Foldable boxes

A foldable box that is interchangeable from a flat configuration to a three-dimensional configuration. The foldable box includes a first set of panels, a second set of panels and a third set of panels. The second set of panels and the third set of panels can be adhesively and foldably connected to the first set of panels to form the foldable box.

BACKGROUND

The disclosed technology relates to a foldable box. More particularly, to a box that is stored flat and folds into a three-dimensional box.

Boxes are used everyday for many purposes. They are used for storage, shipping and even gift-giving. Because of the variety of uses, boxes come in a variety of sizes and shapes. From boxes that hold a small piece of jewelry to ones that hold refrigerators.

But when a box is manufactured by a manufacturing company the box is usually shipped in a three-dimensional form. The manufacturing company than must pay for additional shipping cost for empty space within the box. Additionally, the boxes are also more susceptible to damage when shipped in this fashion.

To overcome these shipping problems, box designers have made collapsible boxes. These boxes are shipped flat and need to be constructed by the ultimate user of the box.

To construct these boxes, the user must unfold the box and place certain folds into certain slots, or in the alternative use glue or tape. These actions are time consuming and labor intensive. Stores must pay for this extra time to construct these boxes. The consumer at the store also has a delay because the boxes will usually be constructed in front of the consumer. This delay results in loss time for all parties involved.

Some stores in order not to delay the customer may employ extra personnel to build boxes. This, however, does not alleviate all of the stores' problems because now the store must find space to store the boxes in their three-dimensional form. This means there will be less space for the products which they stock.

SUMMARY

The present invention overcomes the problem of the conventional art by constructing a foldable box that is stored in a flat position. In order to fold the box into a three-dimensional position, all a user must do is unfold two sides of the box which will in turn construct the foldable box.

In one implementation, a foldable box having a flat configuration and a three-dimensional configuration, comprising: a first set of panels, the first set of panels having a first main panel, a second main panel, a first sub-panel, a second sub-panel and a third sub-panel, the first sub-panel being attached to a first main panel at a first crease, the second sub-panel being attached to a first main panel at a second crease, the second sub-panel being attached to a second main panel at a third crease, the third sub-panel being attached to a second main panel at a fourth crease; a second set of panels, the second set of panels including a rear support panel having a first connecting tab foldably connected at a fifth crease and a front support panel having a second connecting tab foldably connected at a sixth crease, the rear support panel being attached to second sub-panel with the fifth crease coinciding with the second crease, the front support panel being attached to the third sub-panel with the sixth crease coinciding with an exterior edge of the third panel; and a third set of panels, the third set of panels including a right-side panel having a third connecting tab foldably connected at a seventh crease and a left-side panel having a fourth connecting tab foldably connected at an eighth crease, the right-side panel being attached to the second main panel with the seventh crease coinciding with a first exterior edge of the second main panel, the left-side panel being attached to the second main panel with the eighth crease coinciding with a second exterior edge of the second main panel.

In some implementations, attachment tape can be used, securing the first tab, the second tab, the third tab and the fourth tab to their respective panels, and also being capable of reinforcing the third crease and the fourth crease.

In some implementations, the right-side panel can include two attachment wings foldably connected to the right-side panel and the left-side panel can include two attachment wings foldably connected to the left-side panel, each attachment wing having a first triangular connector and a second triangular connector foldably connected to one another where the second triangular connector of one of the attachment wings for the right-side panel is connected to the second sub-panel and the second triangular connector of the other attachment wing for the right-side panel is connected to the third sub-panel and wherein the second triangular connector of one of the attachment wings for the left-side panel is connected to the second sub-panel and the second triangular connector of the other attachment wing for the left-side panel is connected to the third sub-panel.

In some implementations, the foldable box can include a first magnet and a second magnet for securely closing the three-dimensional configuration of the foldable box, the first and second magnet having opposite poles.

