Foldable Box
A foldable box having a first, substantially flat and unfolded configuration which can be easily and conveniently transformed into a second, three-dimensional configuration capable of retaining one or more items.
This application claims the priority benefit of U.S. Provisional Patent Application Ser. No. 62/428,602, filed Dec. 1, 2016, U.S. Provisional Patent Application Ser. No. 62/428,606, filed Dec. 1, 2016, U.S. Provisional Patent Application Ser. No. 62/476,914, filed Mar. 27, 2017; U.S. Provisional Patent Application Ser. No. 62/485,091, filed Apr. 13, 2017; and is a continuation-in-part of U.S. patent application Ser. No. 29/583,811 filed Nov. 9, 2016; U.S. patent application Ser. No. 29/583,815 filed Nov. 9, 2016; U.S. patent application Ser. No. 29/585,394 filed Nov. 23, 2016; U.S. patent application Ser. No. 29/585,399 filed Nov. 23, 2016; U.S. patent application Ser. No. 29/610,397 filed Jul. 12, 2017; U.S. patent application Ser. No. 29/611,998 filed Jul. 27, 2017; U.S. patent application Ser. No. 29/612,002 filed Jul. 27, 2017; U.S. patent application Ser. No. 29/611,995 filed Jul. 27, 2017; U.S. patent application Ser. No. 29/611,992 filed Jul. 27, 2017; U.S. patent application Ser. No. 29/623,678 filed Oct. 26, 2017; U.S. patent application Ser. No. 29/623,680 filed Oct. 26, 2017; U.S. patent application Ser. No. 29/623,683 filed Oct. 26, 2017; U.S. patent application Ser. No. 29/623,686 filed Oct. 26, 2017; U.S. patent application Ser. No. 29/623,688 filed Oct. 26, 2017; U.S. patent application Ser. No. 29/623,689 filed Oct. 26, 2017; U.S. patent application Ser. No. 29/623,693 filed Oct. 26, 2017; U.S. patent application Ser. No. 29/627,144 filed Nov. 22, 2017; U.S. patent application Ser. No. 29/613,487 filed Aug. 10, 2017; and U.S. patent application Ser. No. 29/613,491 filed Aug. 10, 2017, all of which are incorporated herein by reference.
BACKGROUND ON THE INVENTIONBoxes are used every day for many purposes such as storage and shipping. Typically, when boxes are manufactured by a manufacturing company, the boxes are manufactured and shipped in a three-dimensional form. The manufacturing company then must pay for additional shipping cost for empty space within the box. Additionally, the boxes are also more susceptible to damage when shipped in this fashion. To overcome the high shipping cost and inefficient shipping of such boxes, box designers have made collapsible boxes. These boxes are designed to be shipped flat and need to be constructed by the end user of the box. End user construction of these boxes often requires time-consuming processes such as the application of additional or extra materials (e.g., glue, tape, etc.). These actions can be complicated, time-consuming, and labor intensive to the end user, thereby making the assembly of such boxes undesirable.
Non-limiting examples of such prior art foldable boxes include U.S. Patent Publication Nos. 2004/0140345; 2006/0151856; 2010/0006632; 2011/0121062; 2012/0037693 and 2014/0231495, and U.S. Pat. Nos. 2,957,617; 6,568,586; 8,573,471; 8,960,527 and RE 46563, all of which are incorporated herein by reference.
In view of the current state of foldable boxes, there is a need for a foldable box having one or more interchangeable configurations, and which can be easily and conveniently transformed between such interchangeable configurations thereby minimizing the time required for assembly and/or disassembly of the foldable box.
SUMMARY OF THE INVENTIONThe present invention is directed to a foldable box having one or more interchangeable configurations, and which can be easily and conveniently transformed between such interchangeable configurations, thereby minimizing the time required for assembly and/or disassembly of the foldable box.
In one non-limiting aspect of the present invention, there is provided a foldable box having a plurality of interchangeable configurations. In one non-limiting aspect of the present invention, there is provided a foldable box having a first, unfolded configuration in which the foldable box is substantially flat, and a second, folded and/or three-dimensional configuration in which the foldable box is fully assembled. As described above, the first and second configurations of the foldable box are interchangeable. For example, the first configuration (i.e., the flat, unfolded foldable box) can be easily and conveniently transformed into the second configuration (i.e., the folded, three-dimensional foldable box), and, similarly, the second configuration can be easily and conveniently transferred into the first configuration; however, this is not required.
The materials used to form the foldable box are non-limiting. The foldable box can be formed from a single type of material; however, this is not required. As can be appreciated, the foldable box can be formed from one or more types of material. Generally, the foldable box is formed from a moderately rigid material such as, for example, a heavy weight cardboard material or paperboard material; however, this is not required. As can be appreciated the foldable box can be formed from other or alternative materials (e.g., flexible materials, semi-rigid materials, medium weight cardboard, fiberboard, rigid plastic, flexible plastic, composite materials, metal, wood, etc.). The material of the foldable box is typically selected so as to allow folding, bending, or other manipulations of the foldable box without losing the structural integrity of the material; however, this is not required. In one non-limiting configuration, the thickness of the material used to form the foldable box can be from about 0.01 mm to about 10 mm, more particularly about 2 mm; however, this is not required.
In another and/or alternative non-limiting aspect of the present invention, the material of the foldable box can be lined with one or more additional types of material; however, this is not required. In one non-limiting embodiment, the material of the lining is a laminate material; however, other or alternative liners can be used (e.g., cloth, cloth-like materials, tape, tape-like materials, plastic material, fabric material, etc.). Generally, the lining (when used) is designed to completely cover at least a first surface of the foldable box; however, this is not required. In one non-limiting configuration, the lining completely covers a first surface of a portion of the foldable box, wraps around the perimeter thereof, and terminates at a position at or near the perimeter on a second surface of the portion of the foldable box; however, this is not required. The lining can be used to provide an aesthetically pleasing appearance to one or more users of the foldable box; however, this is not required. As such, the lining can include designs, surface structures, etc. on a surface thereof; however, this is not required. The lining (when used) typically has a thickness less than or equal to the material used to form the foldable box; however, this is not required. As such, the lining can be designed to provide support to the foldable box; however, this is not required. The lining can be used to connect together one or more pieces of the foldable box (e.g., connect together multiple pieces of paperboard panels that are used to form one or more sides of the foldable box, etc.), and/or be used to form a hinge or foldable region between two or more pieces of the foldable box; however, this is not required.
