Box with multi-ply base panel and method of constructing same

Abstract

A box part is provided with an eight panel base and sides reinforced with a four-sided, open bottom insert. The box part is constructed by forming a planar four panel subassembly and a tray-like subassembly having four panels and side sections, from a single blank. The insert is received within the tray-like subassembly. The planar subassembly is then folded over the side of the insert and placed into the tray-like subassembly.

1 . A box part comprising a first panel comprising first, second, third and fourth edges, a second panel comprising an edge, a third panel comprising an edge, a fourth panel comprising an edge, a fifth panel comprising first, second, third and fourth edges, a sixth panel, a seventh panel, an eighth panel, and first, second, third and fourth side sections, said edge of said second panel being connected to said first edge of said first panel by said first side section, said edge of said third panel being connected to said second edge of said first panel by said second side section, said edge of said fourth panel being connected to said third edge of said first panel by said third side section, said edge of said fifth panel being connected to said fourth edge of said first panel by said fourth side section, said sixth panel being connected to said second edge of said fifth panel, said seventh panel being connected to said third edge of said fifth panel and said eighth panel being connected to said fourth edge of said fifth panel.  
     
     
         2 . The box part of  claim 1  wherein each of said side sections comprises inner and outer walls which when situated in side-by-side relation define a recess therebetween.  
     
     
         3 . The box part of  claim 2  further comprising a separate insert adapted to be received within said side section recesses.  
     
     
         4 . The box part of  claim 3  wherein said insert comprises four sides and an open bottom.  
     
     
         5 . The box part of  claim 4  wherein each of said insert sides is received in the recess defined by a different one of said box part side sections.  
     
     
         6 . The box part of  claim 1  further comprising means for fixing said fourth panel to said third panel.  
     
     
         7 . The box part of  claim 1  further comprising means for fixing said sixth panel to said fifth panel.  
     
     
         8 . The box part of  claim 7  further comprising means for fixing said seventh panel to said sixth panel.  
     
     
         9 . The box part of  claim 7  further comprising means for fixing said eighth panel to said seventh panel.  
     
     
         10 . The box part of  claim 1  wherein each of said panels has approximately the same shape and dimensions.  
     
     
         11 . The box part of  claim 1  wherein all of said panels are situated in substantially parallel, face-to-face relation.  
     
     
         12 . The box part of  claim 1  further comprising webs connecting said outer walls of said box part side sections.  
     
     
         13 . The box part of  claim 12  wherein each of said webs comprises first and second web sections.  
     
     
         14 . The box part of  claim 13  further comprising means for fixing said web sections of each of said webs to each other.  
     
     
         15 . A box part comprising eight generally rectangular panels situated in substantially face-to-face relation forming the base of the box part, four interconnected side sections extending from said base in directions generally perpendicular to the plane of said base, each of said side sections being formed of inner and outer side-by-side walls defining a recess therebetween and a separate, four-sided, open bottom insert, said insert sides being received within the recesses defined between said walls of said side sections.  
     
     
         16 . A method of constructing a box part from a blank, said method comprising the steps of: 
 forming a planar subassembly of multiple panels from one portion of the blank;    forming a tray-like subassembly comprising a base and side sections from another portion of the blank; and    placing the planar subassembly into the tray-like subassembly.    
     
     
         17 . The method of  claim 16  further comprising the step of forming an open bottom, four sided insert.  
     
     
         18 . The method of  claim 17  wherein each of said side sections defines a recess and further comprising the step of receiving the insert within the side section recesses.  
     
     
         19 . The method of  claim 16  wherein the step of forming the tray-like subassembly comprises the step of forming the tray-like subassembly of multiple base panels by placing the base panels in face-to-face relation.