IMPROVEMENTS IN AND RELATING TO SHEET COVERED BOXES

Field of the invention

The present invention relates to improvements in sheet covered boxes and more particularly related to blanks, boxes and methods of manufacturing and assembling sheet covered boxes.

Background of the invention

Sheet covered boxes are used in a wide range of industries including cosmetics and confectionary. Usually the sheet used is of fabric such as satin or cotton, but it can be paper. Such fabric covered boxes are particularly used to display luxury items and therefore, the quality of the finish of the box is important. However, there are a number of problems with their manufacture.

It is known to create a fabric covered box, where the box is partly made up and then fabric is glued to the outside of the partly made up box. However, fraying of the fabric can be a problem where the fabric is cut at the edges. An insert can be used inside the box to cover the fraying edges, but this adds an additional manufacturing step as well as an additional assembly step. This complexity often leads to adhesive being transferred by an operative onto the outer decorative surface which can lead to wastage.

Pre-glued fabric covered board is available for purchase and can be used to make fabric covered boxes. The fabric is glued to substantially the whole surface of the board and so it is not possible to add padding between the board and the fabric, nor is it possible to obtain the luxury finish that is provided by areas of loose fabric over outer panels and flaps of a box made from the board. Other problems with using pre-glued fabric covered board include difficulties with creasing, scoring, cutting and punching of the board.

It is an aim of the first embodiment of the present invention to address at least one problem associated with the prior art, whether identified herein or otherwise.

Summary of the Invention

According to a first aspect of the invention there is provided a blank for a box, the blank comprising a support layer and a sheet layer, the blank further comprising at least two panels on the support layer, wherein the sheet layer and the support layer are bonded together at at least a part of the periphery of the blank and the sheet layer is not bonded to all of the support layer.

Advantageously, by bonding the sheet layer to the periphery of the support layer, the threads making up the sheet are bound together at the periphery, so that fraying of the sheet at the periphery is reduced, whilst the sheet layer is free to move and stretch over the panels.

Suitably, the sheet layer and the support layer are bonded together around the whole of the periphery of the blank.

Suitably, the sheet of the sheet layer is not bonded to a substantial portion of the support layer. Suitably, the sheet of the sheet layer is not bonded to a region of the support layer. Suitably, the sheet of the sheet layer is not bonded to a panel of the support layer.

Suitably, the sheet layer is at least partly moveable relative to the support layer.

Suitably, the panels comprise a base portion configured to form a top or base wall and at least one flap configured to form a side wall of a box, in use. Suitably, the sheet layer is not bonded to the base portion. Suitably, the sheet layer is not bonded to at least a part of the at least one flap.

Suitably, the side wall comprises a first flap connected to a second flap. Suitably, the first flap comprises an outside panel of the side wall. Suitably, the sheet layer is not bonded to the first flap.

Suitably, the blank comprises a plurality of first flaps connected to second flaps. Suitably, the sheet layer is not bonded to the first flaps.

Suitably, the support layer further comprises a number of flanges connected to the first and/or second flaps. Suitably, the sheet layer is bonded to the flanges.

Suitably, the sheet layer is bonded to the second flaps.

Suitably, the sheet layer is bonded to the support layer using an adhesive.

Most suitably, the sheet layer covers all of one side of the support layer. Suitably, the sheet layer comprises a single sheet sheet.

Suitably, the base portion, flaps and flanges are provided by a plurality of assembly folds. Suitably, the assembly folds comprise creases and/or scores and/or perforations and/or cuts.

Suitably, the support layer comprises stiffened paper. Suitably, the support layer comprises card.

Suitably, the sheet layer comprises knitted, woven or felted fibres.

Suitably, the sheet layer comprises one of a fabric layer or a paper layer.

According to a second aspect of the invention there is provided a sheet covered box comprising a top or base wall and a plurality of side walls, the box being assembled from a blank according to the first aspect of the invention.

Advantageously, by bonding the sheet layer to the periphery of the support layer, not only are the threads making up the sheet layer bound together so that fraying of the sheet at the periphery is reduced, the sheet layer is free to move and stretch over the walls of the assembled box.

Suitably, the box comprises a padded insert between the support layer and the sheet layer. Suitably, the padded insert is arranged between the support layer and the sheet layer as part of the top or base wall. Suitably, the padded insert comprises a foam layer.

