Outer boxes for storing and delivering medical devices used during surgical procedures and methods therefor

A flat box for storing a flat medical device comprising:

• a first panel including an upper edge, a lower edge, a first side edge, and a second side edge;
• a second panel hingedly connected with said lower edge of said first panel;
• a third panel hingedly connected with a lower edge of said second panel;
• a first side flap hingedly connected with said first side edge of said first panel;
• a second side flap hingedly connected with said second side edge of said first panel;
• said third panel being foldable over said second panel and said second panel being foldable over said first panel for forming a first storage compartment between said first and third panels and a second storage compartment between said second and third panels;
• said first side flap being foldable over and interlockable with said second panel for closing a first side of said box;
• said second side flap being foldable over and interlockable with said second panel for closing a second side of said box;
• a cover hingedly connected with said upper edge of said first panel, wherein said cover is foldable over and interlockable with said first and second side flaps and said second panel for holding said cover in a closed position, wherein each of said first and second side flaps and said second panel includes at least one cover locking slit adapted to receive a respective locking tab on said cover for mechanically interlocking said cover with said first and second side flaps and said second panel for holding said cover in the closed position, wherein said cover has central locking tabs that engage central cover locking slits on said second panel and outer locking tabs outside said central locking tabs that engage side flap locking slits of said respective first and second side flaps, and wherein said outer locking tabs are more rigidly connected with said cover than said central locking tabs.

A flat box for storing a surgical mesh comprising:

• a first panel including an upper edge, a lower edge, a first side edge, and a second side edge;
• a second panel hingedly connected with said lower edge of said first panel;
• a third panel hingedly connected with a lower edge of said second panel;
• a first side flap hingedly connected with said first side edge of said first panel;
• a second side flap hingedly connected with said second side edge of said first panel;
• said third panel being foldable over said second panel and said second panel being foldable over said first panel for forming a first storage compartment between said first and third panels and a second storage compartment between said second and third panels;
• a surgical mesh stored in said first storage compartment;
• at least one booklet stored in said second storage compartment;
• said first side flap being foldable over and interlockable with said second panel for closing a first side of said box and holding said second and third panels against said first panel;
• said second side flap being foldable over and interlockable with said second panel for closing a second side of said box and holding said second and third panels against said first panel;
• a cover hingedly connected with said upper edge of said first panel, said cover having a free edge with cover locking tabs, wherein said cover is foldable over said first and second side flaps and said second panel for mechanically interlocking said cover locking tabs with cover locking slits provided on said first and second side flaps and said second panel for holding said cover in a closed position so as to cover said surgical mesh and said at least one booklet, wherein said cover has central locking tabs that engage central cover locking slits on said second panel and outer locking tabs outside said central locking tabs that engage side flap locking slits of said respective first and second side flaps, and wherein said outer locking tabs are more rigidly connected with said cover than said central locking tabs.