The shape of the foldable box is non-limiting. In one non-limiting configuration, the shape of the top plan view of the foldable box in its first, unfolded configuration is rectangular or square; however, the shape of the top plan view foldable box in its first, unfolded configuration can have other shapes. In another and/or alternative non-limiting configuration, the shape of the top plan view of the foldable box in its second, three-dimensional configuration is rectangular or square; however, the shape of the top plan view of the foldable box in its second, three-dimensional configuration can have other shapes. Similarly, the size of the foldable box in its folded and unfolded configuration is non-limiting. In one specific non-limiting configuration, when the foldable box in the folded configuration has a top plan rectangular shape, the dimensions of the foldable box can be about 1-6 inches in height by about 2-20 inches in width by about 1-18 inches in length; however, the foldable box can have other dimensions. In one specific non-limiting configuration, when the foldable box in the folded configuration has a top plan square shape, the dimensions of the foldable box can be about 1-6 inches in height by about 2-20 inches in width by about 2-20 inches in length; however, the foldable box can have other dimensions.
In one non-limiting aspect of the present invention, there is provided a foldable box having a first set of panels and a second set of panels; however, this is not required. The second set of panels is designed to be foldably connected to the first set of panels; however, this is not required. This non-limiting configuration provides a non-limiting advantage in that all components of the foldable box are connected such that no further assembly is required by the end user, a common disadvantage of many existing foldable box types in which at least one component must typically be assembled separately and connected to the remaining portion of a box. This non-limiting configuration also has the advantage that the foldable box, after being assembled into its folded configuration, can later be unassembled into its original unfolded position. Foldable boxes that require the permanent connection of one or more components during assembly cannot thereafter be unassembled into its original unfolded position without having to damage one or more portions of the foldable box.
In another and/or alternative non-limiting aspect of the present invention, the first set of panels further comprises a front panel, a bottom panel, a back panel, a top panel and a top end panel arranged in a predetermined sequence; however, this is not required. In one non-limiting configuration, the front panel, bottom panel, back panel, top panel, and top end panel are defined portions in a single piece of material; however, this is not required. In such a configuration, the front panel, bottom panel, back panel, top panel and top end panel can be defined via cutting, scoring, creasing and/or folding; however, other or alternative methods can be used. The cutting, scoring, creasing and/or folding (when used) also provides the foldable connections between adjacent panels of the first set of panels. The size and shape of the foldable connections are non-limiting. Generally, the foldable connections are designed to permit from about 1° to about 180° angles of relative rotation between adjacent panels; however, this is not required. For example, from a flat, unfolded configuration, the connection arrangements can permit the front panel to be rotated about 90° relative to the bottom panel, the back panel to be rotated about 90° relative to the bottom panel, the back panel to be rotated about 90° relative to the top panel, and the top end panel to be rotated about 90° relative to the top panel; however, this is not required. As such, when the foldable box is in its first, unfolded configuration, the front panel, bottom panel, back panel, top panel and top end panel are designed to lay substantially flat and, in its second, three-dimensional configuration, the foldable box can be folded such that the top end panel is parallel to the front and back panels, and the top panel is parallel to the bottom panel. Thus, the front panel, bottom panel, back panel, top panel and top end panel of the first set of panels are foldably connected in a predetermined sequence along a crease and/or fold; however, this is not required. In such a configuration, the front panel is foldably connected to the bottom panel along a first crease, the back panel is foldably connected to the bottom panel along a second crease, the back panel is foldably connected to the top panel along a third crease, and the top end panel is foldably connected to the top panel along a fourth crease; however, this is not required. As can be appreciated, when a liner or a separate hinge or a hinge material is used, the liner or the separate hinge or the hinge material can be used to allow separate panels to be connected together and folded with respect to one another; however, this is not required.
The size and shape of each of the panels in the first set of panels is non-limiting. In one non-limiting configuration, each of the panels in the first set of panels is rectangular or square, thereby providing a substantially rectangular or square box when folded/assembled and viewed from the top plan view; however, this is not required. The first set of panels of the foldable box can include panels of one or more different sizes; however, this is not required. In one non-limiting configuration, the first set of panels comprises a bottom panel and a top panel which are greater in size that the front panel, the back panel and the top end panel; however, this is not required. In another and/or alternative non-limiting configuration, the front panel, back panel and top end panel are the same or similar in size and shape; however, this is not required.
In another and/or alternative non-limiting aspect of the present invention, the second set of panels further comprises a left side panel and a right side panel. Generally, the left and right side panels are formed from separate pieces of material; however, this is not required. The size and shape of the left and right side panels are non-limiting. In one non-limiting configuration, the left and right side panels are rectangular in shape and formed from the same material as the first set of panels; however, this is not required. The second set of panels are designed to be adhesively and/or foldably connected to the first set of panels; however, this is not required. As can also be appreciated, the second set of panels can be designed to be snap connected to the first set of panels; however, this is not required.