According to a third aspect of the invention there is provided a method of manufacturing a blank for a sheet covered box, the blank comprising a support layer and a sheet layer, the support layer comprising at least two panels, the method comprising the steps of: i. bonding the support layer with the sheet layer at at least a part of a periphery of the blank; and ii. cutting around the periphery of the blank, wherein the sheet layer is not bonded to all of the support layer.

Advantageously, by bonding the support layer with the sheet layer at at least a part of a periphery of the blank, the fibres making up the sheet are bound at the periphery, so that once the periphery is cut, fraying of the sheet is reduced.

Suitably, step (i) is performed before step (ii).

Suitably, the sheet layer and the support layer are bonded together around the whole of the periphery of the blank.

Suitably, prior to step (i) the method further comprises providing at least a base portion configured to form a top or base wall and at least one flap configured to form a side wall of a

box by providing the support layer with a plurality of assembly folds. Suitably, the method comprises creasing and/or scoring the support layer to provide the plurality of assembly folds.

Suitably, prior to step (i) the method further comprises providing flanges associated with the flaps on the support layer. Suitably, the sheet layer is bonded to the flanges of the support layer.

Suitably, the method comprises providing connected first and second flaps on the support layer configured to provide outside and inside walls of a box respectively, in use. Suitably, the sheet layer is bonded to the second flaps of the support layer. Suitably, the sheet layer is not bonded to the first flaps.

Suitably, the method uses an adhesive to bond the sheet layer to the support layer.

Suitably, prior to cutting the sheet layer extends beyond the periphery of the blank.

Suitably, between steps (i) and (ii), a padded insert is arranged on the support layer. Suitably, the padded insert is arranged on the base portion. Suitably, the padded insert is adhered to the base portion. Suitably, the padded insert comprises a foam layer.

Suitably, the method further comprises constructing a box from the blank.

According to a fourth aspect of the invention there is provided a blank for a sheet covered box, the blank comprising a support layer and a sheet layer, the blank comprising a base portion, at least two first flaps and at least two second flaps, each first flap being hingedly connected to the base portion along a fold line and each first flap being hingedly connected to the other first flap by a folding corner webbing, each second flap being hingedly connected to a first flap and each second flap comprising opposing lateral flanges, wherein cut-out portions extend between the corner webbing connecting two first flaps and the lateral flanges of the connected second flaps, and the sheet layer is arranged to provide sheet webs across the cut-out portions.

Advantageously, by providing sheet webs between the corner webbing and lateral flanges of the first and second flaps respectively, the first and second flaps can be folded so that no part of the support layer is visible in each constructed corner, because the sheet webs cover the periphery of the support layer when each corner is constructed.

Suitably, the cut-out portions are generally triangular in shape.

Most suitably, the cut-out portions comprise an irregular quadrilateral comprising a narrow end relative to an opposite end.

Suitably, the apex or narrow end of each cut-out portion is directed at an end of the hinged connection between the corresponding first and second flaps. Suitably, each cut-out portion is arranged such that the facing edges of the corner webbing and the respective lateral flange taper away from one another from the hinged connection towards an outer edge of the flanges respectively.

Suitably, each cut-out portion is arranged to remove a larger portion of the lateral flange relative to the corner webbing. Suitably, the taper on the lateral flange is steeper relative to the taper on the corner webbing.

Suitably, the corner webbings comprise two parts, bisected by a fold line. Suitably, the fold line bisects the angle provided between lateral walls of connected first flaps.

According to a fifth aspect of the invention there is provided a method of manufacturing a blank for a sheet covered box, the blank comprising a support layer and a sheet layer, the support layer comprising a base portion, at least two first flaps and at least two second flaps, each first flap being hingedly connected to the base portion and the other first flap by a folding corner webbing and each second flap being hingedly connected to a first flap, each second flap comprising opposing lateral flanges, the method comprising the steps of: i. creasing/scoring the support layer to provide the base portion, flaps and flanges; ii. removing cut-out portions between the corner webbing connecting the two first flaps and each lateral flange connected to the respective second flaps; iii. bonding the support layer and the sheet layer together; and iv. cutting around a periphery of the blank, such that the sheet layer provides sheet webs across the cut-out portions.

It is noted that steps i. and ii. will often be performed simultaneously.

Advantageously, when the blank is folded, no part of the support layer is visible in a constructed corner, because the sheet webs fold over the otherwise exposed edges of the support layer.

