Improved return box and blank
A box blank with dual top panels and secure closure mechanisms addresses the issue of damaged return boxes by enabling secure reuse and tamper-evident opening, ensuring integrity for both shipping and return packaging.
Patent Information
- Authority / Receiving Office
- GB · GB
- Patent Type
- Patents
- Current Assignee / Owner
- THE REEDBUT GRP LTD
- Filing Date
- 2023-09-07
- Publication Date
- 2026-06-01
AI Technical Summary
Ecommerce has led to increased product returns, often resulting in goods being repackaged in damaged original cardboard boxes, which are not suitable for secure reuse as return containers.
A blank for forming a box with two top panels, featuring slots and tabs for secure closure and tamper-evident opening, allowing damage to one panel to be hidden during return use, ensuring the box can be reused without additional sealing materials.
The solution provides a secure, tamper-evident return box that can be used without visible damage, maintaining integrity for both shipping and return packaging without the need for additional adhesives.
Smart Images
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Abstract
Description
This invention relates to a blank for forming a box and to the box formed from the blank. The success of ecommerce has meant that an increasing number of products that are purchased over the Internet are sent to the purchaser in a box, usually made of cardboard, which is assembled from a blank. The blank will be provided with different score lines, fold lines, cuts and so on and the blank is assembled by folding the various panels of the blank to create the finished box, which is then used to house the goods being transported to the end user. Once the box has been filled and it is usually sealed in some way to ensure that the contents of the box are not tampered with in any way. However, the box still needs to be relatively easy to open by the final end user and ideally provide a tamper-proof opening that the end user can see has not been interfered with. It is also the case that the rise of ecommerce and the sending of goods to end users in a cardboard box via the mail has resulted in a proportion of goods needing to be returned by the end user to the provider. The percentage of goods needing to be returned can be more than 10% of those sent out, depending upon the type of product that is being shipped. This means that there is a requirement for the end user to have a suitable container to repackage the goods and return them to the supplier. In many cases, the end user will simply return the goods in the cardboard box that has been used to ship the goods in the first place. However, this is often less than ideal, since the original box has often been damaged in the process of being opened by the end user. It is therefore an object of the invention to improve upon the known art. 18 08 25 According to the present invention, there is provided a blank for forming a box according to the attached claims. Owing to the invention, it is possible to provide a blank that can be formed into a box that can be used to send goods to an end user, while also 5 being suitable for use as a return box, without any visible damage to the box. The blank (and therefore the resulting box) is provided with two top panels, designated as a primary top panel and a secondary top panel, which are provided on opposite sides of the blank. When the retailer closes the box they will fold in the secondary top panel first and close the box with the primary top io panel. The end user can then open the box and any damage that occurs to the primary top panel during the opening process does not prevent the box being reused as a return box. If the end user wishes to return the goods that have been shipped in the box, then can replace the goods in the box and fold in the primary top panel first and close the box with the secondary top panel. Any 15 damage that has occurred to the primary top panel will not be visible, but the box will still be closed and sealed in a secure manner. The blank further comprises a first slot located on the line of weakness connecting the primary top panel to the front panel, a second slot located on the line of weakness connecting the secondary top panel to the back panel, a 20 first tab located on an edge of the primary top panel opposite the first slot located on the line of weakness connecting the primary top panel to the front panel, and a second tab located on an edge of the secondary top panel opposite the second slot located on the line of weakness connecting the secondary top panel to the back panel. The slots and tabs can be provided on 25 the blank to allow the primary top panel and the secondary top panel to be push locked together without the requirement for any additional locking material such as adhesive