A lining material can optionally be applied to the left and right side panels; however, this is not required. The lining material can be applied such that a portion of the lining material extends at least partially over the lengthwise edge of the left and right side panels, thereby forming an attachment portion suitable for facilitating attachment of the left and right side panels to the first set of panels; however, this is not required. For example, the attachment portion of the left and right side panels can be connected (e.g., glue, tape, adhesive, tack, staple, melted connection, hook and loop fastener, snap, etc.) at or near oppositely disposed edges of the bottom panel of the first set of panels; however, this is not required. As such, the attachment portion of the second set of panels provides a foldable and adhesive connection to the first set of panels. As can be appreciated, the attachment portion of the second set of panels can include a snap connection to the first set of panels
In another and/or alternative non-limiting aspect of the present invention, the foldable box optionally incorporates a plurality of foldable connectors. In one non-limiting configuration, the lining material is applied to the left and right side panels such that the lining material extends at least partially over the side edges of the left and right side panels, thereby forming a plurality of foldable connectors. The plurality of foldable connectors can be foldable relative to the side edges of the left and right side panels, and provide a connection means wherein the left and right side panels can be connected to the first set of panels; however, this is not required. The inherent flexibility, durability and flexibility of lining materials provides a suitable hinge and/or foldable connection; however, this is not required. The connection arrangements are designed to connect the left and right side panels to the front and back panels to facilitate lifting of the front and back panels when the left and right side panels are lifted; however, this is not required. As such, the front panel, back panel and left and right side panels can be lifted in unison to an upright position relative to the bottom panel; however, this is not required and the work required by the end user of the box is significantly minimized. Furthermore, the end user does not need to apply any additional glue and/or tape to the foldable box.
The shape and size of each of the plurality of foldable connectors are non-limiting. Generally, all the foldable connectors are the same in size and shape; however, this is not required. In one non-limiting configuration, each foldable connector comprises a generally square shape having a diagonal crease and/or groove thereby providing a first and second connectable section. The outside surface of a first connectable section can be designed to be connected to an interior surface of the front and/or back panel. In one specific non-limiting configuration, a first connectable section of a first foldable connector of the right side panel is connected to the back panel, a first connectable section of a second foldable connector of the right side panel is connected to the front panel, a first connectable section of a first foldable connector of the left side panel is connected to the back panel, and a first connectable section of a second foldable connector of the left side panel is connected to the front panel; however, this is not required. The type of connection used is non-limiting. For example, the outside surface of the first connectable section can be connected to the interior surface of the front and/or back panel via an adhesive such as, for example, glue, tape, hook and loop fastener, melted connection, staple, tack, snap, etc.; however, this is not required. The second connectable section can be designed to be connected along an edge to a side edge of the left and/or right side panel.
In another and/or alternative non-limiting configuration, the outside surface of the second connectable section can also be designed to be connected to the interior surface of the front and/or back panel; however, this is not required. In one non-limiting configuration, the outside surface of the second connectable section of each foldable connector can include an adhesive material; however, this is not required. The adhesive material (when used) can be positioned on or closely adjacent to one or more edges of the second connectable region and can cover a majority of the second connectable region; however, this is not required. Generally, the adhesive material is a preapplied material that includes a removable top protective release liner that, when removed, exposes a top adhesive surface of the adhesive material. One non-limiting advantage to providing a preapplied adhesive material is that the end user does not need to apply any additional materials to the foldable box prior to its use. When exposed, the top adhesive surface of the adhesive material is designed to bond with a portion of the front and/or back panels that is positioned at or near the second connectable section; however, this is not required. In such a configuration, when the foldable box is converted into its second, three-dimensional structure, the adhesive material on the outside surface of the second connectable section can at least partially hold the foldable box in a three-dimensional configuration; however, this is not required. As can be appreciated, other or alternative releasable connection arrangements can optionally be used to connect the second connectable region of each foldable connector to the front and/or back panels; however, this is not required. As can be appreciated, the adhesive connection can be designed to form a permanent connection with a portion of the front and/or back panels that is positioned at or near the second connectable section so as to permanently hold the foldable box in the three-dimensional configuration; however, this is not required. As can also be appreciated, the adhesive connection can be designed to form a releasable and reusable connection with a portion of the front and/or back panels that is positioned at or near the second connectable section so the foldable box can be unfolded from the three-dimensional configuration back to the unfolded configuration; however, this is not required.
In another and/or alternative non-limiting aspect of the present invention, the foldable box includes a protective material provided on one or more surfaces of the foldable box; however, this is not required. The type of protective material is non-limiting. The protective material can be the same or different than the lining (when used); however, this is not required. In one non-limiting configuration, the protective material is a durable paper material; however, other or alternative types of materials can be used (e.g., fabric, composition material, plastic, metal, wood, fiberglass, etc.). In one non-limiting configuration, the protective material can be applied to a second surface of the first set of panels via an adhesive (e.g., glue, tape, etc.); however, other or alternative connection arrangements can be used (melted connection, tack, staple, snap, etc.). Alternatively, the protective material can be a layer of tape; however, this is not required. The protective material (when used) is designed to cover a majority of the second surface of the first set of panels; however, this is not required. In one non-limiting configuration, the protective material is applied to the second surface of the first set of panels such that the protective material extends at least partially over the portion of the lining which terminates at or near the perimeter of the first set of panels; however, this is not required. In addition to providing improved durability and structural rigidity to the panels of the foldable box, the protective material also provides improved support at or near the foldable connections (i.e., creases and/or folds) between panels of the first set of panels. Optionally, all of the panels includes a protective material; however, this is not required.
In another and/or alternative non-limiting aspect of the present invention, the foldable box can include a connection arrangement provided between the top end panel and the front panel such that, when the foldable box is transformed into its second, three-dimensional configuration, the top end panel can releasably connect to the front panel; however, this is not required. As such, the connection arrangement between the top end panel and the front panel is capable of at least partially retaining the foldable box in its second, three-dimensional configuration; however, this is not required.
