Abstract:
A foldable, stackable box assembly, having a collapsible sleeve component and a foldable container which is insertable into and out of the sleeve by a built-in handle mechanism. The container and sleeve are formed of these folding blanks which, when assembled, create a sturdy, slidable drawer-like box assembly. The front of the container has a compressible handle-like mechanism. It is a characteristic of the container/drawer that the front wall has, extending down from the top, a panel which extends forwardly and terminates short of the bottom of the front of the container/drawer. It is held there by compressible panels, and forms the handle mechanism under which a user can insert hand or finger to pull out the container/drawer from the sleeve.

Description:
CROSS REFERENCES TO RELATED APPLICATIONS 
     Not applicable. 
     STATEMENT REGARDING FEDERALLY-SPONSORED RESEARCH OR DEVELOPMENT 
     Not applicable. 
     BACKGROUND OF THE INVENTION 
     This present invention relates to an improvement in knock-down, collapsible, foldable boxes, and more particularly to shoe boxes for easy storage and shipment, both in the knock-down or assembled state while transporting shoes and, when set up and configured for use, are stackable upon one another and have a removable drawer-like container which, when removed, permits easy retrieval of the shoes within, especially in a shoe store, without adversely affecting the remainder of the stack. It must be understood that, though this invention was prompted by a need for better shoe boxes adapted to storage (in both shoe manufacturing and in retail stores), retrieval, and return, it is capable of being used for any product storage and is not limited to shoes and shoe boxes. 
     Currently shoes are shipped from manufacturer or distributor to a retailer in a pre-formed, generally pasted, shoe box. The typical box has a bottom part and a top part. The bottom part has a base or bottom with four upstanding walls which form a container. The top part is the cover which has an upper base with four downwardly extending walls which snugly fit around the four upstanding walls to cover the opening of the bottom part. Typically the four downwardly extending walls are considerably shorter in length than are the four upstanding walls. This box thus is a pasted-up open-top box closed by a removable lid adapted to fit snugly around the outside of the open-top of the box. 
     It is customary in shoe stores to stack such boxes on top of one another and to have numerous such stacks or columns abutting one another. In such stacking configurations, the stacks can be extremely high consisting of many boxes stacked upon one another. Stacking and columning are generally done in some organized fashion by style and size for example. Shoe boxes such as these generally have information about the shoe style, size, and color which is printed on one or more of their upstanding walls. When a shoe salesperson, for instance, needs a pair of shoes which are in a box on top of the stack, there is no problem in merely taking that box out to the showroom and returning it to the same location without disrupting the organization of the stacks. When a desired shoe is in a box or boxes below the top of a stack, in the middle, or at or near the bottom, pulling the box from the stack is more difficult. Box tops and bottoms can get damaged. 
     For organizational purposes, it is best that the space created by the removed box remain unfilled so that, if a sale is not consummated, the box may be returned to its proper organizational location. This is not what usually occurs however. Once a box is removed from the stack, the boxes in that stack above the removed box simply fall into the space created by the removed box. Given the configuration of the box and lid, the descent generally is not smooth and orderly thereby creating an unsightly, scattered, appearance and unsettling the organization of the stacks. 
     The present invention eliminates the bulk associated with shipping the pre-formed pasted boxes to the shoe manufacturer, for example, and eliminates the problems associated with removing boxes from their stacks in the retail shoe store. In addition, the present invention, with its sleeve, slidable and removable container, permits re-use of the container and placement of the container into its original or any vacant sleeve. 
     Accordingly, several objects and advantages of my invention are to: 
     a. provide boxes which are easy to manufacture and less bulky to ship to the shoe manufacturer, to the retailer, and to an end-user; 
     b. provide boxes for products which are stackable and maintain their stack integrity after the container portion of a box is removed from the stack; 
     c. provide boxes for products which facilitate retrieval of the product therefrom and return thereto; 
     d. provide boxes for products which are not limited to a single product size and style but which are relatively fungible and re-usable; and 
     e. provide product boxes which facilitate reorganization of a retailer&#39;s product inventory. 
