Box blank and method for providing a dispensable product

Abstract

A box blank includes a primary box blank body and markings. The primary box blank body includes primary panel creases defining primary panels, primary flaps connected to the primary panels, and primary flap creases connected to one primary panel via one primary flap crease. The markings are provided on the primary box blank body, and define a shape of a secondary box blank body, which includes secondary panel creases defining secondary panels, secondary flaps connected to secondary panels, and secondary flap creases connected to one secondary panel via one secondary flap crease. The primary box blank body is foldable along the primary panel and flap creases to form a primary box. With the secondary box blank body being cut from the primary box blank body along the markings, the secondary box blank body is foldable along the secondary panel and flap creases to form a secondary box.

Description

BOX BLANK AND METHOD FOR PROVIDING A DISPENSABLE PRODUCTCROSS-REFERENCE TO RELATED APPLICATION

[0001] The present application claims priority to United States Provisional Patent Application No. 63 / 563,671, filed March 11, 2024 entitled “Folding Carton and Method for Providing a Dispensable Product”, which is incorporated by reference herein in its entirety.TECHNICAL FIELD

[0002] The present technology relates to box blanks and to methods for providing a dispensable product.BACKGROUND

[0003] There are a number of different dispensable products on the market such as tissues, bibs, and rolls of paper towels. These dispensable products are conventionally shipped from their manufacturing plant in shipping boxes.

[0004] In some instances, these dispensable products may be received in disposable packaging (e.g., box receiving a stack of tissues). A plurality of these disposable packaging is then received in a shipping box, and the shipping box is shipped to its final location. In other instances, these dispensable products may not be received in disposable packaging, and may be directly received in the shipping boxes. However, in such instances, a dispenser system may be required to properly dispense the dispensable products and / or to protect the dispensable product.

[0005] There is a desire for a technology that can overcome at least some of the abovedescribed drawbacks, notably by decreasing waste and avoiding need of additional dispensing systems.SUMMARY

[0006] It is an object of the present technology to improve at least some of the inconveniences present in the prior art.

[0007] According to one aspect of the present technology, there is provided a method for providing a dispensable product selected from a plurality of dispensable products into a dispenser box. The method includes folding a primary box blank body to form a primary box; after folding the primary box blank body to form the primary box, placing the plurality of dispensable products into the primary box; after placing the plurality of dispensable products into the primary box, removing the plurality of dispensable products from the primary box; after removing the plurality of dispensable products from the primary box, unfolding the primary box into the primary box blank body; after unfolding the primary box into the primary box blank body, cutting a secondary box blank body from the primary box blank body by following a plurality of markings provided on the primary box blank body, the plurality of markings defining a shape of the secondary box blank body; after cutting the secondary box blank body from the primary box blank body, folding the secondary box blank body to form the dispenser box, the dispenser box being smaller than the primary box, and placing the selected dispensable product into the dispenser box.

[0008] In some embodiments, folding the secondary box blank body to form the dispenser box and placing the selected dispensable product into the dispenser box include placing the selected dispensable product onto the secondary box blank body before folding the secondary carton bod, and folding the secondary box blank body around the selected dispensable product to form the dispenser box with the selected dispensable product inside the dispenser box.

[0009] In some embodiments, folding the primary box blank body to form the primary box includes folding the primary box blank along a plurality of primary panel creases and a plurality of primary flap creases, unfolding the primary box into the primary box blank body includes unfolding the primary box along the plurality of primary panel creases and the plurality of primary flap creases, and folding the secondary box blank body to form the dispenser box includes folding the secondary box blank body along a plurality of secondarypanel creases and a plurality of secondary flap creases. At least some of the secondary panel creases correspond to at least part of at least some the primary panel creases. At least some of the secondary flap creases correspond to at least part of at least some the primary flap creases.

[0010] In some embodiments, the dispenser box is formed without glue.

[0011] In some embodiments, the dispenser box is formed by interlocking flaps of the second box blank body.

[0012] In some embodiments, the plurality of markings includes a plurality of cut scores, and cutting the secondary box blank body from the primary box blank body includes cutting along the cut scores without tools.

[0013] In some embodiments, the method further includes making an opening in the dispenser box for providing access to the dispensable product.

[0014] In some embodiments, at least one dispensable product of the plurality of dispensable products defines a central aperture, and the method further includes, before removing the plurality of dispensable products from the primary box, placing a container in the central aperture of the at least one dispensable product of the plurality of dispensable products.

[0015] According to another aspect of the present technology, there is provided a box blank including a primary box blank body and a plurality of markings. The primary box blank body includes a plurality primary panel creases defining a plurality of primary panels, a plurality of primary flaps connected to the plurality of primary panels, and a plurality of primary flap creases, each primary flap of the plurality of primary flaps being connected to one primary panel of the plurality of primary panels via one primary flap crease of the plurality of primary flap creases. The plurality of markings, which are provided on the primary box blank body, define a shape of a secondary box blank body. The secondary box blank body includes a plurality secondary panel creases defining a plurality of secondary panels, a plurality of secondary flaps connected to the plurality of secondary panels, and a plurality of secondary flap creases, each secondary flap of the plurality of secondary flapsbeing connected to one secondary panel of the plurality of secondary panels via one secondary flap crease of the plurality of secondary flap creases. The primary box blank body is foldable along the plurality of primary panel creases and the plurality of primary flap creases to form a primary box. With the secondary box blank body being cut from the primary box blank body along the plurality of markings, the secondary box blank body is foldable along the plurality of secondary panel creases and the plurality of secondary flap creases to form a secondary box.

[0016] In some embodiments, the primary box blank body is made from corrugated cardboard. The corrugated cardboard has a corrugated sheet disposed between a first linerboard and a second linerboard, the first linerboard being different from the second linerboard. With the primary box blank body being folded to form the primary box, the first linerboard is on an exterior of the primary box. With the secondary box blank body being folded to form the secondary box, the second linerboard is on an exterior of the secondary box.

[0017] In some embodiments, the first linerboard is a kraft linerboard and the second linerboard is an oyster linerboard.

[0018] In some embodiments, some markings of the plurality of markings define a dispenser opening of the secondary box.

[0019] In some embodiments, the dispenser opening is one of a rectangular slot and a circular hole.