The type of connection arrangement used between the top end panel and the front panel is non-limiting. In one non-limiting configuration, a magnetic connection arrangement is used; however, this is not required. In such a configuration, the top end panel can include one or more magnets (or magnetically attractive materials) and the front panel can include one or more magnets (or magnetically attractive materials) corresponding to the one or more magnets (or magnetically attractive materials) of the top end panel; however, this is not required. As can be appreciated, other connection arrangements can be used (e.g., releasable adhesive, hook and loop fastener, latch, snap, button, etc.). When two or more magnets are used, the magnets generally have opposite polarity. In one non-limiting configuration, the magnets are positioned within the material of the front panel and the top end panel, spaced apart from the edge of the front and top end panels and the lining; however, this is not required. This size, shape and configuration of the magnets are non-limiting. In one non-limiting configuration, the thickness of each magnet is selected to be about the same or less than the thickness of the material of the panels such that the magnets are completely enclosed; however, this is not required. As such, the magnets are provided within the material of the front and top end panels so that the magnets are not visible to a user. In another configuration, one panel includes one or more magnets and the other panel includes a material that is magnetically attracted to a magnetic (e.g., iron material, etc.).
In another and/or alternative non-limiting aspect of the present invention, the foldable box is designed to be easily and conveniently converted from a flat, unfolded configuration to a three-dimensional configuration. In operation, a user can lift the left and right side panels upward towards a vertical orientation. In doing so, the front and back panels will be also be caused to be rotated or pivot upwards to a vertical orientation via the plurality of connection arrangements connecting the right and left side panels of the second set of panels to the front and back panels of the first set of panels; however, this is not required. As such, the foldable box can be easily and conveniently changed from an unfolded position to a three-dimensional configuration. When the foldable box is in its three-dimensional configuration, the foldable box can be filled with one or more items to be stored and/or held within the foldable box.
In another and/or alternative non-limiting aspect of the present invention, the foldable box can optionally be folded from its flat, unfolded configuration into a space-saving, compact configuration; however, this is not required. The compact configuration (when used) can facilitate space-saving storage and/or transport of one or more foldable boxes; however, this is not required. In one non-limiting configuration, when the compact configuration is used, the gap between the top panel and the back panel is generally designed to permit about 180° rotation, thereby accommodating the combined thicknesses of the back panel, the top panel and the left and/or right side panels; however, this is not required.
In another and/or alternative non-limiting aspect of the present invention, the first set of panels of the foldable box can optionally comprise a plurality of individual panels which can be attached (e.g., glued, taped, melted connection, hook and loop fastener, etc.) to one surface of a liner (e.g., cover, laminate material, etc.) with small gaps and/or spaces between adjacent individual panels; however, this is not required. The small gaps and/or spaces (when used) can provide the foldable connection between individual panels of the first set of panels; however, this is not required. In such a configuration, the first and second sets of panels can optionally be laminated together; however, this is not required. In such a configuration, the left and right side panels are spaced apart from the bottom panel; however, this is not required. The small gap and/or space between the left and right side panels can be designed to provide the foldable connection between the left and right side panels and the bottom panel of the foldable box; however, this is not required. In one non-limiting configuration, the left and right side panels are foldably connected at or near the side edges of the bottom panel; however, this is not required. In one specific non-limiting embodiment, the left and right side panels are spaced inward a predetermined distance from the side edges of the bottom panel; however, this is not required. Generally, the space between the left and/or right side panels and the bottom panel is designed to permit the left and/or right side panels to rotate about 70-150° relative to the bottom panel; however, this is not required. As such, in a three-dimensional configuration, the left and right side panels can be moved to be parallel to each other; however, this is not required.
In another and/or alternative non-limiting aspect of the present invention, there is provided a method for manufacturing a foldable box in accordance with the present invention. As described above, the foldable box can be formed from a first set of panels and a second set of panels; however, this is not required. The method for manufacturing the foldable box of the present invention can include: 1) selecting a material suitable for use in a foldable box, 2) cutting the selected material into a first and second set of panels having a desired size and shape, 3) optionally applying a lining material to at least a first surface of the first set of panels, 4) optionally applying a lining material to at least a first surface of the second set of panels forming at least one attachment portion and at least one foldable connector, 5) optionally applying a protective cover to at least a first surface of the first and/or second set of panels, 6) defining one or more panels within the first set of panels, 7) forming foldable connections between the one or more panels defined within the first set of panels by some means (e.g., cutting, scoring, folding the first set of panels, forming a hinge between the first set of panels, etc.), and/or 8) connecting the second and third set of panels to the first set of panels. The method for manufacturing a foldable box can further comprise the steps of: a) connecting a first portion of the at least one foldable connector to the first set of panels, and/or b) applying a snap or an adhesive having a removable protective liner or use some other type of connector to a second portion of the at least one foldable connector.
In another and/or alternative non-limiting aspect of the present invention, there is provided a method for transforming the foldable box of the present invention from its first, unfolded configuration to its second, three-dimensional configuration. Initially, the foldable box is provided in an unfolded configuration wherein the first set of panels is substantially flat (i.e., the front panel, bottom panel, back panel, top panel and top end panel foldable connections are all at approximately 180°), and the second set of panels lays on top of the first set of panels. The left and right side panels can be lifted upwards, thereby rotating the left and right side panels relative to the bottom panel. In lifting the left and right side panels upwards, the back and front panels of the first set of panels are caused to lift upwards, thereby also rotating the back and front panels relative to the bottom panel. The protective release liner (when used) can be removed from the preapplied adhesive material, thereby exposing the adhesive surface of the adhesive material of the foldable connectors. The left and right side panels are lifted upwards until they reach an approximately vertical position (i.e., about 90° relative to the bottom panel) wherein the adhesive surface of the adhesive material contacts and bonds with a portion of the front and/or back panels. A snap arrangement can also or alternatively be used. The top panel can then be rotated relative to the back panel such that the top panel covers the opening formed by the bottom panel, left side panel, right side panel, back panel and front panel. The top end panel can be rotated relative to the top panel to form a releasable connection. For example, when one or more magnets are provided in the top end panel and/or front panel and are caused to approach one or more connectors (e.g., magnet, hook and loop fastener, etc.) provided on or in the other panel of the foldable box, the magnetic force between the one or more magnets on the top end panel and/or the front panel is sufficient to releasably and securely close the foldable box in a three-dimensional configuration.