     The foregoing has outlined some of the more pertinent objects of the present invention. These objects should be construed to be merely illustrative of some of the more prominent features and applications of the intended invention. Many other beneficial results can be attained by applying the disclosed invention in a different manner or by modifying the invention within the scope of the disclosure. Accordingly, other objects and a fuller understanding of the invention may be had by referring to the summary of the invention and the detailed description of the preferred embodiment in addition to the scope of the invention defined by the claims taken in conjunction with the accompanying drawings. 
     BRIEF SUMMARY OF THE INVENTION 
     The above-noted problems, among others, are overcome by the present invention. Briefly stated, the present invention contemplates a knock-down, foldable, collapsible, stackable box assembly which has a sleeve and a removable container insertable into and out of the sleeve. The container and sleeve are formed of folding blanks which, when folded and assembled, create a sturdy, slidable drawer-like box assembly with the inner container being the removable drawer. The front of the container has a compressible handle-like mechanism which, when one or more box assemblies are shipped together, especially in large shipping containers, compresses without damage to its structure or function. When not in use by the retail purchaser or end-user, the sleeve may be unfolded and collapsed flat and the container may be unfolded and unassembled into a flat blank. When needed, each is easily re-folded, re-assembled into useable box, drawer-like structures. Any suitable materials may be used for the box assembly but a cardboard or cardboard-like materials are best. 
     The foregoing has outlined the more pertinent and important features of the present invention in order that the detailed description of the invention that follows may be better understood so the present contributions to the art may be more fully appreciated. Additional features of the present invention will be described hereinafter which form the subject of the claims. It should be appreciated by those skilled in the art that the conception and the disclosed specific embodiment may be readily utilized as a basis for modifying or designing other structures and methods for carrying out the same purposes of the present invention. It also should be realized by those skilled in the art that such equivalent constructions and methods do not depart from the spirit and scope of the inventions as set forth in the appended claims. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     For a fuller understanding of the nature and objects of the invention, reference should be had to the following detailed description taken in conjunction with the accompanying drawings in which: 
     FIG. 1 is a perspective view of the assembled box assembly. 
     FIG. 2 is a perspective view of the two major components of the box assembly; its container and its sleeve. 
     FIG. 3 is a plan view of the unassembled container component of the box assembly. 
     FIGS. 4-7 and  9 - 14  are views of the container component in various stages of assembly. 
     FIG. 8 is a detailed view of the expansion section of the container component. 
     FIG. 15 is a plan view of the unassembled sleeve component of the box assembly. 
     FIGS. 16-20 are views of the sleeve component in various stages of assembly. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Referring now to the drawings in detail and in particular to FIGS. 1 and 2, reference character  10  of FIG. 1 generally designates a knock-down, collapsible, foldable, stackable box assembly constructed in accordance with a preferred embodiment of the present invention. The two main components of the box assembly  10  include the container  20  and the sleeve  70 . The container  20  is the inner open-top container which functions like a drawer when assembled and inserted into the sleeve  70 . As illustrated in these figures, it has a rear side  24 , a bottom  23 , an opening  21  on top, and a handle-like structure or handle mechanism at the front  22 . The sleeve  70  has a rear,  74  a bottom  73 , a top  71 , and an open front  72 . 
     FIG. 3 represents the container blank  20  in its unfolded state. For the sake of clarity, the dotted lines of this figure only represent fold-lines. As illustrated here the container  20  has a bottom  23  with a front receiving slot  18 ′ and a rear receiving slot  38 ′. A front-end assembly  19  extends forward and outward from the bottom  23  which, when the front-end assemble  19  is folded and assembled, forms the front  22  of the container  20  and also forms a compressible handle mechanism therefor. As shown here, the front-end assembly  19  has a first front panel  11  which is foldably connected to the bottom  23  front, followed by a second front panel  12  which is foldably connected to the first front panel  11 , followed by a third front panel  13  which is foldably connected to the second front panel  12 , followed by a fourth front panel  14  which is foldably connected to the third front panel  13 , followed by the fifth front panel  16  which is foldably connected to the fourth front panel  14 . At least four such front panels are required for this container but a fifth, or more, front panels may be so connected. The main purpose of the fifth front panel  16  will be explained as the assembly of the container is more fully described herein. Adjacent to the far end of the fourth front panel  14 , on or near the fold-line between the fourth and fifth front panels, is a front tab  18  which, when the front-end assembly  19  of the container  20  is assembled, will securingly mate with receiving slot  18 ′. 