In some implementations, the foldable box can include a first cut-out, the first cut-out being formed on a top edge of the rear support panel; and a second cut-out, the second cut-out being formed on a top edge of the front support panel, wherein the first cut-out and the second cut-out can be used to disassemble the three-dimensional configuration of the foldable box.

In some implementations, reinforcement tape can be used for reinforcing the first crease and the second crease. In some implementations, protection foam may be utilized, the protection foam being secured to an underside of the first main panel.

DETAILED DESCRIPTION

Manufacturers of boxes often run into difficulty when shipping boxes because of the way in which they are shipped. To cut down on shipping cost it is more cost efficient to ship boxes in a flat position. However, flat boxes must be assembled by the party to which it is shipped. This takes time on the part of the ultimate user.

To cut down on this time, a box can be constructed in such a way as to make the assembly time to construct a box minimal. This is accomplished by having foldable connectors attached to certain parts of the box. When the box is flat the connectors are also flat. To construct a box a user must only lift the sides of the box. This triggers a chain reaction and as the user lifts the sides the connectors in turn pull other parts of the box. The box is then fully three-dimensional with minimal work on the part of the user. The user will not have to add any additional glue or tape to the box.

The boxes may be constructed out of any material that may be foldably connected such as all types of cardboard and flexible plastics. The material may also be decorated so the box is aesthetically pleasing to the eye. This is accomplished by lining the material with certain types of laminate and cloth-like materials.

FIG. 1is one embodiment of the present invention. InFIG. 1, the box10is in its three-dimensional form. The box has a cover11that is foldably connected to an outside connector12at crease13. The outside connector is also foldably connected to the bottom of the box not shown) at crease22.

The boxes have a right side14, a front side15, a left side16and a rear side21. Right side14is foldably connected to front side15at crease23. Front side15is foldably connected to left side16at crease26. Left side16is foldably connected to rear side21at crease22. Rear side21is foldably connected to right side14at crease24.

The box also has a front connector26having portions17and18and rear connector having portions19and20. Portion18of the front connector is adhered to the bottom of the box and is foldably connected to the bottom of the left side16. Portion17is foldably connected to portion18and the bottom side of the front side17.

The rear connector27is connected between the bottom of back side21and the bottom of right side14. The rear connector is folded in two parts at crease25.

FIG. 1shows the box in its constructed form with the sides14,15.16and21in an upright position. The connectors26and27are on top of the bottom portion not allowing the bottom to visible.

FIG. 2shows the foldable box10from a top view in its constructed position. From this view point, the bottom of the box is split into four sections. Sections17and18represent one connector26and sections19and20represent the second connector27. These connectors26and27when in their unfolded state cover the entire bottom layer of the box.

The cover is connected to connector12at crease13. If a user wanted to close the box10, the user will lift the cover11and fold the cover over the opening created by sides14,15,16and21. The connector12then rests on side21.

FIG. 3shows the box in use as the box is folded from a flat state to a box shape. The sides14,15,16and21are shown. These sides are all interconnected as discussed above.

One portion of the connector18is adhered to the bottom of the box30and is connected to side15at crease31. A second portion of the connector18is connected to the bottom of side14.

Connector27is connected to the bottom of side16and21. The connector27while opening forms a triangular shape.

The bottom30, cover11and connector12all remain flat while the sides of the box are formed.

FIG. 4shows the box in its flat position. Sides14and15are visible from the top while sides16and21are covered by sides14and15.

Connectors26and27are also folded so as to form two triangular areas.

FIG. 5is another embodiment of the foldable box. This foldable box50has a cover which is separately assembled and is not foldably connected to the box.

In this embodiment the box50has a bottom51and four sides52,53,54and55. The sides52,53,54and55are foldably connected to the bottom by four connectors56,57,58,59located in the corners of the box.

FIG. 6shows the box in a partially assembled state. Here, sides52and54are connected to the bottom at crease. Sides52and54are also connected to the bottom at crease60and61.

Also shown are the four connectors56-59. These connectors56-59are foldably attached to the edge of each side. That is, side52is attached to side53by connector56. Side53is attached to side54by connector57. Side54is attached to side55by connector58. Side55is attached to side52by connector59.