These and other objects and advantages will become apparent to those skilled in the art upon reading and following the description taken together with the accompanying drawings.
Reference may now be made to the drawings which illustrate various non-limiting embodiments that the invention may take in physical form and in certain parts and arrangement of parts wherein:
The present invention is directed to a foldable box having one or more interchangeable configurations, and which can be easily and conveniently transformed between such interchangeable configurations, thereby minimizing the time required for assembly and/or disassembly of the foldable box.
The foldable box has a plurality of interchangeable configurations. In one non-limiting aspect of the present invention, there is provided a foldable box having a first, unfolded configuration in which the foldable box is substantially flat, and a second, folded and/or three-dimensional configuration in which the foldable box is fully assembled. As described below, the first and second configurations of the foldable box are interchangeable. For example, the first configuration (i.e., the flat, unfolded foldable box) can be easily and conveniently transformed into the second configuration (i.e., the folded, three-dimensional foldable box), and, similarly, the second configuration can be easily and conveniently transferred into the first configuration; however, this is not required.
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Each panel of the foldable box 10 can be formed from a single type of material, or from one or more types of material. The foldable box 10 may formed from a moderately rigid material such as, for example, a heavy weight cardboard material or paperboard material. The foldable box 10 can be formed from other or alternative materials, such as, for example, a flexible material, semi-rigid material, medium weight cardboard, fiberboard, rigid plastic, flexible plastic, composite materials, metal, or wood. The panel material may be selected so as to allow folding, bending, and/or other manipulations of the foldable box 10 without losing the structural integrity of the panel material. In particular embodiments, the thickness of the material used to form the panels 12, 14, 16, 18, 20, 22, 24, 26, 28 may be from about 0.01 mm to about 10 mm. In further embodiments, the thickness of the material used to form the panels 12, 14, 16, 18, 20, 22, 24, 26, 28 may be about 2 mm.
In particular embodiments, the panel material of the foldable boxes 10 can be lined with one or more additional types of lining materials. The material of the lining is a laminate material; however, other or alternative liners can be used (e.g., cloth, cloth-like materials, tape, tape-like materials, plastic material, fabric material, etc.). Generally, the lining (when used) is designed to partially and/or completely cover at least a first surface of the foldable box 10. In some embodiments, the lining completely covers a first surface of a portion of the foldable box 10, wraps around the perimeter thereof, and terminates at a position at or near the perimeter on a second surface of the portion of the foldable box 10. The lining can be used to provide an aesthetically pleasing appearance to one or more users of the foldable box; however, this is not required. As such, the lining can include designs, surface structures, etc. on a surface thereof; however, this is not required. The lining (when used) typically has a thickness less than or equal to the material used to form the foldable box; however, this is not required. As such, the lining can be designed to provide support to the foldable box; however, this is not required. The lining can be used to connect together one or more pieces of the foldable box (e.g., connect together multiple pieces of paperboard panels that are used to form one or more sides of the foldable box, etc.), and/or be used to form a hinge or foldable region between two or more pieces of the foldable box. The lining can be designed to provide support to the foldable box; however, this is not required. The lining can be used to connect together one or more pieces of the foldable box (e.g., connect together multiple pieces of paperboard panels that are used to form one or more sides of the foldable box, etc.), and/or be used to form a hinge or foldable region between two or more pieces of the foldable box.
The foldable box 10 may be formed such that all components of the foldable box 10 are connected, and no further assembly in required by the end user in order to transform the foldable box 10 into a second or third configuration. In some embodiments, the foldable box 10 may also be disassembled after back into the first configuration or a previous configuration without compromising the structural integrity of the foldable box 10. That is, all of the components (e.g. panels, connectors, and attachment portions) the foldable box 10 may reversibly folded and/or connected. Put another way, the foldable box 10 may not contain a permanent connector of one or more of the panels.
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The foldable box 10 has a first set of panels, a second set of panels 20, 22, 24 and a third set of panels, wherein the second and third sets of panels are designed to be adhesively and/or foldably connected to the first set of panels. This non-limiting configuration provides a non-limiting advantage in that all components of the foldable box are connected such that no further assembly is required by the end user, a common disadvantage of many existing foldable box types in which at least one component must typically be assembled separately and connected to the remaining portion of a box. This non-limiting configuration also has the advantage that the foldable box, after being assembled into its folded configuration, can later be unassembled into its original unfolded position. Foldable boxes that require the permanent connection of one or more components during assembly cannot thereafter be unassembled into its original unfolded position without having to damage one or more portions of the foldable box.
With reference to
The size and shape of each of the panels in the first set of panels is non-limiting. In one non-limiting configuration, for a rectangular shaped box, each of the panels in the first set of panels is rectangular, thereby providing a substantially rectangular box when folded/assembled and viewed from the top plan view. The first set of panels of the foldable box can include panels of one or more different sizes. In one non-limiting configuration, the first set of panels comprises a bottom panel greater in size than the left end panel, left side panel, right side panel and right end panel. In another and/or alternative non-limiting configuration, the left end panel, left side panel, right side panel and right end panel are the same or similar in size and shape. For a square shaped box, each of the panels in the first set of panels is square, thereby providing a substantially square box when folded/assembled and viewed from the top plan view.
In another and/or alternative non-limiting aspect of the present invention, any one of the panels in the first, second and/or third sets of panels can include a hole and/or cutout 46, as seen in
In another and/or alternative non-limiting aspect of the present invention, the left and right end panels in the first set of panels can optionally be formed from separate panels of material than the left side panel, bottom panel and right side pane. In such a configuration, the left and right end panels can be incorporated into the first set of panels by being connected such as, for example, via an adhesive, to the liner material with a small gap and/or space between adjacent panels. As can be appreciated, other connection arrangement can be used (e.g., hinge, etc.). The small gap and/or space (when used) can provide the foldable connection between panels of the first set of panels of the foldable box.