     An extension flap  15 ,  17  is foldably connected to each side of the third front panel  13 . Fold lines  31 ,  32 ,  33  in conjunction with one or more slots  34  form an expansion section  30 ,  30 ′ (illustrated in greater detail in FIG. 8) for the connection of the extension flaps  15 ,  17  to the third front panel  13 . The first, second, and third front panels  11 ,  12 ,  13 , in conjunction with the extension flaps  15 ,  17  will, when the front-end assembly  19  is folded and assembled, form a handle or grabbing mechanism to facilitate the translation of the container  20  in and out of the sleeve  70  and will also provide sound structural support for the front of the container  20 . 
     A rear-end assembly  39  extends rear ward and outward from the bottom  23  which, when the rear-end assembly  39  is folded and assembled, forms the completed, structurally sound, rear  24  of the container  20 . As illustrated, the rear-end assembly  39  has a first rear panel  27  which is foldably connected to the bottom  23  rear, followed by a second rear panel  28  which is foldably connected to the first rear panel  27 , followed by a third rear panel  29  which is foldably connected to the second rear panel  28 . At least two such rear panels are required for this container  20  but a third, or more, rear panels may be so connected. The main purpose of the third rear panel  29  will be explained as the assembly of the container  20  is more fully described. Adjacent to the far end of the second rear panel  28 , at or near the fold-line of the second and third rear panels, is a rear tab  38  which, when the container  20  is assembled, will securingly mate with receiving slot  38 ′. 
     A first-side assembly  43  and a second-side assembly  53  are foldably connected to opposing sides of the bottom  23  of the container  20 . For reference purposes, these respectively form a right side and a left side for the container  20 . Each side assembly  43 ,  53  has a front-side lockable flap  35 ,  37 , respectively, and a rear-side lockable flap  25 ,  26 , respectively. The right front-side lockable flap  35  has an extension tab  45  and a slit  47  which, when folded and assembled, securely mate with the extension tab  46  and slit  48  of the left front-side lockable flap  37 . Similarly, the right rear-side lockable flap  25  has an extension tab  65  and a slit  67  which, when folded and assembled, securely mate with the extension tab  66  and slit  68  of the left rear-side lockable flap  26 . When so folded and assembled, the container  20  has a secure front, rear, and side foundations. As will be described the completed assemblies of the front-end assembly  19  and the rear-end assembly  39  over the front and rear of the container  20  further buttresses the structural integrity of the container&#39;s front and rear and provides the necessary strength to support stacking. 
     FIGS. 4-7 and  9 - 14  illustrate the folding and assembly of the container  20 . It is best to fold and assemble the side assemblies first; either side assembly may be folded and assembled first, either by hand or by mechanical means. In this regard, each side assembly is folded up followed by folding the front-side lockable flaps  35 ,  37  in the direction of arrows A and B and mating the respective flaps as previously described and as illustrated in FIG.  5 . This is followed by folding the rear-side lockable flaps  25 ,  26  in the direction of arrows A′ and B′ and mating these respective flaps similarly as the front-side flaps were mated. It must be understood that the extension tabs  45 ,  46  may be exposed as illustrated in FIG. 5 or may be tucked inward and not exposed. With either method, the side assemblies securely lock together and thereby establishes four upstanding perimeter walls of the container  20 . 
     Reference is now made to FIGS. 6-11 for completion of the front-end assembly  19 . As previously discussed, the handle mechanism is formed by the first front panel  11 , the second front panel  12 , and the third front panel  13  in combination with extension flaps  15 ,  17  and the expansion section in between the third front panel  13  and its extending extension flaps  15 ,  17 . FIG. 8 details the expansion section  30  between, and serving as the connection to, the third front panel  13  and its two extension flaps  15 ,  17 . The expansion section  30  is an important feature of the container  20 . As illustrated here, the expansion section  30  has three fold-lines  31 ,  32 ,  33 . Fold-line  32  has one or more slots  34  and it, the fold-line, is folded or creased inwardly or outwardly in the direction of arrows X. Fold-line  31  is folded or creased in the direction of arrow Z and fold-line  33  is folded or creased in the direction of arrow Y. As so folded, the expansion section takes on an accordion-like appearance and function. The slots  34  facilitate it compressibility. It must be understood that there may be more than three fold-lines as illustrated and that one or more slots  34  may be inserted into any one or more of the fold-lines. Ease of construction, assembly, and use militates in favor of three fold-lines as shown with one or more slots  34  in the middle fold-line  32 . 