[0020] In some embodiments, some markings of the plurality of markings define at least two apertures defining a handle of the secondary box.

[0021] In some embodiments, at least some markings of the plurality of markings are cut scores.

[0022] In some embodiments, at least one of: at least some of the secondary panel creases correspond to at least part of at least some the primary panel creases, and at least some ofthe secondary flap creases correspond to at least part of at least some the primary flap creases.

[0023] In some embodiments, the primary box blank body includes at least one tab connected to a portion of the at least one of the primary box blank body by at least one tab crease, the at least one tab being configured to glue to another part of the primary box blank body.

[0024] In some embodiments, one secondary flap of the plurality of secondary flaps includes a first interlocker, another secondary flap of the plurality of secondary flaps comprises a second interlocker, and with the secondary box blank body being folded along the plurality of secondary panel creases and the plurality of secondary flap creases, the first interlocker is configured to interlock with the second interlocker.

[0025] In some embodiments, the secondary box blank body is configured to form the secondary box having a volume that is smaller than a volume of the primary box.

[0026] In some embodiments, the primary box is sized to store a plurality of dispensable products, and the secondary box is sized to store only one selected dispensable product of the plurality of products.

[0027] In some embodiments, the plurality of products is a plurality of dispensable products. Each dispensable product of the plurality of dispensable products is one of a roll of dispensable items and a stack of dispensable items. The primary box is a shipping box for shipping the plurality of dispensable products, and the secondary box is a dispenser box for dispensing the dispensable items.

[0028] In the context of the present specification, unless expressly provided otherwise, the words “first”, “second”, “third”, etc. have been used as adjectives only for the purpose of allowing for distinction between the nouns that they modify from one another, and not for the purpose of describing any particular relationship between those nouns.

[0029] It must be noted that, as used in this specification and the appended claims, the singular form “a”, “an” and “the” include plural referents unless the context clearly dictates otherwise.

[0030] As used herein, the term “about” in the context of a given value or range refers to a value or range that is within 20%, preferably within 10%, and more preferably within 5% of the given value or range.

[0031] As used herein, the term “and / or” is to be taken as specific disclosure of each of the two specified features or components with or without the other. For example “A and / or B” is to be taken as specific disclosure of each of (i) A, (ii) B and (iii) A and B, just as if each is set out individually herein.

[0032] Embodiments of the present technology each have at least one of the above- mentioned objects and / or aspects, but do not necessarily have all of them. It should be understood that some aspects of the present technology that have resulted from attempting to attain the above-mentioned object may not satisfy this object and / or may satisfy other objects not specifically recited herein.

[0033] Additional and / or alternative features, aspects, and advantages of embodiments of the present technology will become apparent from the following description, the accompanying drawings, and the appended claims.BRIEF DESCRIPTION OF THE DRAWINGS

[0034] For a better understanding of the present technology, as well as other aspects and further features thereof, reference is made to the following description which is to be used in conjunction with the accompanying drawings, where:

[0035] Figure 1 is a top plan view of a primary box blank body of a box blank according to an embodiment of the present technology;

[0036] Figure 2 is a bottom plan view of a secondary box blank body of the box blank of Figure 1;

[0037] Figures 3A, 3B and 3C are perspective views of a primary box formed by folding the primary box blank body of Figure 1;

[0038] Figures 4A and 4B are perspective views of a secondary box formed by folding the secondary box blank body of Figure 2;

[0039] Figure 5A illustrates folding steps of the secondary box blank body of Figure 2 to form a dispenser box;

[0040] Figure 5B is a flowchart illustrating a method for providing a dispensable product selected from a plurality of dispensable products into a dispenser box;

[0041] Figure 6 is a top plan view of a primary box blank body of a box blank according to another embodiment of the present technology;

[0042] Figure 7 is a bottom plan view of a secondary box blank body of the box blank of Figure 6;

[0043] Figures 8 A, 8B and 8C are perspective views of a primary box formed by folding the primary box blank body of Figure 6;

[0044] Figures 9A and 9B are perspective views of a secondary box formed by folding the secondary box blank body of Figure 7;

[0045] Figure 10 is a top plan view of a primary box blank body of a box blank according to another embodiment of the present technology;

[0046] Figure 11 is a bottom plan view of a secondary box blank body of the box blank of Figure 10;

[0047] Figures 12A, 12B and 12C are perspective views of a primary box formed by folding the primary box blank body of Figure 10;

[0048] Figures 13 A and 13B are perspective views of a secondary box formed by folding the secondary box blank body of Figure 11 ;

[0049] Figure 14 illustrates folding steps of the secondary box blank body of Figure 11 to form a dispenser box;

[0050] Figure 15 A is a top plan view of a primary box blank body of a box blank according to another embodiment of the present technology;

[0051] Figure 15B is a top plan view of a primary box blank body of a box blank according to another embodiment of the present technology;

[0052] Figure 16 is a bottom plan view of a secondary box blank body of the box blank of Figure 15 A;

[0053] Figures 17A, 17B and 17C are perspective views of a primary box formed by folding the primary box blank body of Figure 15 A;

[0054] Figures 18A and 18B are perspective views of a secondary box formed by folding the secondary box blank body of Figure 16;

[0055] Figure 19 illustrates folding steps of the secondary box blank body of Figure 16 to form a dispenser box;

[0056] Figure 20 is a top plan view of a primary box blank body of a box blank according to another embodiment of the present technology;

[0057] Figure 21 is a bottom plan view of a secondary box blank body of the box blank of Figure 20;

[0058] Figures 22A, 22B and 22C are perspective views of a primary box formed by folding the primary box blank body of Figure 20;

[0059] Figures 23 A and 23B are perspective views of a secondary box formed by folding the secondary box blank body of Figure 21;

[0060] Figure 24 illustrates folding steps of the secondary box blank body of Figure 21 to form a dispenser box;

[0061] Figure 25 is a top plan view of a primary box blank body of a box blank according to another embodiment of the present technology;

[0062] Figure 26 is a bottom plan view of a secondary box blank body of the box blank of Figure 25;

[0063] Figures 27A, 27B and 27C are perspective views of a primary box formed by folding the primary box blank body of Figure 25;

