FOLDING AND INTERLOCK STRUCTURES FOR REUSABLE AND COLLAPSIBLE BOXES

Abstract

Plastic corrugated reusable boxes are provided. Two opposite side panels 12 erected from a blank over fold lines 18 at bottom panel edges; said side panel 12 having flaps 20 attached on either side folded inward and interlocked with flaps 22 folded inward from the opposite side. Narrow flaps 32 attached to top edges of said side panels 12 folded inward and flat. The rest two opposite side panels 14 erected over fold lines at rest bottom panel edges; top flaps 30 attached to the rest two side panels 14 folded inward covering the top surface. Interlocked flaps 20 and 22 are standing underneath top flaps 30 and alongside two opposite side panels 14. Lock tabs 40 attached to top flaps 20 folded down and inserted into said lock slots embedded in narrow flaps 22 alongside side panels 12 top edges.

Claims

1. A reusable box comprising: Two opposite side panels erected over fold lines of bottom panel edges; Each said side panel having a flap attached on either side over fold lines, said flaps folded inward and interlocked with opposite said flaps folded inward, forming a stabilized open top enclosure together with said side panels and said bottom panel. Top edge of each said side panel attached with a narrow flap, said narrow flaps folded inward and flat over fold lines. The rest two opposite side panels erected over fold lines of rest two bottom panel edges; Said rest side panels having top flaps attached to top edges over fold lines; for a closed box, said top flaps folded inward and covering said box top surface, keeping both said narrow flaps flat and interlocked said flaps standing underneath and alongside the rest two opposite said side panels.

2. Said reusable box of claim 1 wherein the box body, said panels, said flaps, said lock tabs are formed from a plastic corrugated blank.

3. Said reusable box of claim 1 wherein the interlock structure comprising tabs attached to said flaps inserted to said slots embedded in said flaps from opposite side of said box.

4. Said reusable box of claim 3 wherein said flaps with said tabs or said slots both pushed all the way inward until said tabs are pointing to said slots and then inserting. With assistance of folding elasticity, interlocked said flaps with said tabs inserted into said slots pulled back from inside of said box to said box sides.

5.-6. (canceled)

7. Said reusable box of claim 1 wherein one said top flap covering the entire top surface of said box, or said top flaps covering entire or partial top surface of said box.

8. Said reusable box of claim 1 wherein the interlock structure comprising said top flaps attached with lock tabs over fold lines, and said narrow flaps embedded with lock slots. Accordingly positioned said lock tabs folded down and inserted into said lock slots.

9.-10. (canceled)

Description

BRIEF DESCRIPTION OF THE DRAWINGS— FIGURES

[0020] FIG. 1 is a plan view of a plastic corrugated blank having fold lines, slots, tabs, flaps and panels of an embodiment of the present invention.

[0021] FIG. 2 is a partially erected plastic corrugated box with side flaps pushed inward with tabs pointing to slots embedded in flaps attached to the opposite long side panels.

[0022] FIG. 3 is a partially erected plastic corrugated box with interlocked flaps pulled back to the sides by folding elasticity, folding down the narrow flaps and erecting one short side panel.

[0023] FIG. 4 is a partially closed plastic corrugated box by folding one top flap attached to the short side panel and inserting lock tabs into lock slots.

[0024] FIG. 5 is a completely closed plastic corrugated box.

[0025] FIG. 6 is a plan view of a plastic corrugated blank having tabs attached to side flaps to interlock by mutually vertical inserts of an embodiment in the present invention.

[0026] FIG. 7 is a plan view of a plastic corrugated blank having three tabs attached to side flaps to interlock by mutually horizontal inserts of an embodiment in the present invention.

[0027] FIG. 8 is a partially erected plastic corrugated box having tabs attached to side flaps to interlock by mutually vertical inserts from the opposite side panels of the embodiment.

[0028] FIG. 9 is a partially erected plastic corrugated box having flap interlocks by mutually vertical inserts tabs and one closed top flap with lock tabs inserted in lock slots underneath.

[0029] FIG. 10 is a partially erected plastic corrugated box having three tabs attached to each flap further attached to opposite side panels to interlock by mutually horizontal inserts.

[0030] FIG. 11 is a partially erected plastic corrugated box having opposite flap interlocks by mutually horizontal three tab inserts and one closed top flap with lock tabs inserted in lock slots underneath.

[0031] FIG. 12 is a partially closed plastic corrugated shelter house having interlock tabs and interlock slots on opposite side flaps and roof opposite side triangle flaps.

[0032] FIG. 13 is a closed plastic corrugated shelter house having both opposite side flaps and roof opposite side triangle flaps interlocked by interlock tabs inserted into interlock slots.

[0033] FIG. 14 is a plan view of a plastic corrugated blank having fold lines, lock slots, lock tabs, top and bottom flaps, four attached side panels and a joint flap of an embodiment of the present invention.

[0034] FIG. 15 is a partially erected plastic corrugated box having side panels enclosed by fastening the joint flap to the end of sequential and folded side panels.

[0035] FIG. 16 is a partially closed plastic corrugated box having all closed bottom flaps and one closed long top flap with lock tabs inserted in slots embedded on short flaps.

