Gift box container

Abstract

Stiffened double walled gift boxes are formed from paperboard blanks having main panels and wall panels with inner halves connected by gussets. A stiffener with a central panel and hinged sides half as wide as the side panels is placed in the main panel. Adhesive is applied on inner surfaces of the outer panels. As the wall panels are folded along peripheral edges of the main panel the loose stiffener is aligned by the wall panels. Sides of the stiffener bend with side panels of the box. Gussets are folded and placed inside end walls and are secured by outer end panels secured to inner end panels. Outer side panels are folded inward and adhered on sides of the stiffener, locking the stiffener in place.

1 . A double walled tray for forming a base box or cover of a double walled gift box, the double walled tray comprising a main panel, inner and outer opposed side wall panels, inner and outer opposed end wall panels and a stiffening sheet, the inner opposed side wall panels being hinged to the outer opposed side wall panel by fold lines wherein each of said outer opposed end wall panels is hingedly inter connected to an adjacent one of said outer opposed side wall panels by at least one gusset panel, wherein the stiffening sheet comprises a central panel and opposed side walls, the central panel of stiffening sheet being aligned with the main panel of the double walled tray, the inner opposed sidewall panels of the double walled tray being folded about said fold lines and secured in position, such that said opposed sidewalls of the stiffening sheet are disposed between the inner and outer opposed sidewall panels, each of said at least one gusset panels being disposed between said inner and outer end wall panels of the double walled tray and wherein the inner opposed end wall panels comprise a first part of at least one complementary locking mechanism and at least one of the inner opposed side wall panels or said stiffening sheet comprises a second part of said at least one complementary locking mechanism wherein said at least one complementary locking mechanism maintains the double walled tray in an assembled form.  
     
     
         2 . A double walled tray according to  claim 1  wherein one of said at least one gusset panel is secured to an adjacent outer opposed end wall panel to facilitate assembly of the double walled tray.  
     
     
         3 . A double walled tray according to  claim 1  wherein the stiffening sheet comprises opposed end walls disposed between said inner and outer opposed end walls of the double walled tray.  
     
     
         4 . A double walled tray according to  claim 2  wherein said opposed end walls of the stiffening sheet are shaped so as to accommodate said at least one gusset panel between the inner and outer end walls of the double walled tray.  
     
     
         5 . A double walled tray according to  claim 1  wherein said a first part of said at least one complementary locking mechanism comprises a tab connected to and integral with one of said opposed inner end wall panels.  
     
     
         6 . A double walled tray according to  claim 1  wherein said a first part of said a least one complementary locking mechanism is formed from an engaging edge disposed on a side edge of one of the inner opposed end walls.  
     
     
         7 . A double walled tray according to  claim 1  wherein said a second part of said at least one complementary locking mechanism is formed from an edge of said stiffening sheet.  
     
     
         8 . A double walled tray according to  claim 7  wherein said edge of said stiffening sheet is formed from an aperture struck from said stiffening sheet.  
     
     
         9 . A double walled tray according to  claim 8  wherein said aperture is formed in part from said central panel and in part from each of an opposed end wall of the stiffening sheet, wherein said opposed end walls are disposed between said inner and outer opposed end walls of the double walled tray.  
     
     
         10 . A double walled tray according to  claim 1  wherein said edge is formed from an end edge of an opposed sidewall of the stiffening sheet.  
     
     
         11 . A double walled tray according to  claim 1  wherein said a second part of said at least one complementary locking mechanism comprises an engaging edge disposed upon an end edge of one of the inner opposed side walls panels of the double walled tray.  
     
     
         12 . A double walled tray according to  claim 11  wherein said at least one second part of said at least on complementary locking mechanism further comprises a tab hinged to said at least one end edge of said inner opposed side walls, said tab being hinged adjacent said fold line between inner and outer side walls and wherein said tab is disposed between inner and outer end wall panels of the double walled tray.  
     
     
         13 . A double walled tray according to  claim 1  wherein the double walled tray comprises pair gusset panels hinged to a side edge of each outer end wall panel and wherein each of pair said gusset panels are secured to the outer end wall panel to which it is hinged.  
     
     
         14 . A flat collapsible double walled tray for forming a base box or cover of a double walled gift box comprising a main panel, inner and outer opposed side wall panels, inner and outer opposed end wall panels and a stiffening sheet, said inner opposed side walls being hinged to said outer opposed side walls by fold lines, wherein the outer opposed end walls are hingedly interconnected to the outer opposed side walls each by at least one gusset panel, wherein the stiffening sheet comprises a central panel being aligned and positioned in contact with said main panel of the double walled tray, said stiffening sheet further comprising side walls disposed between said opposed inner and outer side wall panels, wherein said inner opposed side walls are folded into overlapping relationship with said central panel of the stiffening sheet and each of said at least one gusset panels are folded into overlapping relationship with a respective one of said outer opposed end walls, wherein said inner opposed end wall panels comprise a first part of at least one complementary locking mechanism and at least one of said inner opposed side wall panels or said stiffening sheet comprises a second part of said at least one complementary locking mechanism wherein said at least one complementary locking mechanism is provided for maintaining the base box or cover in an erected form when the flat collapsible double walled tray is erected into a base box or cover.  
     
     
         15 . A flat collapsible double walled tray according to  claim 14  wherein said first part of said at least one complementary locking mechanism comprises a tab connected to and integral with each of said opposed inner end wall panels.  
     
     
         16 . A flat collapsible double walled tray according to  claim 14  wherein said first part of said at least one complementary locking mechanism is formed from an engaging edge disposed on at least one side edge of each of the inner opposed end walls.  
     
