METHOD AND SYSTEM FOR MANUFACTURING A CUSTOM BOX

The present is a custom storage box comprising a bottom member wherein the bottom member can be attached to at least one first side member creating a width of the box and at least one second side member creating a depth to the box wherein the first side member and second side member can be substantially the same height. The method of creating a custom storage box comprising inputting custom dimension of a box by a user into a program on a first computing device wherein the user can choose a material type and an accessory type creating the user's customized user information. Submitting the user's information to the program wherein the user's information is uploaded onto a second computing device. Converting dimensions of the box into a flat pattern. Creating a computer-aided manufacturing file from the flat pattern.

FIELD OF THE INVENTION

The present specification relates generally to method for manufacturing a box, and even more in particular, embodiments of the invention relate to a box that a consumer can order custom to their application and ship flat.

BACKGROUND OF THE INVENTION

Custom storage boxes exist in the market today but are typically very expensive to manufacture. For example, truck bed boxes commonly known as a saddle box are usually manufactured to fit in a certain truck's make and model bed. These boxes generally have a single or two-part lid that opens on a hinge that extends the width of the truck bed. These truck bed boxes can be configured in various manners to suit the user's needs such as adding storage bins inside the truck box, adding interior shelves or tool holders providing easy access for the user. Truck boxes are commonly supported by the truck's side walls and extend vertically from the truck's side walls to the bed. The truck box usually will extend from the front of the truck bed to the forward portion of the rear wheel well and is usually attached to the side walls or to the bed of the truck through fasteners or truck mounts. As the demand for customization and utility in automotive accessories has increased, various approaches to manufacturing custom truck bed boxes have been developed. However, these conventional methods and systems have their own set of limitations, prompting the need for innovation in this field.

Typically, these truck boxes extend beyond the top of the truck's side walls making it impossible for a truck bed cover to be put over the truck bed. Because these types of storage boxes are large and heavy, manufacturers usually will have to weld all the components of the storage box together and ship the unit has a whole. Shipping these fully manufactured storage boxes can be expensive and cost prohibitive. For example, shipping internationally and trans continentally a manufacturer can use a pre-sized shipping container that will transport multiple boxes at once. However, when shipping a single box to an end user this is not possible costing the end user a large amount in shipping. Some custom truck bed boxes in the related art are constructed using welded metal components. While this approach can provide durability, it may lack flexibility in terms of design changes and may not readily accommodate a variety of materials, limiting the range of customization options available to users.

Another example are standard boxes that a user can purchase in a hardware store, or nursery for planting a garden, for storage or for other types of boxes used at home. These types of boxes are sized to a specific manufacturer's specifications and custom storage boxes are very expensive and are not a cost-effective solution for most consumers. Individuals that have an area that a standard box size will not fit into can order a custom box, but these boxes are usually expensive because of the manufacturing process. Existing manufacturing methods may impose design limitations, making it challenging to produce boxes that fully utilize the available space, fit snugly within the required space, and incorporate innovative features such as drawers, dividers, or locking mechanisms.

These limitations in the related art highlight the opportunity for innovation in the field of custom box manufacturing. The need for a method and system that can efficiently produce highly customized, durable, and resource-efficient boxes, while addressing the challenges mentioned above, is evident in the industry. The present invention aims to overcome these limitations and offer a novel approach to manufacturing boxes that caters to the diverse requirements of users.

BRIEF SUMMARY OF THE INVENTION

Accordingly, the present is a custom storage box comprising a bottom member wherein the bottom member can be attached to at least one first side member creating a width of the box and at least one second side member creating a depth to the box wherein the first side member and second side member can be substantially the same height. At least one attachment brackets wherein the attachment brackets can have a plurality of first holes. A plurality of second holes can be located on the bottom member, first side member, and second side member wherein the plurality of first holes aligns with the plurality of second holes wherein a plurality of fasteners attaches the bottom member to the first side member and the second side member forming the box.

The at least one support can be located and attached to the bottom member. The bottom member, first side member and second side member are sheet metal having a thickness of 0.025 to 0.190. The attachment brackets can be l-shaped rails, or corner brackets. The custom storage box can have a material type wherein the material type is stainless steel, aluminum, plastic or carbon steel. The attachment brackets can be stainless steel, aluminum, or carbon steel. The width and depth of the bottom member, first side member and second side member are chosen by a user. The attachment brackets can be cut to the substantially same dimension of the width, depth and height of the box. The at least one support can be a solid or l-shape metal piece.

The method of creating a custom storage box comprising inputting custom dimension of a box by a user into a program on a first computing device wherein the user can choose a material type and an accessory type creating the user's customized user information. Submitting the user's information to the program wherein the user's information is uploaded onto a second computing device. Converting dimensions of the box into a flat pattern. Creating a computer-aided manufacturing file from the flat pattern. Loading a machine with the chosen material type by the user. Cutting the dimension on the material.

Removing the cut material from the machine and placing material into a packaging box. Placing accessories in packaging box and shipping custom box to the user wherein the user puts together the box when received. The first computing device and the second computing device can be portable computing device, laptop computer, desktop computer, or smartphone. The machine can be a waterjet, laser cutting, machining center, or the like. The material type is stainless steel, aluminum, plastic or carbon steel. The program can be on the world-wide web. The computer-aided manufacturing software can be located on the secondary computer or a third computer in which the computer-aided manufacturing software and machine are attached to.

It is advantageous to have a storage box that the user can specify the dimension for the width, depth, and height for their specific application.

It is another advantage for a user to choose the size and specifications of the box and have it easily shipped as a flat pattern to the user.

