price Apr. 16, 1907 1,602,702 Pinkerton Oct. 12, 1926 1,845,456 Wagner Feb. 16, 1932 1,997,909 Luce Apr. 16, 1935 2,110,782 Weber Mar. 8, 1938 2,220,388 Beaman et al. Nov. 5, 1940 2,237,706 Islieb Apr. 8, 1941 2,718,348 Montfort Sept. 20, 1955