Suitably, step (ii) is performed before step (iii).

Suitably, the method comprises arranging a padded insert on the base portion. Suitably, the padded insert is adhered to the base portion. Suitably, the padded insert comprises a foam layer.

According to a sixth aspect of the invention there is provided a sheet covered box comprising a plurality of side walls, the box being assembled from a blank according to the fourth aspect of the invention.

Advantageously, in the constructed box no part of the support layer is visible in a constructed corner, because the sheet webs fold over the otherwise exposed edges of the support layer.

Suitably, each first flap is configured to form the outside of a side wall and each corresponding second flap is configured to form the inside of the side wall. Suitably, the sheet layer is visible on both the inside and the outside of each side wall.

According to a seventh aspect of the invention there is provided a method of folding a blank according to the fourth aspect of the invention, the method comprising the steps of: i. constructing primary and secondary side walls in a first corner arrangement by: a. folding a corner webbing connecting first flaps of the primary and secondary side walls so that the connected first flaps, the respective second flaps, the respective sheet webs and the respective lateral flanges are upstanding and the folded corner webbing projects inwardly relative to the corner formed; b. arranging the folded corner webbing to generally lie against a primary side wall first flap so that the respective lateral flange of the connected second flap and the sheet web lie against the respective first and second flaps; and c. arranging the secondary side wall lateral flange and the respective sheet web so that they lie against the arrangement of step (b); d. folding the primary side wall second flap and the respective lateral flange of the arrangement formed in step (b) towards the base portion to manoeuvre the same past the secondary side wall lateral flange and the respective sheet web, until the primary side wall sheet web is folded over the secondary side wall sheet web and the primary side wall second flap and the respective flange lie substantially against the primary side wall first flap; and e. folding the secondary side wall second flap towards the base portion, until the respective second flap and the second lateral flange lie substantially against the respective first flap with the respective sheet web folded over the corner webbing.

Advantageously, the method allows each corner to be constructed in turn, so that no part of the support layer is visible in a constructed corner, because the sheet webs fold over the otherwise exposed edges of the support layer.

Suitably, the method further comprises folding each remaining corner in turn by: i. folding a corner webbing connecting first flaps of either the primary or secondary side walls with a tertiary side wall, so that the tertiary side wall first flap, respective second flap, lateral flange and sheet web are upstanding, the lateral flange lies generally against the second flap and the folded corner webbing lies against the tertiary side walls first flap; and ii. folding the tertiary side wall second flap towards the base portion, until the second flap and the respective flange lie against the first flap with the respective sheet web folded over the folded corner webbing.

Any of the features of an aspect of the invention described herein may be combined with any other aspect except where such combinations are mutually exclusive.

Brief Description of the Drawings

For a better understanding of the invention, and to show how embodiments of the same may be carried into effect, reference will now be made, by way of example, to the accompanying diagrammatic drawings in which:

Figure 1 shows a support layer for a blank for a box on a support material according to an embodiment of the present invention;

Figure 2 shows a perspective view of a sheet covered box constructed from the blank shown in Figure 1 ; and

Figure 3 shows the cut-out blank shown in Figure 1 with a sheet layer attached thereto.

Description of the Preferred Embodiment

As shown in Figure 3, a blank 10 for a box 1 comprises a support layer 7 and a sheet layer consisting of a fabric layer 8. The fabric layer 8 is bonded with the support layer 7 at a periphery 101 thereof.

The support layer 7 comprises stiffened paper or card.

As shown in figure 2, a box 1 comprises a top or base wall 2 and a plurality of side walls 3, 4, 5, 6, the box 1 being constructed from the blank 10 shown in Figure 3. Each side wall 3, 4, 5, 6 is hingedly connected to the top or base wall 2 by crease lines.

The top or base wall 2 is rectangular and each of the side walls 3, 4, 5, 6 are rectangular with opposing side walls 3, 4 being substantially the same shape and opposing side walls, 5, 6 being substantially the same shape.

As shown in Figures 1 and 3, the support layer 7 comprises a centrally disposed rectangular panel 12. The base portion 12 is connected to four rectangular first side flaps 13, 14, 15, 16 along crease lines. Each of the four rectangular first side flaps 13, 14, 15, 16 extends along the whole length of the respective crease line.