[0064] Figures 28 A and 28B are perspective views of a secondary box formed by folding the secondary box blank body of Figure 26;

[0065] Figure 29 illustrates folding steps of the secondary box blank body of Figure 26 to form a dispenser box;

[0066] Figure 30 is a top plan view of a primary box blank body of a box blank according to another embodiment of the present technology;

[0067] Figure 31 is a bottom plan view of a secondary box blank body of the box blank of Figure 30;

[0068] Figures 32A, 32B and 32C are perspective views of a primary box formed by folding the primary box blank body of Figure 30;

[0069] Figures 33 A and 33B are perspective views of a secondary box formed by folding the secondary box blank body of Figure 31;

[0070] Figure 34 illustrates folding steps of the secondary box blank body of Figure 31 to form a dispenser box;

[0071] Figure 35 is a top plan view of a primary box blank body of a box blank according to another aspect of the present technology;

[0072] Figure 36 is a top plan view of a primary box blank body of a box blank according to another aspect of the present technology;

[0073] Figure 37 is a top plan view of a secondary box blank body of the box blank of Figure 36;

[0074] Figure 38A is a perspective view of a primary box formed by folding the primary box blank body of Figure 36; and

[0075] Figures 38B and 38C are perspective views of a secondary box formed by folding the secondary box blank body of Figure 37.

[0076] Unless otherwise noted, the Figures may not be drawn to scale.DETAILED DESCRIPTION

[0077] The present disclosure is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the drawings. The disclosure is capable of other embodiments and of being practiced or of being carried out in various ways. Also, the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including” , “comprising”, or “having”, “containing”, “involving” and variations thereof herein, is meant to encompass the items listed thereafter as well as, optionally, additional items. In the following description, the same numerical references refer to similar elements.

[0078] Referring to Figures 1 and 3 A to 3B, a box blank 100 according to an embodiment of the present technology is shown. The box blank 100 is made from corrugated cardboard 102. In other embodiments, the box blank 100 may be made from another material such as single layered paperboard, solid board or corrugated plastic board. In the present embodiment, the corrugated cardboard 102 is a microflute corrugated cardboard (e.g., e- flute corrugated cardboard). It is understood that other types of corrugated cardboard may be used such as, for example, n-flute corrugated cardboard or f-flute corrugated cardboard. The corrugated cardboard 102 has a corrugated sheet 103 that is disposed between a kraft linerboard 104 and an oyster linerboard 106. It is contemplated that corrugated cardboard 102 could be provided with other types of linerboards. In some embodiments, the corrugated sheet 103 could be disposed between two kraft linerboards or between two oyster linerboards. It is further contemplated that part of the kraft linerboard104 and / or part of the oyster linerboard 106 may have a water repelling coating applied thereon. In some instances, the water repelling coating may be a water-based varnish.

[0079] The box blank 100 has a primary box blank body 110. As will be described in greater detail below, the primary box blank body 110 can be manipulated to form a primary box 111 (shown in Figures 3 A to 3C).

[0080] Referring to Figure 1, the primary box blank body 110 has three primary panel creases 112. It is contemplated that in other embodiments, there could be a different number of primary panel creases 112. The three primary panel creases 112 define four primary panels 120, 121, 122, 123. In the illustrated embodiment, the primary panels 120, 122 have the same size, and the primary panels 121, 123 have the same size. The primary panels 120, 122 are longer than the primary panels 121, 123, but all of the primary panels 120, 121, 122, 123 have a same width. As will be described in greater detail below, it is contemplated that the sizing of the primary panels 120, 121, 122, 123 may vary from one embodiment to another. For example, in some embodiments, the primary panels 120, 121, 122, 123 may all have the same size.

[0081] The primary box blank body 110 also has eight primary flaps 130, 131, 132, 133,134, 135, 136, 137. Each one of the primary flaps 130, 131, 132, 133, 134, 135, 136, 137 is connected to one of the primary panels 120, 121, 122, 123 via a primary flap crease 114, such that primary box blank body 110 has eight primary flap creases 114. More specifically, in the present embodiment, each one of the primary panels has two primary flaps connected thereto. The number of primary flaps 130, 131, 132, 133, 134, 135, 136, 137 and the number of primary flap creases 114 may vary from one embodiment to another. The primary flaps 130, 131, 132, 133, 134, 135, 136, 137 have the same length as the primary panel 120, 121, 122, 123 to which the primary panels 130, 131, 132, 133, 134,135, 136, 137 are connected. It will be noted that the primary box blank body 110 defines a plurality of gaps 139. Each gap 139 is defined between two adjacent primary flaps 130, 131, 132, 133, 134, 135, 136, 137 such that there are six gaps 139.

[0082] The primary box blank body 110 also includes a tab 140. The tab 140 is connected to the primary panel 123 via a tab crease 142. The tab 140 is configured to have glue applied thereon. In some embodiments, the tab 140 may be omitted.

[0083] With reference to Figures 1 and 3 A to 3C, the primary box blank body 110 can be folded into the primary box 111. More specifically, the primary box blank body 110 can be folded along the primary panel creases 112 and along the primary flap creases 114 to form the primary box 111. The gaps 139 can provide clearance for the primary panels 120, 121, 122, 123 and the primary flaps 130, 131, 132, 133, 134, 135, 136, 137 to fold. The primary panels 120, 121, 122, 123 correspond to side panels of the primary box 111, the primary flaps 130, 132, 134, 136 correspond to a bottom of the primary box 111 and the primary flaps 131, 133, 135, 137 correspond to a top of the primary box 111. Additionally, the tab 140 is folded along the tab crease 142 and is connected (e.g., via glue or adhesive) to the primary panel 120. This can assist in strengthening the primary box 111. When the primary box 111 is formed, the kraft linerboard 104 is on the exterior side of the primary box 111, and the oyster linerboard 106 is on the interior side of the primary box 111. The present primary box 111 may be referred to as a shipping box 111. The shipping box 111 is configured to store a plurality of different dispensable products. In Figure 3A, the dispensable product is a roll 119. The roll 119 may be a roll of various disposable items such as towels, bibs, or papers. Perforated lines may be present between each item of the roll 119. In the present embodiment, the shipping box 111 is sized to store eight rolls 119 as shown in Figure 3 A.