tape. When the retailer closes the box formed from the blank they will fold in the secondary top panel first and close the box with the primary top panel, with the tab on the primary top panel engaging in the 30 slot on the line of weakness that connects the secondary top panel to the back panel. When the end user closes the box they will fold in the primary top panel first and close the box with the secondary top panel, with the tab on the secondary top panel engaging in the slot on the line of weakness that connects the primary top panel to the front panel. Ideally, each of the two primary locking panels extend from a point adjacent to an edge of the primary top panel opposite the line of weakness connecting the primary top panel to the front panel to a midpoint of the respective side of the primary top panel. Similarly, ideally, each of the two secondary locking panels extend from a point adjacent to an edge of the secondary top panel opposite the line of weakness connecting the secondary top panel to the back panel to a midpoint of the respective side of the secondary top panel. The locking panels present on either side of the primary and secondary top panels are ideally sized so that they extend down half the length of the top panel sides. This provides a complementary function when the two top panels are folded inwards, regardless of which top panel is folded in first. The second top panel that is folded over the first top panel will have its locking panels slotted in alongside the top panel underneath, thereby creating a good and secure seal of the two top panels, one on top of the other, regardless of which of the two top panels has been folded in first. Advantageously, the blank further comprises a line of weakness located on the primary top panel, the line of weakness extending from a first point adjacent to an edge of the primary top panel opposite the line of weakness connecting the primary top panel to the front panel, into the interior of the primary top panel and back to a second point adjacent to the edge of the primary top panel opposite the line of weakness connecting the primary top panel to the front panel. Similarly, the blank advantageously further comprises a line of weakness located on the secondary top panel, the line of weakness extending from a first point adjacent to an edge of the secondary top panel opposite the line of weakness connecting the secondary top panel to the back panel, into the interior of the secondary top panel and back to a second point adjacent to the edge of the secondary top panel opposite the line of weakness connecting the secondary top panel to the back panel. The provision of lines of weakness on the top panels that start at the edge of the respective top panel extend out towards the middle of the panel and then return to the edge (which may be curved or may be made up of a serious of straight lines, for example) provides a method of opening the respective top panel that is both easy for a user to operate, but will also provide a tamper-evident opening mechanism. The end user can break this line of weakness (on the primary top panel) to create a hand hold that allows the user to open a box constructed from the blank. If the box is then used as a return box, then the secondary top panel will be on top when the box is received back at the retailer and their employee can use this line of weakness (on the secondary top panel which is now exposed) to open the box. Embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which:- Figures 1 and 2 are plan views of a blank for forming a box, Figures 3 to 5 are perspective views of a box being constructed from the blank of Figures 1 and 2, Figures 6 to 8 are perspective views of the box of Figure 3 to 5 being opened, and Figures 9 to 11 are perspective views of the box of Figure 3 to 5 being reclosed. Figure 1 shows a blank 10 for forming a cardboard box. The blank 10 is formed from a flat sheet of cardboard and is cut from the flat sheet. The blank 10 is also provided with numerous lines of weaknesses, which can take a number of different forms, such as crease lines, partial cuts, fold lines and the like. A line of weakness has the function that it either facilitates a fold along the line of weakness or the line of weakness allows a break to be made along the line. For example, a line of weakness that is formed by a crease being imprinted will later allow a fold to be made along that line whereas a line of weakness that is formed by partial cuts will later allow a tear to be made along that line. Figure 1 is shown without any reference numerals in order to illustrate the blank 10 for ease of understanding. Figure 2 shows the identical blank 10 but with the reference numerals added. The blank 10 comprises a base panel P1, two side panels P2 connected to respective first and second