In turn, each of the first side flaps 13, 14, 15, 16 is connected to a respective second side flap 23, 24, 25, 26 along a further crease line parallel to one of the four crease lines connecting the base portion 12 to the first side flaps 13, 14, 15, 16. Each of the second side flaps 23, 24, 25, 26 extends along almost the whole length of the adjoining edge and stops short of each end of the respective edge, such that each of the second side flaps 23, 24, 25, 26 is shorter than the respective connected first side flap 13, 14, 15, 16.

Each of the first side flaps 13, 14, 15, 16 is connected to two other first side flaps 13, 14, 15, 16 by a corner webbing 17, 18, 19, 20. Therefore, flap 13 is connected to flap 15 by corner webbing 18 and is also connected to flap 16 by corner webbing 19, flap 16 is connected to flap 14 by corner webbing 20, and flat 14 is connected to flap 15 by corner webbing 17.

The corner webbings 17, 18, 19, 20 each comprise a perforated line that bisects the angle provided between perpendicular edges of the connected first side flaps 13, 14, 15, 16. The perforated line facilitates folding of the corner webbings 17, 18, 19, 20.

Each second side flap 23, 24, 25, 26 comprises two lateral flanges 23a/b, 24a/b, 25a/b, 26a/b along opposing short edges. A main flange 23c, 24c, 25c, 26c extends along substantially the whole length of a further crease line or perforated line that is parallel to one of the four crease lines connecting the base portion 12 to the first side flaps 13, 14, 15, 16.

As shown in Figure 1 , the blank 10 comprises cut-out portions 27a/b, 28a/b, 29a/b, 30a/b between the corner webbings 17, 18, 19, 20 connecting the first side flaps 13, 14, 15, 16 and the lateral flanges 23a/b, 24a/b, 25a/b, 26a/b connected to the second side flaps 23, 24, 25, 26. For example, cut-out portion 27a is located between corner webbing 17 and the lateral

flange 24b, whilst cut-out portion 27b is located between the same corner webbing 17 and lateral flange 25a.

The cut-out portions 27a/b, 28a/b, 29a/b, and 30a/b are irregular quadrilaterals in shape, with a narrow closed end relative to a wide open end and tapering edge between the narrow end and the wide end. The tapering edge which cuts into each lateral flange 23a/b, 24a/b, 25a/b, 26a/b is steeper than the tapering edge that cuts into the corner webbings 17, 18, 19, 20.

The narrow end of each cut-out portion 27a/b, 28a/b, 29a/b, and 30a/b contacts the crease line connecting a first side flap 13, 14, 15, 16 with the respective second side flap 23, 24, 25 and removes a small portion of the corner of the respective first side flap 13, 14, 15, 16.

The base portion 12 and the side flaps 13, 14, 15, 16, 23, 24, 25, 26 are covered by the fabric layer 8 on one side. The fabric layer 8 is a continuous fabric sheet. The fabric layer 8 extends across the cut-out portions 27a/b, 28a/b, 29a/b, 30a/b to form fabric webs 32a/b, 33a/b, 34a/b, and 35a/b as shown in figure 3.

During manufacture, the fold lines are created on the support material by crease lines, cuts and/or perforations to provide the base portion 12, flaps 13 -16, 23 - 26, webbings 17 - 20, 23a/b - 26a/b and tabs 23c - 26c.

The cut-out portions 27a/b, 28a/b, 29a/b, 30a/b are cut out and removed, typically at the same time as the fold lines are created, but not necessarily so.

In the illustrated embodiment, an adhesive 40, shown by the hatching of Figure 1 is applied to the periphery 101 of the support layer 7, the second flaps 23 - 26, the lateral flanges 23a/b - 26a/b the corner webbings 17 - 20 and the main flaps 23c -26c. The adhesive 40 is applied to the same side of the support layer 7 as the fold lines. The periphery 101 reflects the final cutting line of the blank 10.

In an alternative embodiment (not shown) the adhesive 40 is applied to the periphery of the support layer 7 and a small region either side of the periphery, leaving all flaps and flanges substantially free from adhesive 40.

The fabric layer 8 is then applied to the blank 10 so as to entirely cover and overlie the support layer 7 on the side carrying the adhesive 40.

Once the adhesive 40 is sufficiently dry, the final cut is made around the periphery 101 , so as to release the blank 10 with the support layer 7 and the fabric layer from the support material,

with the fabric layer 8 adhered to the periphery 101 and the flaps 23 - 26 and flanges 17 - 20, 23a/b/c - 26a/b/c. The fabric webs 32a/b, 33a/b, 34a/b, 35a/b extend across the cut-out portions 27a/b, 28a/b, 29a/b, 30a/b.