[0084] Referring back to Figure 1, the box blank 100 also has a plurality of markings 145 provided on the primary box blank body 110. The plurality of markings 145 define a shape of a secondary box blank body 150, which will be described in greater detail below, as well as features of the secondary box blank body 150.

[0085] The plurality of markings 145 are provided on both sides of the box blank 110. That is, the plurality of markings 145 are defined on the kraft linerboard 104, as well as on the oyster linerboard 106. It is contemplated that in some embodiments, the plurality of markings 145 may be provided on a single side of the box blank 110.

[0086] The plurality of markings 145 is a plurality of cut scores. The cut scores 145 enable the secondary box blank body 150 to be cut from the primary box blank body 110 without requiring any tool such as scissors or a knife. It can thus be said that the secondary box blank body 150 may be toolessly cut from the primary box blank body 110. However, it is contemplated that in other embodiments, the plurality of markings 145 may simply be printed dotted lines, and the secondary box blank body 150 may be cut from the primary box blank body 110 by cutting along the dotted lines, using a tool such as scissors or a knife.

[0087] Some of the plurality of markings 145 define an opening 147 (see Figures 4A and 4B). The opening 147 is a dispenser opening 147. The dispenser opening 147 is positioned on the primary panel 122, but may be positioned elsewhere in another embodiment. Additionally, in the present embodiment, the dispenser opening 147 is an obround slot, but as will be described below, it is contemplated that a shape and / or configuration of the dispenser opening 147 may vary.

[0088] With reference to Figure 2, the secondary box blank body 150, after it has been cut from the primary box blank body 110 will now be described. The secondary box blank body 150 can be manipulated to form a secondary box 151 (shown in Figures 4A and 4B) as will be described below. The secondary box 151 can be referred to as a dispenser box 151.

[0089] The secondary box blank body 150 has six secondary panel creases 152. It is contemplated that in other embodiments, there could be a different number of secondary panel creases 152. It will be noted that one of the secondary panel creases 152 corresponds to one of the primary panel creases 112 (i.e., only one of the secondary panel creases 152 is aligned with one of the primary panel creases 112). Additionally, some of the secondary panel creases 152 correspond to part of the primary flap creases 114. In some embodiments, the other secondary panel creases 152 may be pre-defined in the box blank 100. Alternatively, the box blank 100 may be provided with markings for indicating where the secondary box blank body 150 is to be folded. The six secondary panel creases 152 define seven secondary panels 160, 161, 162, 163, 164, 165, 166. In the illustrated embodiment,the secondary panels 160, 162, 164 have the same size, the secondary panels 161, 163 have the same size, and the secondary panels 165, 166 have the same size. It is contemplated that the sizing of the secondary panels 160, 161, 162, 163, 164, 165, 166 may vary from one embodiment to another.

[0090] The secondary box blank body 150 also has seven secondary flaps 170, 171, 172, 173, 174, 175, 176. Each one of the secondary flaps 170, 171, 172, 173, 174, 175, 176 is connected to one of the secondary panels 160, 161, 162, 163, 164, 165, 166 via a secondary flap crease 154, such that secondary box blank body 150 has seven secondary flap creases 154. It will be noted that only two of the secondary flap creases 154 corresponds to part of the primary flap creases 114 (i.e., only two secondary flap creases 154 are aligned with the primary flap creases 114). Like the secondary panel creases 152, the secondary flap creases 154 may be pre-defined or may be added manually. The number of secondary flaps 170, 171, 172, 173, 174, 175, 176 and the number of secondary flap creases 154 may vary from one embodiment to another.

[0091] The secondary flaps 170, 171 have a generally trapezoidal shape, and are connected to the secondary panel 164 via the secondary flap creases 154 (which correspond to part of the primary flap creases 114). The secondary flap 170 has a compressed portion 190, and the secondary flap 171 has a compressed portion 191. As will be described in greater detail below, the compressed portions 190, 191 may facilitate forming of the secondary box 151 by being easier to deform. It is contemplated that in some embodiments, the compressed portions 190, 191 may be omitted.

[0092] The secondary flaps 172, 174 are connected to the secondary panel 165. The secondary flaps 173, 175 are connected to the secondary panel 166. It will be noted that the secondary flaps 172, 173 are not connected to the secondary panel 163. This enables the secondary flaps 172, 173 to move relative to the secondary panel 163. The secondary flaps 172, 173 can be disconnected from the secondary panel 163 (i. e. , cut therefrom) when the secondary box blank body 150 is being cut from the primary box blank body 110. Likewise, the secondary flaps 174, 175, are not connected to the secondary panel 161.

[0093] Each of the secondary flaps 172, 173, 174, 175 is provided with an interlocker. More specifically, the secondary flaps 172, 175 are provided with an interlocking proj ection 180, and the secondary flaps 173, 174 define an interlocking recess 182. As will be described in greater detail below, when the secondary box 151 is being formed, the interlocking projection 180 of the secondary flap 172 is received in, and interlocks with, the interlocking recess 182 of the secondary flap 173, and the interlocking projection 180 of the secondary flap 175 is received in, and interlocks with, the interlocking recess 182 of the secondary flap 174.

[0094] The secondary flap 176 has a generally arcuate shape, and is connected to the secondary panel 160 via the secondary flap crease 154.

[0095] With reference to Figures 2, 4A and 4B, the secondary box blank body 150 can be folded into the secondary box 151. More specifically, the secondary box blank body 150 can be folded along the secondary panel creases 152 and along the secondary flap creases 154 to form the secondary box 151. The secondary panels 160, 161, 162, 163, 164 correspond to top, front, bottom and rear side panels of the secondary box 151 and the secondary panels 165, 166 correspond to lateral sides of the secondary box 151.

[0096] When the secondary box 151 is formed, the kraft linerboard 104 is on the interior side of the secondary box 151, and the oyster linerboard 106 is on the exterior side of the secondary box 151. Thus, if the kraft linerboard 104 is damaged and / or soiled while in the primary box 111 form (i.e., if the exterior of the primary box 111 is damaged and / or soiled) the exterior of the secondary box 151 does not show signs of wear. Additionally, the oyster linerboard 106 allows for a good quality printing such that designs, messages and / or advertisements may be printed on the oyster linerboard 106. These designs, messages and / or advertisements would be shown on the exterior of the secondary box 151.

