High-Strength Double Wall/Triple Wall Box, Box Form, and Method of Creating Same

Abstract

A pre-folded automatic bottom box form made from a unitary blank of material. The form has a blank of corrugated material that is die cut and creased so as to form a series of panels and flaps arranged in three rows of four panels or flaps each and a fourth row with two panels, all arranged in four columns, a first row comprising four panels that end up in the box as an automatic bottom, a second row comprising four panels that end up in the box as sidewall and end wall panels, a third row contiguous with the second row and comprising four panels that end up in the box as reinforcing sidewall and end wall panels, and a fourth row coupled to the third row and comprising first and second panels making additional end wall reinforcing panels.

What is claimed is: 
     
         1 . A pre-folded automatic bottom box form made from a unitary blank of material, comprising:
 a blank of corrugated material that is die cut and creased so as to form a series of panels and flaps arranged in three rows of four panels or flaps each and a fourth row with two panels, all arranged in four columns, a first row comprising four panels that end up in the box as an automatic bottom, a second row comprising four panels that end up in the box as sidewall and end wall panels, a third row contiguous with the second row and comprising four panels that end up in the box as reinforcing sidewall and end wall panels, and a fourth row coupled to the third row and comprising first and second panels making additional end wall reinforcing panels;   wherein the two panels of the fourth row are configured to be folded onto, and secured to, the two contiguous panels of the third row; and   wherein the blank is configured to be folded along two fold lines located between columns, and the edges of the end panels of the second row are configured to be fastened together to create a completed box.   
     
     
         2 . A box created from the pre-folded file bottom box form of  claim 1 . 
     
     
         3 . The box form of  claim 1  wherein the edges of the end panels of the second row are fastened together by one of gluing, stitching, or stapling. 
     
     
         4 . A pre-folded file bottom box form made from a unitary blank of material, comprising:
 a blank of corrugated material that is die cut and creased so as to form a series of panels and flaps arranged in three rows of four panels or flaps each and a fourth row with two panels, all arranged in four columns, a first row comprising four panels that end up in the box as the bottom and end wall reinforcing flaps, a second row comprising four panels that end up in the box as sidewall and end wall panels, a third row contiguous with the second row and comprising four panels that end up in the box as reinforcing sidewall and end wall panels, and a fourth row coupled to the third row and comprising first and second panels making additional end wall reinforcing panels;   wherein the two panels of the fourth row are configured to be folded onto, and secured to, the two contiguous panels of the third row; and   wherein the blank is configured to be folded along two fold lines located between columns, and the edges of the end panels of the second row are configured to be fastened together, to create a completed box.   
     
     
         5 . A box created from the pre-folded file bottom box form of  claim 4 . 
     
     
         6 . The box form of  claim 4  wherein the edges of the end panels of the second row are fastened together by one of gluing, stitching, or stapling.