In use, the box 1 is constructed corner-by corner.

Each first flap 13 - 16, respective second flap 23-26 and respective lateral flanges 23a/b - 26a/b are configured to form primary, secondary, tertiary and quaternary side walls 3-6 of the box 1 .

A corner webbing 17 connecting primary and secondary side wall 14, 15 flaps 14, 15 is folded along the perforated line. This causes the primary and secondary side wall first flaps 14, 15, the respective second flaps 24, 25, the fabric webs 32a, 35b and the lateral flanges 24b, 25a to become upstanding relative to the base portion 12. Furthermore, the folded corner webbing 17 projects inwardly relative to the corner being formed.

The folded corner webbing 17 is arranged to lie against the primary side wall first flap 14 so that the lateral flange 24b and the fabric web 35b lie against the respective second flap 24 in part-folded arrangement, whilst the lateral flange 25a and the fabric web 32a of the secondary side wall also lie against the part folded arrangement 14, 24b, 35b.

The primary side wall second flap 24, the respective lateral flange 24b and fabric web 35b are folded towards the base portion 12 to manoeuvre the same past the lateral flange 25a and the fabric web 32a of the secondary side wall by pushing the same out of the way, until the fabric web 35b is folded over the fabric web 32a and the second flap 24 and the flange 24b lie substantially against the first flap 14.

The secondary side wall second flap 25 is folded towards the base portion 12, until the second flap 25 and the lateral flange 25a lie substantially against the first flap 15 with the fabric web 32a being folded between the second flap 25 and the first flap 15. This constructs the primary side wall 4 and the secondary side wall 5.

Once one corner is formed, the remaining tertiary and quarternary side wall corners are formed by folding, for example, an adjacent corner webbing 18, along the perforated line such that the tertiary side wall first flap 13 the respective second flap 23, the respective web 28b and the respective lateral flange 23a become upstanding relative to the base portion 12. This causes the corner webbing 18 to lie against the first flap 13. The second flap 23, the respective web 28b and the respective lateral flange 23a are folded towards the base portion until the fabric web 28b is folded between the second flap 23 and the first flap 13 and the second flap 23 and

the lateral flange 23a lie substantially against the first flap 13. This constructs the tertiary side wall 3.

With this arrangement, when the blank 10 is cut out, the fibres of the fabric layer 8 are bonded together by the adhesive 40 at the periphery 101 to reduce fraying. In addition, when the box

1 is constructed the fabric layer stretches across the support layer 7 to become taught.

However, due to the absence of adhesive 40 across the base portion 12 and the first flaps 13,

14, 15, 16, the fabric is free to move relative to the support layer 7. There is only a small degree of movement, but this provides the desired luxury effect that is otherwise lacking where the fabric layer 8 is adhered to the entire surface of the support layer 7.

Furthermore, during folding, the cut-out portions accommodate the fabric webs 32a/b, 33a/b, 34a/b, 35a/b. Where excessive movement due to folding and unfolding during box and deconstruction would otherwise cause the fabric to tear and rub against other edges causing fraying, the fabric webs 32a/b, 33a/b, 34a/b, 35a/b reduce the visible effects at the edges of the blank. The fabric webs 32a/b, 33a/b, 34a/b, 35a/b ensure that no part of the support layer 7 is visible in the constructed corners providing a professional looking fabric covered box.

It will be appreciated that various modifications to the described embodiment can be made within the scope of the present invention.

By way of example, the adhesive 40 can be applied to the fabric layer instead of the support layer 7, other box shapes can be made and, although generally less desirable, glue can be used in the box construction to bond flaps together in assembly.

As an alternative example, another rigid layer about which the sheet layer and the support layer wrap can be used.

Embodiments of the present invention can provide advantages to other carton constructions.

Attention is directed to all papers and documents which are filed concurrently with or previous to this specification in connection with this application and which are open to public inspection with this specification, and the contents of all such papers and documents are incorporated herein by reference.

All of the features disclosed in this specification (including any accompanying claims, abstract and drawings), and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive.

Each feature disclosed in this specification (including any accompanying claims, abstract and drawings) may be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features.

The invention is not restricted to the details of the foregoing embodiment(s). The invention extends to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed.