Abstract:
A system whereby a collapsible box may be formed in the same way that standard cardboard boxes are made by folding a single sheet of material is provided. Square and rectangular boxes may be constructed which may be collapsed down to compact size and easily popped open. Boxes so constructed remain fully assembled with all seams and edges attached even as they are repeatedly folded and unfolded. The box may be made of corrugated cardboard or plastic and easily folded to a fraction of their open volume. The box may open instantly, and when opened, it becomes structural—that is resistant to applied loads—by “popping” certain points outwards. An element or construction that is comprised of a sheet of material that has been provided with a network of hinges such that when the element is folded its edges maintain a right angle relationship is also provided.

Description:
BACKGROUND OF THE INVENTION  
       [0001]     This application claims priority of Provisional Application No. 60/697,420, filed Jul. 8, 2005.  
         [0002]     It is often useful to have a container or box that may be collapsed to a small volume when not in use and then expanded when needed. A number of different products have been developed for use in both consumer and industrial markets.  
         [0003]     Standard corrugated boxes do, of course, fold down to a flat sheet and are often transported in this folded state. Later, when ready for use, they are unfolded and various flaps are attached in order to make them rigid. The time taken to prepare the box for use, while not extensive, is often not convenient and discourages repeated use of the box.  
         [0004]     An alternative collapsible box design is made of rigid perforated panels and resembles a standard milk crate. It is comprised of a top and bottom panel, as well as sides that are articulated allowing it to fold. This type of box is distributed both as a consumer product as well as for industrial use.  
         [0005]     This design has several drawbacks. The number of parts is relatively large, leading to higher costs. Another limitation is that it is not possible to seal this type of box due to its perforated sides and the difficulty of sealing hinged panels.  
         [0006]     As an alternative to collapsible boxes assembled from multiple parts, I have invented a method whereby a collapsible box may be formed in the same way that standard cardboard boxes are made: by folding a single sheet of material. Boxes made according to the following disclosure may be made of corrugated cardboard or plastic and are easily folded to a fraction of their open volume. They open instantly, and when opened, they become structural—that is resistant to applied loads—by “popping” certain points outwards.  
         [0007]     Construction is simple: boxes can be made of a singled sheet of folded material, or, in some applications of a rigid top surface, a pleated side surface, and a rigid bottom surface. The simplicity of construction leads to low manufacturing costs.  
         [0008]     An alternative manufacturing technique would be to produce the box out of a single piece of blow-molded or roto-cast plastic. In this case it is possible to make the collapsible box entirely sealed and water-tight.  
         [0009]     The design possibilities are extensive allowing for collapsible boxes of different sizes and proportions to be built. Beyond the ability to make such boxes flatten in one dimension, another embodiment of this invention allows boxes to be built that fold in multiple dimensions. 
     
    
     SUMMARY OF THE INVENTION  
       [0010]     Generally speaking, in accordance with the invention, an element that is comprised of a sheet of material that has been provided with a network of hinges such that when the element is folded its edges maintain a right angle relationship is provided.  
         [0011]     This maintained or invariant angle is a critical innovation of the disclosed invention, allowing for a method whereby square and rectangular boxes may be constructed which may be collapsed down to compact size and easily popped open. Boxes so constructed, according to the present disclosure, remain fully assembled with all seams and edges attached even as they are repeatedly folded and unfolded.  
         [0012]     Further disclosed are boxes that have second degrees of folding such that they fold in half even as they flatten. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0013]      FIG. 1  shows a plan view of four shapes that may be assembled to provide an embodiment of the inventive assembly;  FIG. 1A  is a plan view of a two regions that are assembled from the shapes shown in  FIG. 1A ;  
         [0014]      FIG. 2  shows a plan view of an element which embodies the inventive assembly;  
         [0015]      FIG. 3  shows a perspective view of the embodiment shown in  FIG. 2  in a first folded condition;  
         [0016]      FIG. 4  is a perspective view of the embodiment shown in  FIG. 2  in a second folded condition;  
         [0017]      FIG. 5  is a perspective view of the embodiment shown in  FIG. 2  in a third folded condition;  
         [0018]      FIG. 6  is a perspective view of the embodiment shown in  FIG. 2  in a fourth folded condition;  
         [0019]      FIG. 7  shows a plan view of the embodiment shown in  FIG. 2  in a first folded condition;  
         [0020]      FIG. 8  is a plan view of the embodiment shown in  FIG. 2  in a second folded condition;  
         [0021]      FIG. 9  is a plan view of the embodiment shown in  FIG. 2  in a third folded condition;  