opposite sides of the base panel P1 along respective lines of weakness L1 and L2, a front panel P3 connected to a third side of the base panel P1 along a line of weakness L3 and a back panel P4 connected to a fourth side of the base panel P1 along a line of weakness L4. Two front tuck-in panels P3a and P3b are each connected to the front panel P3 along respective lines of weakness L5 and L6. Similarly, two back tuck-in panels P4a and P4b each connected to the back panel P4 along respective lines of weakness L7 and L8. A primary top panel P5 is connected to the front panel P3 along a line of weakness L9 parallel to the line of weakness L3 connecting the front panel P3 to the base panel P1 and a secondary top panel P6 is connected to the back panel P4 along a line of weakness L10 parallel to the line of weakness L4 connecting the back panel P4 to the base panel P1. The primary top panel P5 has two primary locking panels P5a and P5b each connected to respective opposite sides of the primary top panel P5 along respective lines of weakness L11 and L12, and the secondary top panel P6 has two secondary locking panels P6a and P6b each connected to respective opposite sides of the secondary top panel P6 along respective lines of weakness L13 and L14. The blank 10 also comprises a first slot S1 located on the line of weakness L9 connecting the primary top panel P5 to the front panel P3, a second slot S2 located on the line of weakness L10 connecting the secondary top panel P6 to the back panel P4, a first tab T1 located on an edge of the primary top panel P5 opposite the first slot S1 located on the line of weakness L9 connecting the primary top panel P5 to the front panel P3, and a second tab T2 located on an edge of the secondary top panel P6 opposite the second slot S2 located on the line of weakness L10 connecting the secondary top panel P6 to the back panel P4. Each of the two primary locking panels P5a, P5b extend from a point adjacent to an edge of the primary top panel P5 opposite the line of weakness L9 connecting the primary top panel P5 to the front panel P3 to a midpoint of the respective side of the primary top panel P5. Similarly, each of the two secondary locking panels P6a, P6b extend from a point adjacent to an edge of the secondary top panel P6 opposite the line of weakness L10 connecting the secondary top panel P6 to the back panel P4 to a midpoint of the respective side of the secondary top panel P6. Each side panel P2 is provided with a respective double line of weakness L15 and L16 parallel to the respective line of weakness L1 and L2 connecting the respective side panel P2 from the base panel P1. Two holes H1 are located in the secondary top panel P6. A line of weakness L17 is located on the primary top panel P5. The line of weakness L17 extends from a first point adjacent to an edge of the primary top panel P5 opposite the line of weakness L9 connecting the primary top panel P5 to the front panel P3, into the interior of the primary top panel P5 and back to a second point adjacent to the edge of the primary top panel P5 opposite the line of weakness L9 connecting the primary top panel P5 to the front panel P3. The line of weakness L17 forms a loop and can be used when a box formed from the blank 10 is to be opened by an end user. Similarly, a line of weakness L18 is located on the secondary top panel P6. The line of weakness L18 extends from a first point adjacent to an edge of the secondary top panel P6 opposite the line of weakness L10 connecting the secondary top panel P6 to the back panel P4, into the interior of the secondary top panel P6 and back to a second point adjacent to the edge of the secondary top panel P6 opposite the line of weakness L10 connecting the secondary top panel P6 to the back panel P4. Similarly to the line of weakness L17, the line of weakness L18 can be used to open the box, once it has been closed and resealed by the end user. The process of forming a box from the blank 10 is illustrated in Figures 3 to 5. Figure 3 shows the first stage of this process, which is to assemble the sides of the box around the base panel P1. The two side panels P2 are folded in half along the double lines of weakness L15 and L16 and folded over trapping the front and back tuck-in panels P3a, P3b, P4a and P4b in-between the two halves of the side panels P2. Tabs T3 on the outward edges of the side panels P2 are located in slots S3 that lie on the lines of weakness L1 and L2 that connect the base panel P1 to the respective side panels P2 (see Figure 2) to hold the folded side panels P2 in place. These actions result in the creation of the partially formed box shown in Figure 3. The process of forming the box is continued, as shown in Figure 4. The two secondary locking panels P6a and P6b are folded inwards by 90 degrees and the secondary top panel P6 is folded