     
         17 . A flat collapsible double walled tray according to  claim 14  wherein said second part of said at least one complementary locking mechanism is formed from an edge of said stiffening sheet.  
     
     
         18 . A flat collapsible double walled tray according to  claim 17  wherein said edge of said stiffening sheet is formed from an aperture struck from said stiffening sheet.  
     
     
         19 . A flat collapsible double walled tray according to  claim 18  wherein said aperture is formed in part from said central panel and in part from each of an opposed end wall of the stiffening sheet, wherein said opposed end walls are disposed between said inner and outer opposed end walls of the double walled tray.  
     
     
         20 . A flat collapsible double walled tray according to  claim 19  wherein said edge is formed from an end edge of an opposed side wall of the stiffening sheet.  
     
     
         21 . A flat collapsible double walled tray according to  claim 14  wherein said a second part of said at least one complementary locking mechanism comprises an engaging edge disposed upon an end edge of each of the inner opposed side wall panels of the double walled tray.  
     
     
         22 . A flat collapsible double walled tray according to  claim 21  wherein said second part of said at least on complementary locking mechanism further comprises a tab hinged to said an end edge one of said inner opposed side walls, said tab being hinged adjacent said fold line between inner and outer side walls and wherein said tab is disposed between inner and outer end wall panels of the double walled tray.  
     
     
         23 . A flat collapsible double walled tray according to  claim 14  wherein the inner opposed end walls are hinged to the outer opposed end walls by further fold lines and said inner opposed end walls are folded into overlapping relationship with said outer opposed end walls such that respective ones of said at least one gusset panels are disposed between their respective inner and outer end wall panels.  
     
     
         24 . A flat collapsible double walled tray according to  claim 23  wherein each of said at least one gusset panels hinged to said outer opposed end wall panels are secured to an outer opposed end wall panel to which is hinged.  
     
     
         25 . A flat collapsible double walled tray according to  claim 23  wherein each of said at least one gusset panel is adhesively secured to the outer opposed end wall panel to which it is hinged.  
     
     
         26 . A flat collapsed double walled tray according to  claim 22  wherein the tab is disposed between a respective one of said at least one gusset panels and a respective one of said outer opposed end wall panels.  
     
     
         27 . A flat collapsed double walled tray for forming a base box or cover of a double walled gift box comprising a tray forming sheet having a main panel, hinged inner and outer side and end walls, wherein each outer end wall is hinged to each adjacent outer side or end walls by at least one gusset panel, the tray further comprising a stiffening sheet comprising a central panel and opposed side walls wherein the central panel is aligned in registry with the main panel of the tray forming sheet and to opposed side walls of the stiffening sheet are disposed between the inner and outer side walls of the tray forming sheet, wherein the outer side walls of the tray forming sheet are folded automatically in response to folding of the outer end walls to assemble the flat collapsed double walled tray into a base box or cover and wherein the double walled tray further comprises two part complementary locking mechanism to maintain the double walled tray in an erected position.  
     
     
         28 . A method of constructing a flat collapsible double walled tray from a tray forming sheet and a stiffening sheet, said tray forming sheet comprising a main panel having opposed side and end edges and opposed inner and outer side wall panels and opposed inner and outer end wall panels hinged to said opposed side and end edges respectively, the tray forming sheet further comprising at least one gusset panel hingedly interconnecting each of said outer side wall panels to an adjacent one of said outer end wall panels, said stiffening sheet comprising a central panel having opposed side and end edges and opposed side panels hinged to said opposed side edges, the method comprising: 
 placing said central panel of the stiffening sheet into contact with the main panel of the tray forming sheet and aligning the central panel with the main panel;    folding said opposed outer side wall panels into overlapping relationship with said opposed side panels of the stiffening sheet;    securing said stiffening sheet to said tray forming sheet;    and folding said opposed outer and inner side wall panels into overlapping relationship with a portion of the central panel of the stiffening sheet such that in response to folding of the outer and inner side panels each of said at least one gusset panels are folded into overlapping relationship with a respective opposed end wall panel.    
     
     
         29 . A method of constructing a flat collapsible double walled tray according to  claim 28  wherein the method comprises folding said inner opposed end wall panels into overlapping relationship with the opposed outer end wall panel.  
     
     
         30 . A method of constructing a flat collapsible double walled tray according to  claim 28  wherein the method further comprises; applying adhesive to either the main panel of the tray forming sheet or the central panel of the stiffening sheet in order to secure the stiffening sheet to the tray forming sheet.  
     
     
         31 . A method of constructing a flat collapsible double walled tray according to  claim 28  wherein the method further comprises; applying adhesive to either the opposed outer side wall panels of the tray forming sheet or to the opposed side panels of the stiffening sheet to secure the stiffening sheet to the tray forming sheet.  
     
     
         32 . A method of constructing a flat collapsible double walled tray according to  claim 28  wherein the method further comprises; adhesively securing one of said at least one gusset panel to a respective outer end wall panel.  
     
     
         33 . A method of forming a double walled tray for forming a base box or cover of a double walled gift box from a flat collapsible double walled tray according to  claim 27  wherein the method comprising: 
 folding the outer end wall panels into a substantially perpendicular relationship with the main panel of the flat collapsible double walled tray, whereby the inner and outer side walls of the flat collapsible double walled tray are raised automatically into a substantially perpendicular alignment with the main panel in response to folding the outer end wall panels;    folding inner end wall panels inwardly of the double walled tray;    deploying said at least one complementary locking mechanism to secure the opposed inner end wall panels maintaining said double walled tray in an erected form.