[0097] The present secondary box 151 is smaller than the primary box 111. More specifically, a volume of the secondary box 151 is smaller than a volume of the primary box 111. The secondary box 151 is sized to receive a single selected roll 119 of the eight rolls 119 that were received in the primary box 111. As will be described below, thesecondary box 151 is a dispenser box 151 and items of the selected roll 119 that is contained within the secondary box 151 may be dispensed from the dispenser box 151.

[0098] Referring to Figures 1, 2, 3 A to 3C, 4A, 4B and 5A and 5B, a method 200 for providing one roll 119 selected from a plurality of rolls 119 into the dispenser box 151 will now be described. In the present embodiment, the rolls 119 each have a plurality of items that are configured to be dispensed form a circumference thereof.

[0099] The method 200 begins at step 205 by folding the primary box blank body 110 (Figure 1) to form the primary box 111 (Figures 3A to 3C). This is done by folding the primary box blank body 110 along the primary panel creases 112 and the primary flap creases 114. Additionally, while forming the primary box 111, glue is applied to the tab 140 in order to glue it to the primary panel 120, and tape is applied to the bottom of the primary box 111).

[0100] Following step 205, the method 200 continues with step 210 by placing eight rolls 119 into the primary box 111 as shown in Figure 3 A since the primary box 111 is sized to receive eight rolls 119. It is contemplated that in some embodiments, the primary box 111 may be sized to receive additional items. Thus, the method may further include placing containers into the primary box 111 with the rolls 119. For example, in an embodiment where the rolls 119 are rolls of paper towels, the primary box 111 may be sized to receive one or more containers such as spray bottles of cleaning liquid in addition to the rolls of paper towels. It is further contemplated that in some embodiments, as illustrated in Figure 3 A, containers 198 may be received between the rolls 119 and containers 199 may be received within a central aperture 117 defined in the rolls 119. This can assist in maximizing usage of space within the primary box 111. As a result, a need for another separate shipping box, such as for cleaning products, may be bypassed. The primary box 111 is then closed with an adhesive such as glue or tape. At this point, the primary box 111 can be shipped from one location to another (e.g., manufacturing plant to reception site).

[0101] Following step 210, the method 200 continues with step 215 by removing the eight rolls 119 from the primary box 111. Indeed, once the primary box 111 has arrivedto the reception site, the primary box 111 has to be opened to remove the rolls 119 therefrom.

[0102] Following step 215, the method 200 continues with step 220 by unfolding the primary box 111 back into the primary box blank body 110. To unfold the primary box 111, tape along the edges of the primary flaps 130, 131, 132, 133, 134, 135, 136, 137 has to be cut, and then the tab 140 has to be ripped from the primary panel 120. Alternatively, the tab 140 can be cut along the tab crease 142. The primary box 111 is unfolded along the primary panel creases 112 and the primary flap creases 114. It is contemplated that in some embodiments, the primary box 111 could only be partially unfolded.

[0103] Following step 220, the method 200 continues with step 225 by cutting the secondary box blank body 150 from the primary box blank body 110 by following the markings 145. In the present embodiment, the step 225 is done without needing any tools, as the markings 145 are cut scores. In other embodiments, the step 225 may be completed with a tool. It will be noted that at step 225, the dispenser opening 147 is also cut open.

[0104] Following step 225, the method 200 continues with step 230 by placing a selected roll 119 from the eight rolls 119 on the secondary box blank 150, as shown in the top, middle image of Figure 5A. At this step 230, part of an item of the selected roll 119 (e.g., part of a bib or a paper towel) may be received through the dispenser opening 147. This can facilitate dispensing of the selected roll 119 once the dispenser box 151 is ready to dispense.

[0105] Following step 230, the method 200 continues with step 235 by folding the secondary box blank body 150 around the selected roll 119. This enables to form the dispenser box 151 with the selected roll 119 inside the dispenser box 151. In other embodiments of the present technology, a dispensable product such as a stack of napkins may be inserted into the dispenser box 151 after forming the dispenser box 151.

[0106] The secondary box blank body 150 is folded along the secondary panel creases 152 and the secondary flap creases 154.

[0107] More specifically, with reference to the top, rightmost image of Figure 5A, the secondary panels 165, 166 are folded about their respective secondary panel crease 152. The secondary flaps 172, 173 are folded about their secondary flap crease 154, such that the interlocking projection 180 of the secondary flap 172 is received in the interlocking recess 182 of the secondary flap 173. Similarly, the secondary flaps 174, 175 are folded about their secondary flap crease 154, such that the interlocking projection 180 of the secondary flap 175 is received in the interlocking recess 182 of the secondary flap 174.

[0108] Then, with reference to the bottom, leftmost image of Figure 5A, the secondary panels 160, 161 are folded about their respective secondary panel creases 152, such that the secondary panel 161 extends over a top of the secondary box 151. The secondary flap 176 is folded about its secondary flap crease 154 and is received inwardly from the flap panels 172, 173.

[0109] Then, with reference to the second image from the left of the bottom row, the secondary panels 163, 164 are folded about their respective secondary panel creases 152 such that the secondary panel 164 extends over a top of the secondary box 151. The secondary flaps 170, 172 are folded about their respective secondary flap creases 154. The secondary flap 170 is received between the secondary panels 160, 165 whereas the secondary flap 171 is received between the secondary panels 160, 166, which effectively loses the secondary box 151. At this point, the presence of the compressible portions 190, 191 may facilitate insertion of the secondary flaps 170, 171 between their respective secondary panels. The dispenser box 151 can then be positioned such that the dispenser opening 147 is in a desired position.

[0110] The method 200 is thus finished, and the dispenser box 151 is ready to dispense items of the selected roll 119.

[0111] It will be appreciated that the dispenser box 151 can be formed without glue or another fastener.

[0112] It will further be appreciated that when the selected roll 119 is done, the dispenser box 151 may be unfolded, partially or fully back to the secondary box blank body150 (i.e., the above steps may be performed backwards until step 230). Then, another roll 119 may be placed on the secondary box blank body 150. Then, the secondary box blank body 150 may be re-folded to re-form the dispenser box 151.