[0036]

TABLE-US-00004 Drawing-Reference Numerals 10 bottom panel 12 long side panel 14 short side panel 15 joint flap 18 fold line 20 side flap with tab 22 side flap with slot 24 flap with vetical tab 28 flap with horizontal tabs 30 top flap 32 narrow flap 34 long flap 36 short flap 40 lock tab 42 lock slot 44 interlock slot 45 vertical tab 46 interlock slot 48 middle tab 49 side tab 50 roof

DETAILED DESCRIPTION OF THE INVENTION

[0037] One embodiment of my reusable plastic corrugated boxes is illustrated in FIG. 1. Bottom panel 10 is located in the center of the die cut blank. Each of long side panels 12 is attached to opposite sides of bottom panel 10 over fold line 18, also further attached with a narrow flap 32 having lock slots 42. One long side panel 12 is attached with two side flaps 20 having interlock tabs 44, while the opposite long side panel 12 is attached with two side flaps 22 embedded with interlock slots 46. Short side panels 14 are attached to the other opposite sides of bottom panel 10 over fold lines 18, also further attached with top flaps 30 having lock tabs 40.

[0038] FIG. 2 illustrates that long side panels 12 are erected over fold lines 18; each attached side flap with tab 20 and each attached side flap with slot 22 are folded inward over fold lines 18, all the way until getting inside space of the unformed box when each interlock tab 44 is pointing to each interlock slot 46.

[0039] FIG. 3 illustrates that after inserting lock tabs 40 into lock slots 42, folding elasticity on the plastic corrugated sheet between side flaps (20 and 22) and long side panels 12 pulls back the interlocked flaps (20 and 22) from inside space to the box sides and close the rest two box sides. The flap interlocks meanwhile hold down the upward move tendency caused by folding elasticity between long side panels 12 and the bottom panel 10, forming an enclosure among the bottom panel 10, opposite long side panels 12 and interlocked rest two side flaps (20 and 22). At this stage, the loading can be carried out.

[0040] Narrow flaps 32 attached to long side panels 12 are folded flat and lock slots 42 are facing upward. Right outside of interlocked flaps (20 and 22), one short side panel 14 and attached top flap 30 are erected over fold lines 18 while attached lock tabs 40 are folded forward and ready to insert into lock slots 42.

[0041] FIG. 4 discloses that one top flap 30 is folded down over fold lines 18 on top of narrow flaps 32, attached lock tabs 40 are also inserted into lock slots 42 underneath the top flap 30. Interlocked side flaps (20 and 22) are holding the position at the box side.

[0042] A completely closed box is illustrated in FIG. 5 with both top flaps 30 folded down over fold lines 18 onto the top surface of the box.

[0043] Another embodiment of the present invention is illustrated in FIG. 6. Bottom panel 10 is located in the center of the die cut blank. Each of long side panels 12 is attached to opposite sides of bottom panel 10 over fold lines 18, further attached with a narrow flap 32 having lock slots 42. Long side panels 12 are attached with side flaps 24 and interlock tabs 45. Short side panels 14 are attached to the other opposite sides of bottom panel 10 over fold lines 18, further attached with top flaps 30 having lock tabs 40.

[0044] Another embodiment of the present invention is illustrated in FIG. 7. Bottom panel 10 is located in the center of the die cut blank. Each of long side panels 12 is attached to opposite sides of bottom panel 10 over fold lines 18, further attached with a narrow flap 32 having lock slots 42. Long side panels 12 are attached with side flaps 28 having middle tabs 48 and side tabs 49. Short side panels 14 are attached to the other opposite sides of bottom panel 10 over fold lines 18, further attached with top flaps 30 having lock tabs 40.

[0045] One long side panel 12 is erected over fold lines 18; another long side panel 12 erected half ways is illustrated in FIG. 8. Flaps with vertical tabs 24 are folded toward each other ready to interlock by mutually inserting interlock tabs 45 vertically.

[0046] An interlock between side flaps with vertical tabs 24 having vertical tabs 45 mutually inserted is illustrated in FIG. 9. Narrow flaps 32 having lock slots 42 are folded flat so that one top flap 30 is folded over on the top, underneath which lock slots 42 are inserted by folded down lock tabs 40.

[0047] FIG. 10 illustrates that one long side panel 12 is erected over fold lines 18 with one side flap having three horizontal tabs 28 folded crosswise, and the other long side panel 12 is erected with one side flap having three horizontal tabs 28 unfolded.

[0048] FIG. 11 illustrates the interlock between flaps having three horizontal tabs 28 by mutually inserted middle tabs 48 and side tabs 49. Narrow flaps 32 having lock slots 42 are folded flat so that a top flap 30 is folded over on the top, underneath which lock slots 42 are inserted by folded down lock tabs 40.

[0049] FIG. 12 illustrates a shelter house made of plastic corrugated sheets having side flaps (20 and 22), and roof triangle side flaps (20 and 22) unfolded. Interlock tabs 44 are attached to side flaps 20, and interlock slots 46 are embedded in side flaps 22. Long side panels 12 are the walls of the shelter house and roofs 50 are on the top of the entire structure.

