Pre-Folded File Bottom Box Form, and Method of Creating Same

Abstract

A pre-folded file bottom box form ( 80 ) created from a unitary blank ( 10 ) of corrugated material that is die cut and creased so as to form a series of panels and flaps arranged in three rows (A, B and C) of four panels or flaps each that define four columns (D, E, F and G). The blank ( 10 ) includes a first row (A) with four panels ( 32, 34, 36 and 38 ) that end up in the box as reinforcing sidewall and end wall panels, a middle row (B) contiguous with the first row (A) and having four panels ( 20, 24, 28 and 40 ) that end up in the box as sidewall and end wall panels, and a third row (C) coupled to the second row (B) and including first ( 16 ) and second ( 18 ) panels and two flaps ( 12, 14 ), the first ( 16 ) and second ( 18 ) panels making up the bottom of the box and the two flaps ( 12, 14 ) contiguous with the first third-row panel ( 16 ) and making up portions of the two end-walls. The four panels of the first row (A) are folded onto the four panels of the second row (B). The blank is then folded along two of the fold lines ( 42, 44 ) located between columns, and the edges ( 24, 26 ) of the end panels ( 30, 20 ) of the middle row (B) are fastened together, to create the completed form ( 80 ).

1 . A pre-folded file bottom box form, comprising:
 a unitary blank of corrugated material that is die cut and creased so as to form a series of panels and flaps arranged in three rows of four panels or flaps each that define four columns, the blank comprising:   a first row comprising four panels that end up in the box as reinforcing sidewall and end wall panels;   a middle row contiguous with the first row and comprising four panels that end up in the box as sidewall and end wall panels; and   a third row coupled to the second row and comprising first and second panels and two flaps, the first and second panels making up the bottom of the box and the two flaps contiguous with the first third-row panel and making up portions of the two end-walls;   wherein the four panels of the first row are folded onto the four panels of the second row; and   wherein the blank is then folded along two of the fold lines located between columns, and the edges of the end panels of the middle row are fastened together, to create the completed form.   
     
     
         2 . The box form of  claim 1  wherein the four panels of the first row are separated from one another by slots. 
     
     
         3 . The box form of  claim 2  wherein the four panels of the first row are glued to the four panels of the second row. 
     
     
         4 . The box form of  claim 2  wherein the slots are skip slots that comprise a small region of material that spans the slots such that two panels separated by a slot are connected by the small region. 
     
     
         5 . The box form of  claim 4  wherein the four panels of the first row lie against but are not fixed to the four panels of the second row. 
     
     
         6 . The box form of  claim 1  wherein the edges of the end panels of the middle row are fastened together by gluing, stitching or stapling. 
     
     
         7 . A box created from the box form of  claim 1 . 
     
     
         8 . A method of creating a pre-folded file bottom box form made from a unitary blank of material, comprising:
 i) providing a blank of corrugated material that is die cut and creased so as to form a series of panels and flaps arranged in three rows of four panels or flaps each that define four columns, a first row comprising four panels that end up in the box as reinforcing sidewall and end wall panels, a middle row contiguous with the first row and comprising four panels that end up in the box as sidewall and end wall panel, and a third row coupled to the second row and comprising first and second panels and two flaps, the first and second panels making up the bottom of the box and the two flaps contiguous with the first third-row panel and making up portions of the two end-walls;   ii) folding the four panels of the first row to the four panels of the second row;   iii) then folding the blank along two of the fold lines located between columns; and   iv) then fastening together the edges of the end panels of the middle row, to create the completed form.   
     
     
         9 . The method of  claim 8  wherein the four panels of the first row are separated from one another by slots. 
     
     
         10 . The method of  claim 9  wherein the four panels of the first row are glued to the four panels of the second row. 
     
     
         11 . The method of  claim 9  wherein the slots are skip slots that comprise a small region of material that spans the slots such that two panels separated by a slot are connected by the small region. 
     
     
         12 . The method of  claim 11  wherein the four panels of the first row lie against but are not fixed to the four panels of the second row. 
     
     
         13 . The method of  claim 8  wherein the edges of the end panels of the middle row are fastened together by gluing, stitching or stapling. 
     
     
         14 . The method of  claim 8  further comprising:
 v) creating from the box form an open-top box. 
 
     
     
         15 . The method of  claim 14  wherein creating from the box form an open-top box comprises the following steps:
 vi) squaring up the box form into an open rectangular box shape; 
 vii) pulling a first panel of the third row up inside the box shape; 
 viii) folding the two flaps of the third row onto the second panel of the third row and pulling the panel up inside the box shape; 
 ix) pushing the second panel of the third row down such that it lies generally at right angles to the four sidewalls; 
 x) unfolding the two flaps of the third row against the two middle row panels that make up the end walls; and 
 xi) pushing the first panel of the third row down onto the second panel of the third row.