Also shown on sides52and54are additional means64for ensuring that the sides of the box are tightly in place. This makes sure that when a user folds the box50, the box50will not inadvertently collapse while in use.

The additional means64can be an adhesive, tape or Velcro strip. This additional means64is already in place when a user assembles the box. The user does not need any additional items to make the box.

A securing means (not shown) can also be attached to a side of the box as will be discussed in detail inFIGS. 8-10. This securing means adds additional strength to the box when the box is constructed by a user. That is, when the sides are in their upright position the securing means ensures the box will not collapse when the box is in use.

FIG. 7shows the box in its constructed state. The sides52-55are in their upright position with the bottom face down. The additional securing means64are not visible when the box50in its constructed state.

FIG. 8shows a third embodiment of the present invention. In this embodiment, the sides81-84and the bottom92are constructed as in the second embodiment. However, in this embodiment the cover89is integrated into the construction of the box80. During shipping, when the box80is in its flat state, the cover89and lip90may be turned 180 degrees and stored against the bottom92of the box80.

The sides81-84are constructed with a cover89being foldably attached to side82at crease93. The cover89is then attached to lip90for securing the cover89to the constructed box80at side84.

A securing means91is attached to side84at crease94. This securing means91adds additional strength to the box when the box is constructed by a user. That is, when the sides are in their upright position, the securing means is placed between81and83. This ensures the box80will not collapse when the box80is in use.

The box also may have additional means95for ensuring that the sides of the box are tightly in place. The additional means95can be an adhesive, tape or Velcro strip. This additional means95is already in place when a user assembles the box. The user does not need any additional items to make the box.

FIG. 9shows the box80in a transition state between folded and unfolded. The box80as it is being lifted from its unfolded state will raise the sides81-84of the box80.

FIG. 10shows the box80with the sides81-84raised. To fully close the box80, the cover89is thrown over the open area created by the sides81-84. The cover80is then secured as a lid to the sides by the use of a locking means94such as a magnet which may be located between the surfaces of the box. However, other types of locking means such as snaps may be placed on the lip and the sides to lock the cover89in place.

In another implementation of a foldable box in accordance with the disclosed technology, a foldable box is interchangeable from a flat configuration to a three-dimensional configuration. The foldable box can include a first set of panels, a second set of panels and a third set of panels, the second set of panels and the third set of panels being adhesively and foldably connected to the first set of panels to form the foldable box.

Referring toFIGS. 11a-b, the foldable box100can have a first flat configuration in which box100is flat (seeFIG. 11a), and a second three-dimensional configuration in which the box is built upright (SeeFIG. 11b). The second configuration is transferable to the first flat configuration and vice versa. The foldable box100includes a first set of panels110, a second set of panels150and a third set of panels180arranged and secured to one another in a predefined fashion. In one embodiment, the size of the three-dimensional foldable box100may be 15-30 cm (l)×12-24 cm (w)×2-10 cm (h). Larger and smaller sizes are possible.

Each set of the panels110,150,180can include panels that are preferably rectangular in shape and can be made from a substrate such as paperboard, cardboard, flexible plastic, or any other suitable substrate. In some implementations, the substrate can be laminated with a predefined material. In some implementations, the laminate can be decorated so the box is aesthetically pleasing to the eye. This is accomplished by lining the substrate with certain types of decorative laminate and cloth-like materials.

Referring toFIG. 12, a first set of panels110is shown. The first set of panels110can include a plurality of panels that are coupled in a predefined fashion along predefined creases/folds. The first set of panels110can have two classes of panels, e.g., main panels and sub-panels. Main panels are preferably bigger than sub-panels. In some implementations, lengths of main panels and sub-panels can be approximately identical, whereas widths of the main panels can be two to five times the widths of sub-panels.