[0113] With reference to Figures 6, 7, 8A to 8C, 9A and 9B, a box blank 300 according to an alternative embodiment of the present technology is shown. Features of the box blank 300 similar to those of the box blank 100, have been labeled with the same reference numerals and will not be described in detail herewith.

[0114] The box blank 300 has a primary box blank body 310 used to form a primary box 311. The box blank body 310 has markings 145 to allow a secondary box blank body 350 to be cut from the primary box blank body 310. The secondary box blank body 350 is used to form a secondary box 351, also referred to as dispenser box 351.

[0115] The box blank 300 notably differs from the box blank 100 in that the primary box blank body 310 is smaller than the primary box blank body 110. More specifically, the primary box blank body 310 is sized such that when the primary box blank body 310 is folded to form the primary box 311, the primary box 311 can store six rolls 119 (as opposed to the eight rolls 119 of the primary box 111).

[0116] Due to the smaller size of the primary box blank body 310, the interlocking projection 180 and the interlocking recess 182 of the secondary flaps 174, 175 are smaller than the interlocking projection 180 and the interlocking recess 182 of the secondary flaps 172, 173.

[0117] With reference to Figures 10, 11, 12Ato 12C, 13A, 13B and 14, a box blank 400 according to an alternative embodiment of the present technology is shown. Features of the box blank 400 similar to those of the box blank 100, have been labeled with the same reference numerals and will not be described in detail herewith.

[0118] The box blank 400 has a primary box blank body 410 used to form a primary box 411. The box blank body 410 has markings 145 to allow a secondary box blank body 450 to be cut from the primary box blank body 410. The secondary box blank body 450 is used to form a secondary box 451, also referred to as dispenser box 451.

[0119] The box blank 400 notably differs from the box blank 100 in that the primary box blank body 410 is smaller than the primary box blank body 110. More specifically, the primary box blank body 410 is sized such that when the primary box blank body 410 is folded to form the primary box 411, the primary box 411 can store four rolls 119 (as opposed to the eight rolls 119 of the primary box 111).

[0120] Due to the smaller size of the primary box blank body 410, the interlocking projections 180 and the interlocking recesses 182 have been omitted from the secondary flaps 172, 173, 174, 175, and the secondary flaps 172, 173, 174, 175 have been reduced in size such that when the secondary panels 165, 166 are folded about their respective secondary fold crease 154, the secondary flaps 172, 174 do not engage with, respectively, the secondary flaps 173, 175.

[0121] With reference to Figures 15A, 16, 17A to 17C, 18A, 18B and 19, a box blank 500 according to an alternative embodiment of the present technology is shown. Features of the box blank 500 similar to those of the box blank 100, have been labeled with the same reference numerals and will not be described in detail herewith.

[0122] The box blank 500 has a primary box blank body 510 used to form a primary box 511. The box blank body 510 has markings 145 to allow a secondary box blank body 550 to be cut from the primary box blank body 510. The secondary box blank body 550 is used to form a secondary box 551, also referred to as dispenser box 551.

[0123] The box blank 500 notably differs from the box blank 100 in that the primary box blank body 510 is smaller than the primary box blank body 110. More specifically, the primary box blank body 510 is sized such that when the primary box blank body 510 is folded to form the primary box 511, the primary box 511 can store two rolls 119 (as opposed to the eight rolls 119 of the primary box 111).

[0124] Due to the smaller size of the primary box blank body 510, the shape of the secondary box blank body 550 has changed. The secondary box blank body 550 has five secondary panels 560, 561, 562, 563, 564 and ten secondary flaps 570, 571, 572, 573, 574, 575, 576, 577, 578, 579.

[0125] For this embodiment, the folding of the secondary box blank 550 is different from the folding of the secondary box blank 150. Referring to the top, rightmost image of Figure 19, the secondary panel 564 is folded about its secondary panel crease 152, the secondary flaps 570, 571 are folded about their respective secondary flap creases 154, and then the secondary flaps 572, 573 are folded about their respective secondary flap creases 154. The secondary flaps 572, 573 are disposed outwardly from the flaps 570, 571.

[0126] With reference to the bottom, leftmost image of Figure 19, the secondary panel 563 is folded about its secondary panel crease 152, which also causes the secondary panels 564, 563 and the secondary panels 570, 571, 572, 573 to move. The secondary flaps 574, 575 are then folded about their respective secondary flap creases 154. The secondary flaps 574, 575 are disposed outwardly from the secondary flaps 570, 571, 572, 573.

[0127] This is repeated with the remaining secondary panels and flaps. At the end, the secondary flaps 578, 579 are positioned such that: one end of the secondary flap 578 is disposed outwardly from the secondary flap 576 and the other end of the secondary flap578 is disposed inwardly from the secondary flap 572, and one end of the secondary flap579 is disposed outwardly from the secondary flap 579 and the other end of the secondary flap 579 is disposed inwardly from the secondary flap 573.

[0128] It can thus be said that the dispenser box 551 is formed by interlocking the secondary flaps of the second box blank body.

[0129] Referring to Figure 15B, a box blank 500’ according to an alternative embodiment of the present technology is shown. The box blank 500’ is similar to the box blank 500, and will therefore not be described in detail herewith.

[0130] The box blank 500’ notably differs from the box blank 500 in that the markings 145’ for the dispenser opening 147’ of the box blank 500’ are different from the markings 145 of the dispenser opening 147 of the box blank 500. The dispenser opening 147’ has a central section 148’ that extends generally orthogonally to a remaining of the dispenser opening 147’. The central section 148’ is sized and shaped to accommodate thefingers of a person. Thus, the central section 148’ facilitates grasping of one of the dispensable products when the secondary carton 550 is assembled.

[0131] With reference to Figures 20, 21, 22Ato 22C, 23 A, 23B and 24, a box blank 600 according to an alternative embodiment of the present technology is shown. Features of the box blank 600 similar to those of the box blank 100, have been labeled with the same reference numerals and will not be described in detail herewith.

[0132] The box blank 600 has a primary box blank body 610 used to form a primary box 611. The box blank body 610 has markings 145 to allow a secondary box blank body 650 to be cut from the primary box blank body 610. The secondary box blank body 650 is used to form a secondary box 651, also referred to as dispenser box 651.