         [0022]      FIG. 10  is a perspective view of the embodiment shown in  FIG. 2  in a fourth folded condition;  
         [0023]      FIG. 11  shows an elevation view of the embodiment shown in  FIG. 2  in a first folded condition;  
         [0024]      FIG. 12  is an elevation view of the embodiment shown in  FIG. 2  in a second folded condition;  
         [0025]      FIG. 13  is an elevation view of the embodiment shown in  FIG. 2  in a third folded condition;  
         [0026]      FIG. 14  is an elevation view of the embodiment shown in  FIG. 2  in a fourth folded condition;  
         [0027]      FIG. 15  shows a plan view of sheet comprised of four elements similar to that shown in  FIG. 2 ;  
         [0028]      FIG. 16  shows an exploded view of the sheet shown in  FIG. 15 , which has been folded to a first position, along with upper and lower surfaces;  
         [0029]      FIG. 17  shows a perspective view of a box comprised of the sheet and surfaces shown in  FIG. 16 ;  
         [0030]      FIG. 18  shows a perspective view of the box of  FIG. 16  in a second folded condition;  
         [0031]      FIG. 19  shows a perspective view of the box of  FIG. 16  in a third folded condition;  
         [0032]      FIG. 20  shows a perspective view of a box which is another embodiment of the invention;  
         [0033]      FIG. 21  shows a plan view of box shown in  FIG. 20 ;  
         [0034]      FIG. 22  shows a perspective view of the box shown in  FIG. 20  with an outward force applied to its sides;  
         [0035]      FIG. 23  shows a perspective view of the box shown in  FIG. 22  in a “popped-open” condition;  
         [0036]      FIG. 24  shows a plan view of the box shown in  FIG. 23 ;  
         [0037]      FIG. 25  shows a perspective view of the box shown in  FIG. 20  with an outward force applied to its corners;  
         [0038]      FIG. 26  shows a perspective view of the box shown in  FIG. 25  in a second “popped-open” condition;  
         [0039]      FIG. 27  shows a plan view of the box shown in  FIG. 26 ;  
         [0040]      FIG. 28  shows a perspective view of a box which is an alternate embodiment of the invention in a folded condition;  
         [0041]      FIG. 29  shows a perspective view of the box shown in  FIG. 28  in a second further unfolded condition;  
         [0042]      FIG. 30  shows a perspective view of the box shown in  
         [0043]      FIG. 28  in a third fully unfolded condition;  
         [0044]      FIG. 31  shows a plan view of an element which is an alternate embodiment of the inventive assembly;  
         [0045]      FIG. 32  shows a plan view of sheet comprised of four elements, two of which are similar to that shown in  FIG. 31 ;  
         [0046]      FIG. 33  shows an exploded perspective view of the sheet shown in  FIG. 32 , which has been folded to a first position, along with upper and lower surfaces;  
         [0047]      FIG. 34  shows a perspective view of a box comprised of the sheet and surfaces shown in  FIG. 33 ;  
         [0048]      FIG. 35  shows a perspective view of the box shown in  FIG. 34  in a second folded condition;  
         [0049]      FIG. 36  shows a perspective view of the box shown in  FIG. 34  in a third folded condition;  
         [0050]      FIG. 37  shows a perspective view of the box shown in  FIG. 34  in a fourth fully folded condition;  
         [0051]      FIG. 38  shows a box which is an alternate embodiment of the invention in a first folded condition;  
         [0052]      FIG. 39  shows the box shown in  FIG. 38  in a second folded condition;  
         [0053]      FIG. 40  shows the box shown in  FIG. 38  in a third folded condition;  
         [0054]      FIG. 41  shows a container of the invention comprised of two stacked boxes in a first folded condition;  
         [0055]      FIG. 42  shows the container shown in  FIG. 41  in a second folded condition;  
         [0056]      FIG. 43  shows the container shown in  FIG. 41  in a third folded condition;  
         [0057]      FIG. 44  shows an assembly of the invention in a first folded condition;  
         [0058]      FIG. 45  shows the assembly shown in  FIG. 44  in a second folded condition;  
         [0059]      FIG. 46  shows the assembly shown in  FIG. 44  in a third folded condition;  
         [0060]      FIG. 47  shows the assembly shown in  FIG. 44  in a fourth folded condition;  
         [0061]      FIG. 48  shows a group of boxes constructed in accordance with the invention and in a first folded condition;  
         [0062]      FIG. 49  shows the group of boxes shown in  FIG. 48  in a second folded condition; and  
         [0063]      FIG. 50  shows the group of boxes shown in  FIG. 49  assembled into a cabinet unit. 
     
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0064]      FIG. 1  shows a plan view of four flat shapes  2 ,  4 ,  6  and  8 . Shape  2  is a scalene triangle having a longer side and two shorter sides. Preferably, shape  2  has internal angles of approximately 45, 22.5 and 112.5 degrees respectively. Shape  4  is a symmetric or isosceles trapezoid having first and second sides of equal length and third and fourth sides of different lengths. Preferably, shape  4  has internal angles of approximately 45 and 135 degrees. Shape  6  is a scalene triangle which is essentially a mirror image of shape  2 . Shape  8  is an isosceles triangle having first and second sides of equal length and a third side. Preferably, shape  8  has internal angles of approximately 67.5 and 45 degrees.  