     After the folds have been made to ready the expansion sections  30 ,  30 ′ on both extension flaps  15 ,  17  but, before the extension flaps  15 ,  17  are folded, the first front panel  11  should be folded upward and inward, in the direction of arrow C followed by the downward and inward folding of the second front panel  12  in the direction of arrow D. As so folded, these front panels  11 ,  12  resemble an up-side-down “V”. The third front panel  13  is then folded upward and inward, in the direction of arrow E. This is followed by the inward folding, in the direction of arrows F, of the extension flaps  15 ,  17  over the first front panel  11 . FIG. 9 represents the result of these folds. 
     The front-end assembly  19  is completed by folding the fourth front panel  14  and, in the direction of arrow G, carrying it over and into the container  20  to the bottom and inserting the tab  18  into the receiving slot  18 ′ thereat. Although a fifth front panel  16  is not required, it is preferred in that it protects and better secures the tab  18  to receiving slot  18 ′ connection. The front-end assembly  19  is now complete and sturdy. A compressible handle mechanism extends from the front end and is suitable for grabbing, holding, and moving the container into and out of the sleeve  70 . 
     The container  20  is completed with the folding and carrying over, in the direction of arrow H, of the rear-end assembly  39  and, similar to the assembly of the front-end assembly  19 , insertion of the tab  38  into the receiving slot  38 ′. Similar to the front-end assembly  19 , the third rear panel  29 , though not necessary, is preferred as it too protects and better secures in place the rear-end assembly tab  38  to receiving slot  38 ′ connection. 
     FIGS. 15-20 illustrate the sleeve  70  component of the box assembly  10 . The sleeve  70  is generally formed from a single flat blank with fold lines folded and the ends fastened by glue, a self-adhesive strip, or similar means to thereby form a collapsible basically rectangular hollow into which the container  20  may be insertable and removable. FIG. 15 illustrates the sleeve  70  in its knock-down, collapsed state. FIG. 16 illustrates the sleeve  70 , from the rear, in an uncollapsed or open state ready for assembly. The sleeve  70  has a foldable top rear flap  77 , a foldable bottom rear flap  79  and two foldable rear side flaps  75 ,  76 . The top rear flap  77  has inward and upward angled sides terminating at and creating a top extension flap  97 . It also has a hole or vent  78  which facilitates the insertion and removal of the container  20 . The vent  78  is shown on the top rear flap  77  but instead may be on the bottom rear flap  79 , or on either rear side flap  75 ,  76 , or any combination thereof. The bottom rear flap  79  has a depression or channel  96  centered on its outer edge and two step taps  95  extending farther outward beyond the channel  96 . Each rear side flap  75 ,  76  has a protruding tab  85 ,  86  and groove  87 ,  88 , respectively. 
     Assembly of the sleeve  70  entails folding the bottom rear flap  70  upward to resemble the sleeve  70  as depicted in FIG.  17 . This is followed by the inward folding of each rear side flap  75 ,  76  in the direction of arrows I and inserting the respective protruding tabs  85 ,  86  over the channel  96  and into the sleeve  70 . The result of this operation is depicted in FIG.  18 . Next the top rear flap  77  is folded downward and the top extension flap  97  inserted over the channel  96  and into the sleeve  70 . As assembled, the top extension flap  97  is seated in between the bottom rear flap  79  and the protruding tabs  85 ,  86 , and such configuration forms a walled rear for the sleeve  70  and a stop for the container  20 . The box assembly  10  is now ready for full use and stacking without experiencing excess damage from shipping or use. 
     The components (container  20  and sleeve  70 ) of the box assembly  10  each come with fold or crease lines and cuts, slits, or slots as described herein already incorporated in the respective component. 
     The present disclosure includes that contained in the present claims as well as that of the foregoing description. Although this invention has been described in its preferred form with a certain degree of particularity, it is understood that the present disclosure of the preferred form has been made only by way of example and numerous changes in the details of construction and combination and arrangement of parts may be resorted to without departing from the spirit and scope of the invention. Accordingly, the scope of the invention should be determined not by the embodiments illustrated, but by the appended claims and their legal equivalents.