[0133] In this embodiment, the dispensable product is a roll 129 of center pull paper towels (i.e., the paper towels can be dispensed by pulling on the center the roll 129).

[0134] The box blank 600 notably differs from the box blank 100 in that the primary box blank body 610 is smaller than the primary box blank body 110. More specifically, the primary box blank body 610 is sized such that when the primary box blank body 610 is folded to form a primary box 611, the primary box 611 can store six rolls 129. It will be noted that the rolls 129 are different in height and diameter from the rolls 119.

[0135] Additionally, in the present embodiment, the dispenser opening 147 is a circular dispenser opening 147. The circular dispenser opening 147 being disposed centrally on the secondary panel 147 accommodates for the center pull configuration of the rolls 129.

[0136] Furthermore, in this embodiment, the markings 145 also define apertures for defining a handle on the secondary box 651. Indeed, as shown in Figure 21, the secondary box blank body 650 defines a panel aperture 605 and two flap apertures 606. When the secondary box 651 is formed, the panel aperture 605 and the flap aperture 606 are positioned such that fingers may be passed through the panel and flap apertures 605, 606. Thus, the panel and flap apertures 605, 606 define a handle 607 (Figures 23A and 23B), which enables the secondary box 651 to easily be carried. It is contemplated that thesize and shape of the panel and flap apertures 605, 606 may vary from one embodiment to another.

[0137] With reference to Figures 25, 26, 27A to 27C, 28A, 28B and 29, a box blank 700 according to an alternative embodiment of the present technology is shown. The box blank 700 is similar to the box blank 600 and will thus not be described in detail.

[0138] The box blank 700 has a primary box blank body 710 used to form a primary box 711. The box blank body 710 has markings 145 to allow a secondary box blank body 750 to be cut from the primary box blank body 710. The secondary box blank body 750 is used to form a secondary box 751, also referred to as dispenser box 751.

[0139] In this embodiment, the dispensable product is also a roll 129 of center pull paper towels, but other rolls are contemplated.

[0140] The box blank 700 notably differs from the box blank 600, in that the primary box blank body 710 is smaller than the primary box blank 610. More specifically, the primary box blank body 710 is sized such that when the primary box blank body 710 is folded to form the primary box 711, the primary box 711 can store four rolls 129 (as opposed to the six rolls 129 of the primary box 611).

[0141] As a result, the secondary flap 172 defines a smaller interlocking recess 182, and the secondary flap 173 defines a smaller interlocking projection 180 in comparison to the interlocking projection 180 and the interlocking recess 182 of the box blank 600. Additionally, the interlocking projection 180 and the interlocking recess 182 have been omitted from the secondary flaps 174, 175.

[0142] With reference to Figures 30, 31, 32Ato 32C, 33 A, 33B and 34, a box blank 800 according to an alternative embodiment of the present technology is shown. The box blank 800 is similar to the box blank 500. Features of the box blank 800 similar to those of the box blank 500 have been labeled with the same reference numerals and will not be described in detail herewith.

[0143] The box blank 800 has a primary box blank body 810 used to form a primary box 811. The box blank body 810 has markings 145 to allow a secondary box blank body 850 to be cut from the primary box blank body 810. The secondary box blank body 850 is used to form a secondary box 851, also referred to as dispenser box 851.

[0144] In this embodiment, the dispensable product is also a roll 129 of center pull paper towels.

[0145] In this embodiment, the dispensing opening 147 is in part defined by recesses 810 defined on the secondary flaps 571, 573, 575, 577, 579 thereof. When the secondary box 851 is formed, the recesses 810 form the dispensing opening 147.

[0146] Also, the secondary box blank body 850 defines apertures 805. When the secondary box 851 is formed, the apertures 805 are positioned such that fingers may be passed therethrough. Thus, the apertures 805 define a handle 807 (Figures 33A and 33B), which enables the secondary box 851 to easily be carried.

[0147] Referring to Figure 35, a box blank 100’ according to an alternative embodiment of the present technology is shown. The box blank 100’ is similar to the box blank 100. Features of the box blank 100 similar to those of the box blank 100 have been labeled with the same reference numerals, and will not be described in detail herewith. The box blank 100’ notably differs from the box blank 100 in that the box blank 100’ has two secondary box blank bodies 850’ instead of a single secondary box blank body 150. The secondary box blank bodies 850’ are similar to the secondary box blank bodies 850. Thus, in this embodiment, two secondary boxes can be formed from the single box blank 100’.

[0148] With reference to Figures 36, 37 and 38Ato 38C, a box blank 900 according to an alternative embodiment of the present technology is shown. The box blank 900 is similar to the box blank 100. Features of the box blank 900 similar to those of the box blank 100 have been labeled with the same reference numerals, and will not be described in detail herewith. The box blank 900 notably differs from the box blank 100 in that the box blank 900 has a primary box blank body 910 that is foldable to form a primary box 911 that canaccommodate four rolls 119 (only one roll shown in Figure 38 A), as opposed to eight rolls 119.

[0149] Additionally, the box blank 900 has a secondary box blank body 950. The secondary box blank body 950 has eight panels 960, 961, 962, 963, 964, 965, 966, 967, seven secondary flaps 970 disposed on one side of secondary box blank body 950 and seven secondary flaps 980 disposed on another side of the secondary box blank body 950. Each one of the panels 960, 961, 962, 963, 964, 965, 966 has a respective secondary flap 970, 980 connected thereto.

[0150] The secondary flaps 970, 980 are generally symmetrical to one another. Each one of the secondary flaps, 970, 980 has an inner section 990 and an outer section 991 (the inner and outer sections 990, 991 of only one of the flaps 970, 980 being labeled in Figure 37 for clarity). The outer section 991 is disposed at an angle relative to the inner section 990. This configuration can simplify the folding process of the secondary box blank body 950.

[0151] Additionally, the secondary box blank body 950 defines two slots 992 between the panels 960, 961, and the secondary box blank body 950 has two flaps 993 connected to the panel 967. When the secondary box blank body 950 is folded into a dispenser box 951, the panel 967 is disposed over the panel 960, and the flaps 993 are received in the slots 992. The dispenser box 951 is thus a heptagonal dispenser box, and surrounds the roll 119.