The second set of panels comprises a back panel 20, a top panel 22 and a top end panel 24. In some embodiments, the back panel 20, top panel 22 and top end panel 24 are formed from a single piece of material. The size and shape of the second set of panels are non-limiting. In one non-limiting configuration, the back panel 20, top panel 22 and top end panel 24 are each substantially rectangular in shape and formed from the same material as the first set of panels; however, other shapes can be used (e.g., square, etc.). The second set of panels are designed to be adhesively and/or foldably connected to the first set of panels. As can be appreciated, other types of connection arrangements can be used (e.g., hook and loop fastener, tack, staple, melted connection, snap, etc.). In one non-limiting configuration, the back panel 20, top panel 22 and top end panel 24 are foldably connected in sequence along a crease and/or fold. In such a configuration, the back panel 20 is foldably connected to the bottom panel 28 along a fifth crease 36, the top panel 22 is foldably connected to the back panel 20 along a sixth crease 34, and the top end panel 24 is foldably connected to the top panel 22 along a seventh crease 38. As such, when the foldable box 10 is in its first, unfolded configuration, the back panel 20, top panel 22 and top end panel 24 are designed to lay substantially flat.
The size and shape of each of the panels in the second set of panels is non-limiting. In one non-limiting configuration, each of the panels in the second set of panels is rectangular, thereby providing a substantially rectangular box when folded/assembled; however, other shapes can be used (e.g., square, etc.). In one non-limiting configuration, the second set of panels includes panels of two different sizes; however, this is not required. In such a configuration, the second set of panels can comprise a top panel greater in size than the back panel and the top end panel. In another and/or alternative non-limiting configuration, the back panel and the top end panel are the same in size and shape.
In another and/or alternative non-limiting aspect of the present invention, the back panel, top panel and top end panel can be defined in the second set of panels by cutting, scoring and/or folding the material. As can be appreciated, the back panel 20, top panel 22 and top end panel 24 are can be individual, separate panels joined together via the liner material, hinge, etc.; however, this is not required.
In another and/or alternative non-limiting aspect of the present invention, the cutting, scoring and/or folding of the second set of panels or hinge (when used) can provide foldable connections between the panels in the second set of panels of the foldable box. The size and shape of the foldable connections are non-limiting. In one non-limiting configuration, the foldable connection is designed to permit limited rotation between two adjacent panels. In one non-limiting configuration, the foldable connections are designed to permit from about 1° to about 360° rotation about the foldable connection; however, this is not required. For example, in one specific non-limiting embodiment, the top end panel can be rotated from about 1-360° relative to the top panel, the back panel can be rotated about 1-360° relative to the top panel, and the back panel can be rotated about 1-180° relative to the bottom panel. In such a configuration, when the second set of panels is folded, the second set of panels can be caused to move to a configuration wherein both the back panel and the top end panel extend approximately perpendicularly (e.g., about 85-95°) from opposing edges of the top panel; however, this is not required.
In another and/or alternative non-limiting aspect of the present invention, the third set of panels of the foldable box further comprises at least a front panel; however, this is not required. The size and shape of the front panel are non-limiting. In one non-limiting configuration, the shape of the front panel is rectangular; however, other shapes can be used (e.g., square, etc.). In another and/or alternative non-limiting aspect of the present invention, the third set of panels also includes a laminate material. The front panel can be adhesively and/or foldably connected to the bottom panel of the first set of panels forming an eighth crease.
A lining material can optionally be applied to the first, second and/or third sets of panels. In one non-limiting configuration, the lining material can be applied to panels of the foldable box such that a portion of the lining material extends at least partially over the lengthwise edge of the front and back panels, thereby forming an attachment portion suitable for facilitating attachment of the front (i.e., the third set of panels) and back (i.e., the second set of panels) panels to the bottom panel (i.e., the first set of panels). For example, the attachment portion of the front and back panels can be connected (e.g., glue, tape, adhesive, melted connection, hook and loop fastener, tack, staple, etc.) at or near oppositely disposed edges of the bottom panel of the first set of panels. In one specific non-limiting embodiment, an attachment portion of the back panel can be connected at or near the edge of the bottom portion forming the fifth crease, and an attachment portion of the front panel can be connected at or near the edge of the bottom portion forming the eighth crease; however, this is not required. As such, the attachment portions of the second and third sets of panels provide a foldable and adhesive connection or some other type of connection to the first set of panels.
In another and/or alternative non-limiting aspect of the present invention, the foldable box incorporates a plurality of foldable connectors. In one non-limiting configuration, the lining material is optionally applied to the front and back panels of the foldable box such that the lining material extends at least partially over the side edges thereof, thereby forming a plurality of foldable connectors. The plurality of foldable connectors can be foldable relative to the side edges of the front and back panels, and provide a connection means wherein the front and back panels can be connected to the first set of panels. The inherent flexibility, durability and flexibility of optional lining materials provides a suitable hinge and/or foldable connection. The foldable connectors are designed to connect the front and back panels to the left and right side panels of the first set of panels to facilitate lifting of the left and right side panels when the front and back panels are lifted. As such, the front panel, back panel and left and right side panels can be lifted in unison to an upright position relative to the bottom panel; however, this is not required. In such a configuration, the work required by the end user of the box can be significantly minimized. Furthermore, the end user does not need to apply and/or remove any additional glue, tape, or other materials during assembly and/or disassembly of the foldable box.
The shape and size of each of the plurality of foldable connectors are non-limiting. In some embodiments, all foldable connectors are the same in size and shape. In one non-limiting configuration, each foldable connector comprises a generally square shape having a diagonal crease and/or groove thereby providing a first and second connectable section. The outside surface of a first connectable section can be designed to be connected to an interior surface of the left or right side panel. In one specific non-limiting configuration, a first connectable section of a first foldable connector of the front panel is connected to the left side panel, a first connectable section of a second foldable connector of the front panel is connected to the right side panel, a first connectable section of a first foldable connector of the back panel is connected to the left side panel, and a first connectable section of a second foldable connector of the back panel is connected to the right side panel; however, this is not required. The type of connection used is non-limiting. For example, the outside surface of the first connectable section can be connected to the interior surface of the left and/or right side panels via an adhesive, such as, for example, glue, tape, hook and loop fastener, a tack, and/or a staple. The second connectable section can be designed to be connected along an edge to a side edge of the front and/or back panel.