downwards into a closed position. The second tab T2 located on the edge of the secondary top panel P6 is also folded in by 90 degrees, but does not engage with any other part of the blank 10 as the secondary top panel P6 is closed. Figure 5 shows the box 12 being finally closed, with the primary top panel P5 being closed in a similar manner to the secondary top panel P6. The two primary locking panels P5a and P5b are folded in by 90 degrees and the first tab T1 engages with the slot S2. The engagement of the tab T1 with the slot S2 creates a tamper proof seal and the box cannot be opened without damaging the tab and slot arrangement, which will be obvious to anyone examining the box 12. The two top panels P5 and P6 are essentially the same size and shape as the base panel P1 and either top panel P5 or P6 can be used to close the box 12. The construction of the blank 10 and hence the box 12 is such that the box 12 is effectively provided with two alternative lids (the two panels P5 and P6), one of which is intended to be used as the normal lid when the box 12 is closed for the original transit of the goods packaged inside the box 12 and the other which can be used if the end receiver of the packaged goods wishes to return the received goods. The outlines of the two top panels P5 and P6 are mirror images of each other, as can be seen in Figure 3, for example. To open the box, the end user needs to break open the tab T1 from the slot S2, as shown in Figure 6. The easiest way to achieve this is for the end user to open the locking tab T1 on the primary top panel P5 by tearing along the line of weakness L17, which is a perforation, and pulling away the tab T1 from the box 12. As can be seen in the Figure, this action separates part of the box 12 from the remainder of the box 12, allowing the primary top panel P5 to be opened, but also creating the tamper-evident opening configuration, which means that the box 12 cannot be closed again with the primary top panel P5, without it being obvious that the box 12 has already been opened. Once the end user has opened the primary top panel P5, the box 12 is in the configuration shown in Figure 7. Figure 7 shows the box 12 with the primary top panel P5 open, but the secondary top panel P6 is still closing the interior of the box 12. The secondary top panel P6 is not secured in any way and the end user can easily open the secondary top panel P6 using the holes H1 that are present in the top panel P6. The user can insert their fingers into the holes H1 and then lift up the secondary top panel P6 to access the interior of the box 12. Figure 8 shows the configuration of the box 12 after the secondary top panel P6 has been opened by the end user. The configuration shown in Figure 8 is the same as that shown in Figure 3 (when the box 12 is being constructed) with the exception that the end user has broken off part of the primary top panel P5 (the tab T1 and part of the panel P5). If the end user wishes to return the contents of the box 12, for any reason, then they can reuse the box 12 for that purpose. The end user will replace the contents in the box 12 and then close the primary top panel P6 first, as shown in Figure 9. Instructions can be printed on the various panels explaining to the user the process of closing the panels to reuse the box as a return box. The primary top panel P6 being closed in this manner does not engage with any other panels of the box 12 in a locking manner, the primary top panel P6 is simply folded down to create a lid of the box 12. The end user then completes the process of closing and sealing the box 12 by folding down the secondary top panel P6, as shown in Figure 10. In the process of folding down the secondary top panel P6, so that this panel P6 lies on top of and in contact with the primary top panel P5, the user will engage the second tab T2 in the slot S1. The second tab T2 is the tab T2 that extends from the outer edge of the secondary top panel P6 and has not been used in the previous construction of the box 12 at the original retailer. This tab T2 locks into the slot S1 that lies on the line of weakness L9 which divides the primary top panel P5 from the front panel P3. The locking between the tab T2 and the slot S1 ensures a new tamper-evident closure of the secondary top panel P6 and the box 12 cannot be reopened without visible damage occurring to the box 12. Figure 11 shows the final configuration of the resealed box 12. The box 12 is now closed and secure and the two top panels P5 and P6 have been 5 folded down to create the top lid of the box 12 (with the secondary panel P6 on top). When the box 12 is closed for the use as a return box, the secondary top panel P6 is on top of the primary top panel P5 (the reverse of the configuration of Figure 5) and the end user can now return the received goods in the same box 12 in which the goods were originally shipped. The blank 10 provides a io one-piece returnable box 12 that can be used in ecommerce, without the requirement to use any tape or glue in either the original shipping or the return while also providing a tamper evident closure for both legs of the box transfer. 18 08 25
