Foldable box or tray

Abstract

A tray comprising a cover comprising a planar rectangular panel having a flap on each edge. The cover can also include a gusset coupling at least one flap to an adjacent flap. There can also be at least one tab coupled to at least one flap and an insert comprising a planar rectangular base which is substantially the same size as the planar rectangular panel. There can also be a plurality of flaps coupled to the base with at least one flap coupled to each edge of the base. In addition, there can be at least one additional cover, comprising a planar rectangle, wherein in use, the first cover is wrapped around the insert to form a full cover over the insert while the additional cover is wrapped around the cover to cover over an opening tray section, to form a substantially closed box.

1 . A packaging box comprising: 
 a) a tray comprising 
 i) a cover comprising: 
 a) a planar rectangular panel having a flap on each edge;  
 b) a gusset coupling at least one flap to an adjacent flap; and  
 c) at least one tab coupled to at least one flap;  
 
 ii) an insert comprising 
 a) a planar rectangular base which is substantially the same size as said planar rectangular panel;  
 b) a plurality of flaps coupled to said base with at least one flap coupled to each edge of said base;  
 
   c) at least one additional cover, comprising a planar rectangle, wherein in use, said first cover is wrapped around said insert to form a full cover over said insert while said at least one additional cover is wrapped around said cover to cover over an opening tray section, to form a substantially closed box.    
     
     
         2 . A box according to  claim 1 , wherein the insert is of a card like material.  
     
     
         3 . A box according to  claim 2 , wherein the card has a thickness in the range 0.5-3 mm.  
     
     
         4 . A box according to  claim 2 , wherein the card has a thickness is in the range 0.8-2 mm.  
     
     
         5 . A box according to  claim 2 , wherein the card is comprised of recycled chipboard.  
     
     
         6 . A box according to  claim 1 , wherein the cover is bonded to the insert at spaced locations.  
     
     
         7 . The box as in  claim 1 , wherein said cover further comprises at least one spacer panel having at least one beveled edge.  
     
     
         8 . The box as in  claim 7 , wherein each tab on said cover has a beveled edge.  
     
     
         9 . The box as in  claim 1 , wherein said insert further comprises at least one spacer flap having a beveled edge.  
     
     
         10 . The box as in  claim 9 , wherein said at least one spacer flap comprises at least four spacer flaps and wherein when said insert is folded into a tray, said at least one spacer flap forms a top surface of said tray.  
     
     
         11 . A method of assembling a box comprising the steps of: 
 providing a pre-formed planar cover comprising a rectangular panel forming a floor with at least one flap on each edge forming a wall, a portion of each flap being connected to an adjacent flap with a gusset, and at least one flap having a tab at the free edge thereof,    providing an insert blank comprising a rectangular base forming a floor, the base having flaps on each edge forming a wall portion, and    placing the insert blank on the cover;    folding said walls of said insert blank upright so that the insert forms a tray-like shape,    folding said flaps of said cover over the walls of said insert,    folding each gusset inward of said cover to form a tray-like shape cover over said insert;    folding at least one of said tabs on said cover onto said floor, and    coupling said tabs to said floor of said blank to secure said cover to said insert;    coupling said additional cover to said tray to cover said tray.    
     
     
         12 . A method according to  claim 12 , further comprising the step of providing opposite flaps with secondary tabs and adhesively bonding said secondary tabs to said adjacent flaps.  
     
     
         13 . The method as in  claim 11 , wherein said additional cover covers an opening in said tray.  
     
     
         14 . The method as in  claim 13 , wherein said additional cover is coupled to said cover by folding over said cover and then coupling at least two end portions of said additional cover together via an adhesive.  
     
     
         15 . The method as in  claim 11 , wherein said tabs are coupled to said floor of said insert via an adhesive.  
     
     
         16 . A tray comprising: 
 a) a cover comprising: 
 i) a planar rectangular panel having a flap on each edge;  
 ii) a gusset coupling at least one flap to an adjacent flap; and  
 iii) at least one tab coupled to at least one flap;  
   b) an insert comprising 
 i) a planar rectangular base which is substantially the same size as said planar rectangular panel; and  
 ii) a plurality of flaps coupled to said base with at least one flap coupled to each edge of said base wherein said cover is folded over said insert to form a cover for said insert.  
   
     
     
         17 . A method of assembling a tray comprising the steps of: 
 providing a pre-formed planar cover comprising a rectangular panel forming a floor with at least one flap on each edge forming a wall, a portion of each flap being connected to an adjacent flap with a gusset, and at least one flap having a tab at the free edge thereof,    providing an insert blank comprising a rectangular base forming a floor, the base having flaps on each edge forming a wall portion, and    placing the insert blank on said cover;    folding said walls of said insert blank upright so that said insert forms a tray-like shape,    folding said flaps of said cover over said walls of said insert,    folding each gusset inward of said cover to form a tray-like shape cover over said insert;    folding at least one of said tabs on said cover onto said floor, and    coupling said tabs to said floor of said blank to secure said cover to said insert to form a tray.