With reference to
In another and/or alternative non-limiting aspect of the present invention, the first, second and third sets of panels can be individually laminated; however, this is not required. As can be appreciated, the foldable box can be formed from a single set of panels wherein the single set of panels is laminated. In embodiments where the first, second and third sets of panels are separately laminated, the first, second and third sets of panels can be connected together via an adhesive (e.g., glue, tape, etc.). In one non-limiting configuration, the second and third sets of panels are connected to the top surface of the first set of panels. As can be appreciated, other connection arrangements can be used (e.g., melted connection, staple, tack, hook and loop fastener, etc.). In one specific non-limiting embodiment, the second and third sets of panels are connected to the bottom panel of the first set of panels; however, this is not required.
In another and/or alternative non-limiting aspect of the present invention, the foldable box includes a second liner material; however, this is not required. In one non-limiting configuration, the second liner material is a protective material; however, this is not required. The protective material can be applied to one or more surfaces of the foldable box; however, this is not required. The type of protective material is non-limiting. The protective material can be the same or different than the first liner material (as described earlier). In one non-limiting configuration, the protective material (when used) is a durable paper material; however, other or alternative types of materials can be used (e.g., plastic, metal, wood, composite material, etc.). The protective material can be applied to a second surface of the first, second and/or third set of panels via an adhesive (e.g., glue, tape, etc.); however, other or alternative connection arrangements can be used (e.g., hook and loop fastener, melted connection, tack, staple, etc.). Alternatively, the protective material can be a layer of tape; however, this is not required. The protective material (when used) is designed to cover a majority of the second surface of the first, second and/or third sets of panels; however, this is not required. In one non-limiting configuration, the protective material is applied to the second surface of the first and second sets of panels such that the protective material extends at least partially over the portion of the first liner material which terminates at or near the perimeter of the first and second sets of panels. In addition to providing improved durability and structural rigidity to the panels of the foldable box, the protective material also provides improved support at or near the foldable connections (i.e. creases and/or folds) between panels of the first and second sets of panels. Optionally, the third set of panels includes a protective material.
In another and/or alternative non-limiting aspect of the present invention, the foldable box can include a connection arrangement provided between the top end panel and the front panel such that, when the foldable box is transformed into its second, three-dimensional configuration, the top end panel can releasably connect to the front panel. As such, the connection arrangement between the top end panel and the front panel is capable of at least partially retaining the foldable box in its second, three-dimensional configuration; however, this is not required.
The type of connection arrangement used between the top end panel and the front panel is non-limiting. In one non-limiting configuration, a magnetic connection arrangement is used; however, this is not required. In such a configuration, the top end panel can include one or more magnets (or magnetically attractive materials) and the front panel can include one or more magnets (or magnetically attractive materials) corresponding to the one or more magnets (or magnetically attractive materials) of the top end panel; however, this is not required. As can be appreciated, other connection arrangements can be used (e.g., releasable adhesive, hook and loop fastener, latch, snap, button, etc.). When two or more magnets are used, the magnets generally have opposite polarity. In one non-limiting configuration, the magnets are positioned within the material of the front panel and the top end panel, spaced apart from the edge of the front and top end panels and the lining. This size, shape and configuration of the magnets are non-limiting. In one non-limiting configuration, the thickness of each magnet is selected to be about the same or less than the thickness of the material of the panels such that the magnets are completely enclosed. As such, the magnets are provided within the material of the front and top end panels so that the magnets are not visible to a user. In another configuration, one panel includes one or more magnets and the other panel includes a material that is magnetically attracted to a magnetic (e.g., iron material, etc.).
In another and/or alternative non-limiting aspect of the present invention, the foldable box is designed to be easily and conveniently converted from a flat, unfolded configuration to a three-dimensional configuration. In operation, a user can lift the front and back panels upward towards a vertical orientation. In doing so, the left and right side panels will be also be caused to be rotated upwards to a vertical orientation via the plurality of foldable connectors connecting the front and back panels to the left and right side panels; however, this is not required. As such, the foldable box can be easily and conveniently changed from an unfolded position to a three-dimensional configuration. When the foldable box is in its three-dimensional configuration, the foldable box can be filled with one or more items to be stored and/or held within the foldable box.
In another and/or alternative non-limiting aspect of the present invention, the foldable box can optionally be folded from its flat, unfolded configuration into a space-saving, compact configuration; however, this is not required. The compact configuration (when used) can facilitate space-saving storage and/or transport of one or more foldable boxes; however, this is not required. In one non-limiting configuration, when the compact configuration is used, the gap between the top panel and the back panel is generally designed to permit about 180° rotation, thereby accommodating the combined thicknesses of the back panel, the top panel and the left and/or right side panels; however, this is not required.
In another and/or alternative non-limiting aspect of the present invention, the first, second and/or third set of panels of the foldable box can optionally comprise a plurality of individual panels which can be attached (e.g., glued, taped, melted connection, hook and loop connection, tack, staple, etc.) to one surface of a liner (e.g., cover, laminate material, etc.) with small gaps and/or spaces between adjacent individual panels; however, this is not required. The small gaps and/or spaces (when used) can provide the foldable connection between individual panels of the first, second and/or third sets of panels; however, this is not required. In such a configuration, the first, second and third sets of panels can optionally be laminated together; however, this is not required. The small gap and/or space between the individual panels can be designed to provide the foldable connection between adjacent panels of the foldable box; however, this is not required.
