Foldable Box
20180127140 ยท 2018-05-10
Inventors
- Daniel V. Perella (Cleveland, OH, US)
- Benjamin Hietanen (Cleveland, OH, US)
- Zhenghong Li (Shenzhen City, CN)
- Jensen Tuen (Fanling, HK)
- Jinyuan Li (Shenzhen City, CN)
Cpc classification
B65D2313/08
PERFORMING OPERATIONS; TRANSPORTING
B65D5/365
PERFORMING OPERATIONS; TRANSPORTING
B65D5/241
PERFORMING OPERATIONS; TRANSPORTING
B65D5/3657
PERFORMING OPERATIONS; TRANSPORTING
International classification
B65D5/36
PERFORMING OPERATIONS; TRANSPORTING
Abstract
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.
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.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] 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:
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DETAILED DESCRIPTION
[0043] 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.
[0044] 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.
[0045] With reference to
[0046] With reference to
[0047] With reference to
[0048] 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.
[0049] 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.
[0050] 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.
[0051] As also seen in
[0052] 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.
[0053] With reference to
[0054] 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.
[0055] 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
[0056] 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.
[0057] 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.
[0058] 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.
[0059] 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.
[0060] 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.
[0061] 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.
[0062] 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.
[0063] 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.
[0064] 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.
[0065] With reference to
[0066] 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.
[0067] 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.
[0068] 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.
[0069] 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.).
[0070] 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.
[0071] 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.
[0072] 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.
[0073] 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.
[0074] 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.
[0075] Referring now to
[0076] 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.