Claims
1. A blank (10) for forming a box (12), the blank (10) comprising:• a base panel (P1),5 • two side panels (P2) connected to respective first and secondopposite sides of the base panel (P1) along respective lines of weakness (L1, L2),• a front panel (P3) connected to a third side of the base panel (P1) along a line of weakness (L3),io • a back panel (P4) connected to a fourth side of the base panel(P1) along a line of weakness (L4),• two front tuck-in panels (P3a, P3b) each connected to the front panel (P3) along respective lines of weakness (L5, L6),• two back tuck-in panels (P4a, P4b) each connected to the back 15 panel (P4) along respective lines of weakness (L7, L8),• a primary top panel (P5) connected to the front panel (P3) along a line of weakness (L9) parallel to the line of weakness (L3) connecting the front panel (P3) to the base panel (P1),• a secondary top panel (P6) connected to the back panel (P4)20 along a line of weakness (L10) parallel to the line of weakness(L4) connecting the back panel (P4) to the base panel (P1), the two top panels (P5, P6) being the same size and shape as the base panel (P1),• two primary locking panels (P5a, P5b) each connected to25 respective opposite sides of the primary top panel (P5) alongrespective lines of weakness (L11, L12), and• two secondary locking panels (P6a, P6b) each connected to respective opposite sides of the secondary top panel (P6) along respective lines of weakness (L13, L14)30 wherein the blank further comprises:18 08 25• a first slot (S1) located on the line of weakness (L9) connecting the primary top panel (P5) to the front panel (P3),• a second slot (S2) located on the line of weakness (L10) connecting the secondary top panel (P6) to the back panel (P4), 5 • a first tab (T1) located on an edge of the primary top panel (P5)opposite the first slot (S1) located on the line of weakness (L9) connecting the primary top panel (P5) to the front panel (P3), and• a second tab (T2) located on an edge of the secondary top panel (P6) opposite the second slot (S2) located on the line of io weakness (L10) connecting the secondary top panel (P6) to theback panel (P4).
2. A blank according to claim 1, wherein each of the two primary locking panels (P5a, P5b) extend from a point adjacent to an edge of the 15 primary top panel (P5) opposite the line of weakness (L9) connecting the primary top panel (P5) to the front panel (P3) to a midpoint of the respective side of the primary top panel (P5).
3. A blank according to claim 1 or 2, wherein each of the two 20 secondary locking panels (P6a, P6b) extend from a point adjacent to an edge of the secondary top panel (P6) opposite the line of weakness (L10) connecting the secondary top panel (P6) to the back panel (P4) to a midpoint of the respective side of the secondary top panel (P6).25 4. A blank according to any preceding claim, wherein each sidepanel (P2) is provided with a respective double line of weakness (L15, L16) parallel to the respective line of weakness (L1, L2) connecting the respective side panel (P2) from the base panel (P1).30 5. A blank according to any preceding claim, and further comprisingone or more holes (H1) located in the secondary top panel (P6).18 08 256. A blank according to claim 5, wherein the secondary top panel (P6) is provided with two holes (H1).
7. A blank according to any preceding claim, and further comprising 5 a line of weakness (L17) located on the primary top panel (P5), the line of weakness (L17) extending from a first point adjacent to an edge of the primary top panel (P5) opposite the line of weakness (L9) connecting the primary top panel (P5) to the front panel (P3), into the interior of the primary top panel (P5) and back to a second point adjacent to the edge of the primary top panel (P5) io opposite the line of weakness (L9) connecting the primary top panel (P5) to the front panel (P3).
8. A blank according to any preceding claim, and further comprising a line of weakness (L18) located on the secondary top panel (P6), the line of 15 weakness (L18) extending from a first point adjacent to an edge of the secondary top panel (P6) opposite the line of weakness (L10) connecting the secondary top panel (P6) to the back panel (P4), into the interior of the secondary top panel (P6) and back to a second point adjacent to the edge of the secondary top panel (P6) opposite the line of weakness (L10) connecting 20 the secondary top panel (P6) to the back panel (P4).
9. A box formed from the blank of any one of claims 1 to 8.