A first main panel112has approximately identical dimensions as that of a second main panel114. Panels120,122and124define sub-panels that have approximately identical dimensions. Sub-panel panel120is coupled to first main panel112. Sub-panel122is coupled between first main panel112and second main panel114. Sub-panel panel124is coupled to second main panel114. Sub-panels120and122are foldable relative to panel112along creases130and132, respectively. Sub-panels122and124are foldable relative to second main panel114along creases134and136, respectively. The main panels and sub-panels are preferably laminated to define a uniform construction of the first set of panels110. The first set of panels110including main panels and sub-panels can be made by die cutting, scoring and then folding to define a desired combination of main panels and sub-panels in a single piece.

The first set of panels110can also include an inbuilt magnetic locking arrangement140,142,144,146. That is, sub-panels120and124can include magnets140,142,144,146. The magnets140,142,144,146can be positioned within the sub-panels120and124preferably below the lamination. The magnets140,142,144,146can be positioned in the respective sub-panel such that the magnets are not visible with the naked eye from the sub-panel. Thickness of each of the magnets140,142,144,146can be substantially close to the thickness of the respective sub-panels120,124. Magnets140,142have opposite polarity to that of magnets144,146. The magnets140,142,144,146can be positioned in the respective sub-panels28and30so that the magnets can be mated when the box100is in a closed position. In some implementations, one set of magnets can be replaced with a magnetically attractive material, e.g. a ferric metal.

Referring toFIG. 13, a second set of panels150is shown that includes a rear support panel160and a front support panel170. The rear support panel160can be a rectangular panel that includes a cutout164and an attachment tab162. The attachment tab is coupled to the rear support panel at crease166. The front support panel170can be a rectangular panel that includes a cutout174and an attachment tab172. The attachment tab172can be coupled to the front support panel170at crease176.

Referring toFIG. 14, a third set of panels180is shown that includes a right-side panel190and a left-side panel200. The right-side panel190can be a rectangular panel that includes an attachment tab192and a pair of attachment wings194,196. The attachment wings194,196are foldably connected to the right-side panel190at crease193,191, respectively. The pair of attachment wings194,196include diagonal folds195,197that respectively define triangular connectors194a-b,196a-b. The attachment tab192can be coupled to the right-side panel190at crease198. The left-side panel200can be a rectangular panel that includes an attachment tab202and a pair of attachment wings204,206. The pair of attachment wings204,206are foldably connected to the left-side panel at crease203,201, respectively. The pair of attachment wings204,206include diagonal folds205,207that respectively define triangular connectors204a-b,206a-b. The attachment tab202can be coupled to the right-side panel200at crease208.

FIGS. 15-17show various stages of the construction of the foldable box. These stages can be performed in any order and for sake of clarityFIGS. 15-17each show a single stage of construction.

As shown inFIG. 15, the first set of panels110can laminated with a first piece of protection paper240. The protection paper240can be applied to an interior side of the first set of panels110with an adhesive or the protection paper240can be a type of adhesive tape. The protection paper240is partially applied to the first set of panels110. That is, the perimeter of the protection paper240is in close proximity to the exterior edges of panel120and main panel112and extends onto panel122just slightly over crease132. The protection paper provides support for crease130and132. A protective layer242can also be applied to the interior side of the first set of panels110and used as a protection for contents within the foldable box100. That is, the protective layer242can be formed from a foam-like material having a pre-defined thickness of approximately 0.1-1 mm.

As shown inFIG. 16, the second set of panels150and the third set of panels180can be attached to the first set of panels110using attachment tape250. That is, the rear support panel160, the front support panel170, the right-side panel190and the left-side panel200can be arranged with respect to the first set of panels110so that (1) the crease166of the rear support panel160is coincident with crease132and the tab162is laid on the sub-panel122, (2) the crease176of the front support panel170is coincident with an exterior edge of panel124and the tab172is laid on the sub-panel124, (3) the crease196of the right-side panel190is coincident with a right exterior edge of the main panel114and the tab192is laid on the main panel114, (4) the crease206of the left-side panel200is coincident with a left exterior edge of the main panel114and the tab202is laid on the main panel114. Once arranged, attachment tape250is adhered to the first set of panels with a portion of the tabs172,182,192and202being beneath the attachment tape250and the perimeter of the protection paper250is in close proximity to the exterior edges of panel124and main panel114and extends onto panel122just slightly before crease132. In other words, the attachment tape250adheres the second and third panels150,180to the first panels110and provides support for creases134and136. In some implementations, the tabs172,182,192,202can be directly adhered to the main panel114with adhesive glue.