In another and/or alternative non-limiting aspect of the present invention, there is provided a method for manufacturing a foldable box in accordance with the present invention. As described above, the foldable box can be formed from a first set of panels, a second set of panels and a third set of panels; however, this is not required. A method for manufacturing a foldable box in accordance with the present invention can include: 1) selecting a material suitable for use in a foldable box, 2) cutting the selected material into a desired number of panels (e.g., a first, second and third set of panels), each panel having a desired size and shape, 3) optionally applying a first liner material (e.g., a laminate material) to at least one surface of the first, second and third set of panels, 4) forming at least one attachment portion and at least one foldable connector on the second and third set of panels, 6) optionally applying a second liner material (e.g., a protective cover) to at least one surface of the first and/or second set of panels, 7) defining one or more panels within the first set of panels, second set of panels and/or third set of panels, 8) forming foldable connections between the one or more panels defined within the first, second and/or third sets of panels by cutting, scoring and/or folding the first, second and/or third sets of panels, and/or 9) connecting the second and third set of panels to the first set of panels.
In another and/or alternative non-limiting aspect of the present invention, there is provided a method for transforming a foldable box of the present invention from a first, unfolded configuration to a second, three-dimensional configuration. Initially, a foldable box is provided in an unfolded configuration wherein the first set of panels is substantially flat (i.e., the left end panel, left side panel, bottom panel, right side panel, and right end panel foldable connections are all at approximately 180°), and the second and third sets of panels lays on top of the first set of panels. The foldable connectors connecting the second and third sets of panels to the first set of panels can be configured to be folded and/or unfolded. The front and back panels can be lifted upwards such that the front and back panels are relative to the bottom panel. In lifting the front and back panels upwards, the left and right side panels of the first set of panels are caused to lift upwards, thereby also rotating the left and right side panels upwards relative to the bottom panel. In such a configuration, the front and back panels are lifted away from a middle portion of the bottom panel while the left and right side panels are caused to move towards a middle portion of the bottom panel. The front and back panels (and therefore also the left and right side panels) are lifted upwards until they reach an approximately vertical position (i.e. about 85-95°) relative to the bottom panel. The left and right end panels can be rotated (i.e., folded) approximately 180° relative to the left and right side panels, so as to hold the foldable connectors flat between the left and right side panels and the left and right end panels, respectively. As such, the foldable box can be at least partially secured in an open, three-dimensional configuration. Next, the top panel can then be rotated relative to the back panel such that the top panel covers the opening formed by the front panel, back panel, left side panel, left end panel, right side panel and right end panel. As such, the foldable box can be transformed into a closed, three-dimensional configuration. The top end panel can be rotated relative to the top panel to form a releasable connection. For example, when one or more magnets are provided in the top end panel and/or front panel and are caused to approach one or more connectors (e.g., magnet, hook and loop fastener, etc.) provided on or in the other panel of the foldable box, the magnetic force between the one or more magnets on the top end panel and/or the front panel is sufficient to releasably and securely close the foldable box in a three-dimensional configuration.
Referring now to
It will be appreciated that variants of the above-disclosed and other features and functions, or alternatives thereof, may be combined into many other different systems or applications. Various presently unforeseen or unanticipated alternatives, modifications, variations or improvements therein may be subsequently made by those skilled in the art which are also intended to be encompassed by the following claims.
Claims
1. A foldable box having a plurality of interchangeable configurations, the box comprising:
- a first configuration wherein the box is substantially flat; and
- a second configuration wherein the box is an assembled three-dimensional shape;
- wherein the first and second configurations are interchangeable.
2. The foldable box of claim 1, wherein the box further comprises a first set of panels and a second set of panels, each set of panels comprising one or more panels having a length and a width.
3. The foldable box of claim 2, wherein each panel comprises a single piece of panel material.
4. The foldable box of claim 3, wherein the box further comprises a lining material extending over at least a portion of the first and second set of panels, the lining material forming a foldable attachment portion connecting at least a first and a second panel.
5. The foldable box of claim 4, wherein the at least first and second panels further comprise a second attachment portion.
6. The foldable box of claim 5, wherein the second attachment portion comprises at least one of a hook, loop fastener, tack, staple, latch, snap, releasable adhesive, magnet, and button.
7. The foldable box of claim 5, wherein the second attachment portion of the at least first and second panels forms a reversible connection between the first and second panels.
8. The foldable box of claim 2, wherein the box further comprises a third set of panels, the third set of panels comprising one or more panels having a length and a width.
9. The foldable box of claim 2, wherein the one or more panels includes at least one of a: left end panel, left side panel, bottom panel, right side panel, right end panel, back panel, top panel, top end panel, and front panel.
10. The foldable box of claim 3, wherein the panel material comprises at least one of a: heavy weight cardboard, heavy weight paperboard, medium weight cardboard, fiberboard, plastic, composite material, metal, or wood.
10. The foldable box of claim 9, wherein the box further comprises a third configuration wherein the box is substantially flat and one or more of the panels is layered on top of at least one other panel.
11. A method for manufacturing a foldable box having a plurality of interchangeable configurations, the method comprising:
- selecting a material suitable for use in a foldable box;
- cutting the selected material into a desired number of panels, each panel having a desired size and shape;
- optionally applying a first liner material to at least one surface of the panels;
- forming at least one attachment portion and at least one foldable connector on the panels; and
- optionally applying a second liner material to at least a second surface of the panels.
12. The method of claim 11, wherein method further comprising forming a second attachment portion on one or more of the panels, the second attachment portion comprising at least one of a hook, loop fastener, tack, staple, latch, snap, releasable adhesive, magnet, and button;
- wherein the first liner material forms a foldable attachment portion connecting at least a first and a second panel.
Type: Application
Filed: Dec 1, 2017
Publication Date: May 10, 2018
Inventors: Daniel V. Perella (Cleveland, OH), Benjamin Hietanen (Cleveland, OH), Zhenghong Li (Shenzhen City), Jensen Tuen (Fanling), Jinyuan Li (Shenzhen City)
Application Number: 15/829,170