         [0065]      FIG. 1A  is a plan view of a region  20  wherein shapes  2 ,  4 ,  6  and  8  have been attached to each other by a hinged connection. Also shown in  FIG. 1A  is a second region  22  which is essentially a mirror image of region  20 .  
         [0066]      FIG. 2  shows a plan view of an element  24  which is comprised of regions  20  and  22  which have been hingedly joined along their respective bottom and top edges. Also shown are outer edges  3  and  13  which border shapes  2  and  12  respectively, as well as outer edges  5  and  15  which border shapes  8  and  18  respectively.  
         [0067]      FIG. 3  shows a perspective view of element  24  which has been folded to a certain degree. Outer edges  3 ,  13 ,  5  and  15  are also shown.  FIGS. 4-6  show perspective views of element  24  as it is folded down to a flattened configuration.  
         [0068]      FIG. 7  shows a plan view of element  24  which is folded to the same degree as  FIG. 3 . Seen from this perspective, edge  3  forms an angle with edge  13 , said angle being approximately ninety degrees. Likewise edge  5  (which lies directly below edge  3 ) forms an angle with edge  15 , again said angle being approximately ninety degrees.  
         [0069]      FIG. 8  shows a plan view of element  24  which is folded to the same degree as  FIG. 4 . The angle formed between edges  3 ,  13  and  5 ,  15  remains approximately ninety degrees.  
         [0070]      FIGS. 9 and 10  show plan views of element  24  folded to the same degree as  FIGS. 5 and 6  respectively. The angles formed between edges  3 ,  13  and  5 ,  15  remain approximately ninety degrees for both positions.  
         [0071]      FIGS. 11-14  show elevation views of element  24  as it is folded, the positions being the same as shown in  FIGS. 3-6  and  FIGS. 7-10  respectively.  
         [0072]      FIG. 15  shows a plan view of sheet  30  which is comprised of four elements  32 ,  34 ,  36  and  38 ; each element comprises six triangles and two trapezoids similar to element  24  as shown in  FIG. 2 . Also shown are outer edges  31  and  35  which border element  32  as well as outer edges  33  and  37  which border element  38 .  
         [0073]      FIG. 16  shows a perspective view of sheet  30  which has been folded in a three-dimensional manner to form a loop such that edge  31  has been joined to edge  33  and edge  35  has been joined to edge  37 . The upper perimeter  43  of sheet  30  forms a square shape as does the lower perimeter  44 . Also shown in exploded view are top surface  40  and bottom surface  42  which each have an essentially square shape.  
         [0074]      FIG. 17  shows an assembled box  50  wherein the upper and lower perimeter of sheet  30  have been joined to upper surface  40  and lower surface  42 .  
         [0075]      FIG. 18  shows box  50  in a further folded position.  FIG. 19  shows box  50  in a fully folded position.  
         [0076]      FIG. 20  shows a perspective view of box  60  according to the present invention. This embodiment of the invention shows shapes  63 ,  65 ,  67  and  69  at the four comers of box  60 , each of which have a trapezoidal profile rather than a triangular profile as in previous drawings. Also shown in this view are four shapes  62 ,  64 ,  66  and  68  that are part of the sides of box  60 .  
         [0077]      FIG. 21  shows a plan view of box  60 . It may be seen that trapezoids  62 ,  64 ,  66  and  68  lie within the interior space of box  60 .  
         [0078]      FIG. 22  shows a second perspective view of box  60 . Also shown is force vector  61  which indicates an outward force on the sides of the box.  
         [0079]      FIG. 23  shows a perspective view of box  60  where its four sides are pushed outwards relative to the position shown in  FIG. 22 . This position is a result of the force  61  applied in  FIG. 22 . In this position, the box resists downwards forces on its upper surface.  
         [0080]      FIG. 24  shows a plan view of box  60  in the same position as  FIG. 23 . Side shapes  62 ,  64 ,  66  and  68  of box  60  now lie outside of the box&#39;s interior space.  
         [0081]      FIG. 25  shows a perspective view of box  70  which is essentially the same as box  60  except that additional pleat lines  72 ,  74 ,  76  and  78  are shown at its comers. Also shown is force vector  71  which indicates an outward force on the comers of the box.  
         [0082]      FIG. 26  shows a perspective view of box  70  wherein the outward force  71  having been applied to its comers results in forcing the comers outwards to form straight creases  72 , 74  and  76 , 78 . In this position, the box will also resist downwards force on its upper surface.  