[0152] Modifications and improvements to the above-described embodiments of the present invention may become apparent to those skilled in the art. The foregoing description is intended to be exemplary rather than limiting. The scope of the present invention is therefore intended to be limited solely by the appended claims.

Claims

What is claimed is:

1. A method for providing a dispensable product selected from a plurality of dispensable products into a dispenser box, the method comprising: folding a primary box blank body to form a primary box; after folding the primary box blank body to form the primary box, placing the plurality of dispensable products into the primary box; after placing the plurality of dispensable products into the primary box, removing the plurality of dispensable products from the primary box; after removing the plurality of dispensable products from the primary box, unfolding the primary box into the primary box blank body; after unfolding the primary box into the primary box blank body, cutting a secondary box blank body from the primary box blank body by following a plurality of markings provided on the primary box blank body, the plurality of markings defining a shape of the secondary box blank body; after cutting the secondary box blank body from the primary box blank body, folding the secondary box blank body to form the dispenser box, the dispenser box being smaller than the primary box; and placing the selected dispensable product into the dispenser box.

2. The method of claim 1 , wherein folding the secondary box blank body to form the dispenser box and placing the selected dispensable product into the dispenser box comprise: placing the selected dispensable product onto the secondary box blank body before folding the secondary carton body; and folding the secondary box blank body around the selected dispensable product to form the dispenser box with the selected dispensable product inside the dispenser box.

3. The method of claim 1 or 2, wherein: folding the primary box blank body to form the primary box comprises folding the primary box blank along a plurality of primary panel creases and a plurality of primary flap creases; unfolding the primary box into the primary box blank body comprises unfolding the primary box along the plurality of primary panel creases and the plurality of primary flap creases; folding the secondary box blank body to form the dispenser box comprises folding the secondary box blank body along a plurality of secondary panel creases and a plurality of secondary flap creases; at least some of the secondary panel creases correspond to at least part of at least some the primary panel creases; and at least some of the secondary flap creases correspond to at least part of at least some the primary flap creases.

4. The method of any one of claims 1 to 3, wherein the dispenser box is formed without glue.

5. The method of any one of claims 1 to 4, wherein the dispenser box is formed by interlocking flaps of the second box blank body.

6. The method of any one of claims 1 to 5, wherein: the plurality of markings comprises a plurality of cut scores; and cutting the secondary box blank body from the primary box blank body comprises cutting along the cut scores without tools.

7. The method of any one claims 1 to 6, further comprising making an opening in the dispenser box for providing access to the dispensable product.

8. The method of any one of claims 1 to 7, wherein at least one dispensable product of the plurality of dispensable products defines a central aperture, and the method further comprising, before removing the plurality of dispensable products from the primary box, placing a container in the central aperture of the at least one dispensable product of the plurality of dispensable products.

9. A box blank comprising: a primary box blank body comprising: a plurality primary panel creases defining a plurality of primary panels; a plurality of primary flaps connected to the plurality of primary panels; and a plurality of primary flap creases, each primary flap of the plurality of primary flaps being connected to one primary panel of the plurality of primary panels via one primary flap crease of the plurality of primary flap creases; a plurality of markings provided on the primary box blank body, the plurality of markings defining a shape of a secondary box blank body, the secondary box blank body comprising: a plurality secondary panel creases defining a plurality of secondary panels; a plurality of secondary flaps connected to the plurality of secondary panels, and a plurality of secondary flap creases, each secondary flap of the plurality of secondary flaps being connected to one secondary panel of the plurality of secondary panels via one secondary flap crease of the plurality of secondary flap creases,the primary box blank body being foldable along the plurality of primary panel creases and the plurality of primary flap creases to form a primary box; and with the secondary box blank body being cut from the primary box blank body along the plurality of markings, the secondary box blank body being foldable along the plurality of secondary panel creases and the plurality of secondary flap creases to form a secondary box.

10. The box blank of claim 9, wherein: the primary box blank body is made from corrugated cardboard, the corrugated cardboard has a corrugated sheet disposed between a first linerboard and a second linerboard, the first linerboard being different from the second linerboard; with the primary box blank body being folded to form the primary box, the first linerboard is on an exterior of the primary box; and with the secondary box blank body being folded to form the secondary box, the second linerboard is on an exterior of the secondary box.

11. The box blank of claim 10, wherein the first linerboard is a kraft linerboard and the second linerboard is an oyster linerboard.

12. The box blank of any one of claims 9 to 11 , wherein some markings of the plurality of markings define a dispenser opening of the secondary box.

13. The box blank of claim 12, wherein the dispenser opening is one of a rectangular slot and a circular hole.

14. The box blank of any one of claims 9 to 13, wherein some markings of the plurality of markings define at least two apertures defining a handle of the secondary box.

15. The box blank of any one of claims 9 to 14, wherein at least some markings of the plurality of markings are cut scores.

16. The box blank of any one of claims 9 to 15, wherein at least one of: at least some of the secondary panel creases correspond to at least part of at least some the primary panel creases; and at least some of the secondary flap creases correspond to at least part of at least some the primary flap creases.

17. The box blank of any one of claims 9 to 16, wherein the primary box blank body comprises at least one tab connected to a portion of the at least one of the primary box blank body by at least one tab crease, the at least one tab being configured to glue to another part of the primary box blank body.

18. The box blank of any one of claims 9 to 17, wherein: one secondary flap of the plurality of secondary flaps comprises a first interlocker, an other secondary flap of the plurality of secondary flaps comprises a second interlocker, and with the secondary box blank body being folded along the plurality of secondary panel creases and the plurality of secondary flap creases, the first interlocker is configured to interlock with the second interlocker.

19. The box blank of any one of claims 9 to 18, wherein the secondary box blank body is configured to form the secondary box having a volume that is smaller than a volume of the primary box.

20. The box blank of claim 19, wherein: the primary box is sized to store a plurality of dispensable products; and the secondary box is sized to store only one selected dispensable product of the plurality of products.

21. The box blank of claim 20, wherein: the plurality of products is a plurality of dispensable products; each dispensable product of the plurality of dispensable products being one of a roll of dispensable items and a stack of dispensable items; the primary box is a shipping box for shipping the plurality of dispensable products; and the secondary box is a dispenser box for dispensing the dispensable items.