As shown inFIG. 17, triangular connectors194b,196bof the right-side panel190are attached to sub-panels122and124at connection surfaces260a,260b, respectively and the triangular connectors204b,206bof the left-side panel200are attached to sub-panels122and124at connection surfaces270a,270b, respectively. The connectors are attached to their respective panels using an adhesive, e.g., adhesive glue. The attachments wings are folded onto each other so that194alays on194b,196blays on top of196a,204alays on204band206blays on top of206a. The right-side panel190and the left-side panel200is folded over so the panel is laid flat onto the main panel114.

Referring toFIGS. 18-21, a folding assembly of the first set of panels110, the second set of panels150and the third set of panels180is described that defines the first closed configuration of the foldable box in accordance with the disclosed technology. In the first closed position, the first set of panels110, the second set of panels150and the third set of panels180are completely folded in the first closed position. (SeeFIG. 11a). In a next step the right and left panels190and200are pulled upward (seeFIG. 18) to separate the right and left panels190and200from main panel114as indicated by arrow A1. The right and left panels190and200are moved from their flat position to an upright position relative to main panel114. The opening of the right and left panels190and200bring sub-panels122and124to an upright position (seeFIG. 19). The sub-panels122and124foldably rotate about crease134and136, respectively, as indicated by arrow A2and A3to achieve upright positions.

In a next step, as shown inFIG. 20, the rear support panel160is folded about crease166as indicated by arrow A5and the front support panel170is folded about crease176as indicated by arrow A4. In this step, sub-panels122and124and right and left panels190,200define the sides of the foldable box100with rear and front support panels supporting the upright positions of the sub-panels122and124and the right and left panels190,200with the main panel114defining a base of the foldable box100. In a next step, as shown inFIG. 21, the main panel112is folded about crease132as indicated by arrow A6. Main panel112defines a top of the box100. In a next step, sub-panel120is foldably rotated about fold130as indicated by arrow A7such that sub-panel130is positioned on sub-panel124. Sub-panels130and124are lockable by magnetic forces between magnets. The box100in a three-dimensional configuration can be folded back to a flat state by following the above-mentioned steps in a reverse sequence.

The foldable box100is advantageously designed to provide a simple assembly method that allows a box to be easily folded from a flat state into a three-dimensional state. More importantly, once the box is in its three-dimensional state, the front support panel170and the rear support panel160securely lock the box in its three-dimensional state until the user manually unlocks the front support panel and the rear support panel from their locked positions and returns the box to its flat, folded state.

While this specification contains many specific implementation details, these should not be construed as limitations on the scope of the disclosed technology or of what can be claimed, but rather as descriptions of features specific to particular implementations of the disclosed technology. Certain features that are described in this specification in the context of separate implementations can also be implemented in combination in a single implementation. Conversely, various features that are described in the context of a single implementation can also be implemented in multiple implementations separately or in any suitable subcombination. Moreover, although features can be described above as acting in certain combinations and even initially claimed as such, one or more features from a claimed combination can in some cases be excised from the combination, and the claimed combination can be directed to a subcombination or variation of a subcombination.

The foregoing Detailed Description is to be understood as being in every respect illustrative, but not restrictive, and the scope of the disclosed technology disclosed herein is not to be determined from the Detailed Description, but rather from the claims as interpreted according to the full breadth permitted by the patent laws. It is to be understood that the implementations shown and described herein are only illustrative of the principles of the disclosed technology and that various modifications can be implemented without departing from the scope and spirit of the disclosed technology.