         [0083]      FIG. 27  shows a plan view of box  70  in the same position as  FIG. 26 .  
         [0084]      FIG. 28  shows a perspective view of box  100  which is an alternate embodiment of the invention. Box  100 , shown in its fully folded position, is comprised of a top surface  120 , a folded sheet  110  and a bottom surface  130 . Additionally shown are four links  101 ,  102 ,  103  and  104  which are attached to folded sheet  110 .  
         [0085]      FIG. 29  shows box  100  in a partially folded condition. Links  101 ,  102 ,  103  and  104 , which are attached to the comers of sheet  110 , are rotated relative to the position shown in  FIG. 28 .  
         [0086]      FIG. 30  shows box  100  in an unfolded position. Arms  101 ,  102 ,  103  and  104  have been further rotated, creasing the comers of sheet  110  such that the box is stiffened and self-supporting.  
         [0087]      FIG. 31  shows a plan view of an alternate embodiment of the invention, element  150  which is comprised of two regions  148  and  149 . Region  148  is comprised of shapes  151 ,  152 ,  153 ,  154 ,  155  and  156 . Shapes  151 ,  155  and  156  correspond to shapes  2 ,  6  and  8  as shown in  FIG. 2 . However, shapes  152 ,  153  and  154 , in effect, take the place of shape  4  in  FIG. 2 . Likewise region  149  is comprised of shapes  161 ,  162 ,  163 ,  164 ,  165  and  166  wherein shapes  161 ,  166  and  166  correspond to shapes  12 ,  16  and  18  as shown in  FIG. 1 . However, shapes  162 ,  163  and  164 , in effect, take the place of shape  14  in  FIG. 2 .  
         [0088]      FIG. 32  shows a plan view of sheet  135  which is comprised of four elements  140 ,  150 ,  160  and  170 . Elements  140  and  160  are similar to element  24  shown in  FIG. 2 , except that the symmetric trapezoid is replaced by an isosceles triangle. Elements  150  and  170  differ from elements  140  and  160  in that they have additional fold-lines. Also shown are edges  141  and  142  which border element  140 , as well as edges  143  and  144  which border element  170 .  
         [0089]      FIG. 33  shows sheet  135  which has been folded in a three-dimensional manner to form a loop, wherein edge  141  has been joined to edge  143  and edge  142  has been joined to edge  144 . The upper perimeter  176  of sheet  135  forms an essentially rectangular shape as does the lower perimeter  177 . Also shown in exploded view are top surface  145  and bottom surface  175  which each have an essentially rectangular shape.  
         [0090]      FIG. 34  shows an assembled box  180  wherein the upper and lower perimeters of sheet  135  have been joined to upper surface  145  and lower surface  175 .  
         [0091]      FIGS. 35 and 36  shows box  180  in a successively further folded positions.  FIG. 37  shows box  180  in a fully folded position. It may be seen that as box  180  flattens, it also folds in half, somewhat in the manner of closing a book, so that its packaged size is further reduced. This additional degree of folding is due to the additional fold-lines in elements  150  and  170 .  
         [0092]      FIG. 38  shows an alternate embodiment of the invention, box  190  which has a pair of fold lines that define a strip  191  of material that separates the upper and lower halves of the box. As the box is flattened, as shown in  FIGS. 39 and 40 , strip  191  provides some relief for the fold-lines at the center of the box by distributing the crease over two fold-lines rather than one fold-line as shown in previous drawings.  
         [0093]      FIG. 41  shows an alternate embodiment of the invention in the form of a container  200  which is comprised of two boxes  202  and  204  which are attached to one another in a stacked arrangement.  FIGS. 42 and 43  show container  200  as it is successively unfolded.  
         [0094]      FIG. 44  shows another embodiment, unit  300  which is comprised of two boxes  310  and  320  which are connected by a hinge.  FIG. 45  shows unit  300  after boxes  310  and  320  have been rotated such that they lie side by side.  
         [0095]      FIG. 46  shows box  310  is comprised of a lower part  314  and an upper hinged plate  312  which has been rotated around a hinged connection. Likewise, box  320  is comprised of a lower part  324  and an upper hinged plate  322 .  
         [0096]      FIG. 47  shows unit  300  after boxes  310  and  320  have been fully unfolded, thereby providing a bench with storage space.  
         [0097]      FIG. 48  shows a stack  400  of folded boxes  402 ,  4040 ,  406 ,  408  and  410 .  FIG. 49  shows the boxes in their unfolded positions sitting side by side. It may be seen that each box has cabinet-style doors.  
         [0098]      FIG. 50  shows boxes  402 ,  404 ,  406 ,  408  and  410  have been attached to one another to provide a cabinet unit.  
         [0099]     The scope of the invention will now be set forth in the following claims.