[0050] FIG. 13 illustrates the closed shelter house of plastic corrugated sheets having side flaps (20 and 22) interlocked at the shelter house sides, while roof triangle side flaps (20 and 22) are interlocked under the roof 50. The shelter house is a closed enclosure.

[0051] Another embodiment of the present invention is illustrated in FIG. 14. Two long side panels 12 and two short side panels 14 alternately attached to each other over fold lines 18, and further attached with one joint flap 15. Each long flap 34 is attached to either side of long side panel 12 over fold line 18. Each short flap 36 is attached to either side of short side panel 14 over fold line 18. Each long flap 34 is attached with two lock tabs 40 and each short flap 36 is embedded with two lock slots 42.

[0052] As illustrated in FIG. 15, joint flap 15 is either welded or glued or stapled to the edge of end short side panel 14, together with all long side panels 12 and short side panels 14 forming a rectangular enclosure, with long flaps 34 and short flaps 36 standing unfolded. Part of lock tabs 40 attached to long flaps 34 over fold lines 18 are actually cutaways from short flap 36 nominal rectangle areas. Short flaps 36 carry lock slots 42 and lock tab 40 cutaway notches.

[0053] FIG. 16 discloses the locking structure of the box by folding down short flaps 36 flat over fold lines 18 first, then folding down one long flap 34 flat meanwhile folding down lock tabs 40 to insert into lock slots 42 on short flaps 36. The flap folding and locking procedures apply the same to the bottom and the top of the box to complete the box enclosure.

Advantages

[0054] 1) The folding and interlock structures in the present invention are designed to build for box strength. [0055] 2) The plastic corrugated blanks in the present invention are designed for high speed die cut productions, minimizing costs. [0056] 3) The plastic blanks cut and creased for boxes in the present invention are in restricted shapes and areas that minimize cutaway areas, reducing costs on material waste. [0057] 4) Plastic corrugated panels provide cushioning protections to contents in the boxes. [0058] 5) Simply pushing side flaps all the way inward till interlock tabs pointing to interlock slots and interlock, folding elasticity pulls back the interlocked flaps at opposite sides of the boxes, together with side panels and bottom panel, an enclosure is built for loading before complete closing. [0059] 6) Interlocked flaps with locked tabs and slots stay alongside the vertical side panels without interrupting contents in the box. [0060] 7) The interlock and locking mechanism use frictions and engagement, mutually blocking upward move tendencies of side flaps, preventing self-opening. [0061] 8) Disassembly of the interlocks is simple by pushing interlocked flaps inward until withdrawing interlock tabs from interlock slots. [0062] 9) The designs in the present invention are based on symmetric principles, user friendly and packaging equipment friendly for continuous flow in fulfillment centers. [0063] 10) When an integral bottom panel is located at the center of the blank, it saves assembly work on the bottom panel itself unlike the auto bottom in other boxes. [0064] 11) The interlock designs in the present invention reduce multiple over layers on the plastic corrugated boxes, lessening the total weight. [0065] 12) Interlocked flaps are right under a top flap or top flaps, held in place and in reverse supporting the side panels alongside for stack load. [0066] 13) Designs in the present invention eliminate the flute openings facing upward, preventing contamination falling into flutes causing visual discomfort or problems. [0067] 14) All the boxes described in the present inventions are made in one piece folder without any accessories. [0068] 15) The flattened blanks in the present invention contain no dead spots along flutes, easily washed and dried out.

CONCLUSION, RAMIFICATIONS, AND SCOPE

[0069] Accordingly, the reader will see that the panel and flap interlocking and locking structures in the present invention for building reusable boxes are simple, convenient and practical. Substituting cardboard boxes with the reusable boxes can cut down carbon footprint, pollutions and preserve enormous amount of natural resources. It supplies sustainable, reusable and economical solutions of daily necessity to consumers, retailers, supply chains and eCommerce.

[0070] Although the description above contains much specificity, these should not be construed as limiting the scope of the embodiments but as merely providing illustrations of some of several embodiments. For instance, the box materials can extend to categories of cardboard, various types of polymers, composites or even metals, while the blanks can be made in single sheets instead of fluted panels. Regarding side flap interlocks on the opposite sides of the box, the interlock structures are not limited to the three interlock embodiments described in the present invention.

[0071] Top flaps for final box enclosure can be symmetrically identical from both sides as described in embodiments, or can be in forms of single top flap to cover across the whole top area, or top flaps of uneven sizes to cover the entire top area, or only partial top areas, or top flaps converted into sloped roof shapes or in other irregular shapes.

[0072] Lock tabs folded down from the top flaps to insert into lock slots embedded on the narrow flaps alongside the folding lines can apply to boxes beyond designs described in the present invention.

[0073] Even though embodiments in the present invention describe reusable plastic corrugated boxes, the design scope can extend to structures with similarities to those in the present invention. For instances, reusable plastic corrugated shelter homes carry double interlocked side flaps on one wall with roofs on the top. Others can be applied to play houses, pet houses, easily assembled furniture etc.