Additional features and advantages of the present specification will become apparent to those skilled in the art upon consideration of the following detailed description of the illustrative embodiment exemplifying the best mode of carrying out the invention as presently perceived.

DETAILED DESCRIPTION

Referring initially toFIG.1-3a custom storage box is shown generally at10. The custom storage box10can have a bottom member14wherein the bottom member can be attached to at least one first side member12,13creating the width of the box and at least one side member16,17creating the depth of the box wherein the first side member and the second side member can have the substantially the same height. The bottom member14, first side members12,13and the second side member16,17can form the outer walls and bottom of the box. The bottom member14, first side members12,13and the second side member16,17can be attached together by at least one attachment brackets20wherein the attachment brackets and the members can have a plurality of first holes18and a plurality of second holes19.

The plurality of second holes19can be located on the bottom member14, first side members16,17, and second side member12,13wherein the plurality of first holes18can align with the plurality of second holes wherein a plurality of fasteners (not shown) can be attached to the bottom member and to the first side member and the second side member by the at least one attachment brackets20which can form the box fastened together. At least one leg member22can be located and attached to the bottom member14or in other embodiments can be attached to the first side member12,13, or the second side member16,17. The at least one leg member22can be a solid piece, multiple pieces, or hollow piece, or the like wherein the leg member can have one or more holes to attach itself to the first side member12,13, or the second side member16,17. In other embodiments, the at least one leg member22can be omitted. In embodiments, the user can specify the bottom member14, first side members12,13and the second side members16,17length, width and thickness. The thickness of each member can be at least 0.025 inches up to at least 0.190 inches or any standard gauge of sheet metal and in the preferred embodiment the user chooses from a list of thicknesses from a computer app or webpage.

The attachment brackets20can be such as, for example, l-shaped rails, corner brackets, machine brackets, structural brackets, or the like. In certain embodiments, the attachment bracket20can have threaded holes in the plurality of holes for the fastener to attach to or the bottom member14, first side members12,13and second side members16,17can have threaded holes in the plurality of holes so that the fastener can go through either the attachment bracket or the members. In other embodiments the fasteners can be attached to a nut to connect the bottom member14, first side members12,13and second side members16,17. The attachment brackets can be cut to the substantially the same dimensions of the width, depth, and height of the box.

The custom storage box10including the bottom member14, first side members12,13and second side members16,17, and attachment brackets can be made from such as, for example, stainless steel, aluminum, carbon steel, steel, plastics or the like but in the preferred embodiment the user can choose what material type the custom storage box can be made out of. As shown inFIG.3the custom storage box10can fit into a user's truck bed50wherein the custom storage box can be manufactured from sheet metal to fit into any size of bed with the user's chosen specifications such as the user can measure the truck's height of the bed52and the length of the bed56and can fit behind the truck's wheel well in the truck bed. The custom storage box10can be cut from the flat sheet metal wherein when cut it can be put into a box, shipped to the user and assembled by the user as shown inFIG.4.

Referring toFIG.5the method of creating a custom storage box100comprising receiving input specifications of a box by a user into a program on a user's first computing device at step102wherein the user can choose a material type, design features and accessory types which can create user's customized information, at step104. The material type can be such as, for example, stainless steel, aluminum, carbon steel, plastic, ceramic, or the like. The accessory type can be such as, for example, handles, lid, wheels, slide out drawers, inner compartments, inner storage shelves, or the like. Submitting the user's information to a second computing device wherein the second computing device can create a digital model of the custom storage box based on the user's information, at step106. The digital model can be such as, for example, computer aided design model, vector drawing, or the like.

The user can submit their information to a second computing device wherein a digital model of the custom storage box can be generated based on the user's information wherein the information can be the dimensions of box, material type, accessories, and any other custom information of the box, at step108. At step110, the second computer can calculate and convert the user's input into dimensions for the box into a flat pattern. The second computer can be such as, for example, cloud computing, manufacturer's computer, a second user, or the like. At step112the second computing device can create a computer-aided manufacturing file from the flat pattern uploaded from the user wherein the computer-aided manufacturing file can be such as, for example, g-code, stereolithography, CAM files, CNC program files, or the like.

At step114, the machine can be loaded with the chosen material type by the user. The material can be loaded by such as, for example, robot, by user, a machine, or the like. The machine can be a waterjet, laser cutting, machining center, or the like. The dimensions can be converted into a flat pattern wherein, at step116, the user's dimensions can be cut out of the chosen material wherein the dimensions are width, height, and length of the box for each member. The calculated material requirements can include optimizing the material usage to minimize waste wherein the second computer can calculate the optimal layout for the dimensions of the box. The first computing device and the second computing device can be portable computing device, laptop computer, desktop computer, or smartphone.

At step118, the access material can be removed, and the cut material can be removed from the machine and the cut material can placed into a packaging box at step120. The packaging box can be such as, for example, folding cartons, corrugated boxes, rigid boxes, telescopic boxes or the like. The cut material can lay flat within the box allowing the box to be shipped easily as a flat pattern. At step122, the accessories can be placed in the packaging box, and, at step124, the custom box can be shipped to the user wherein the user puts together the box when received at their home or office space. The material type is stainless steel, aluminum, plastic, or carbon steel. The program can be on the world-wide web, cloud, LAN, WANN, or the like. The computer-aided manufacturing software can be located on the secondary computer or a third computer in which the computer-aided manufacturing software and machine are attached to. Shipping the custom box as a flat pattern can allow the user to order a custom box and save on shipping and allow the user to create a box that can fit the user's needs including such as, for example, a truck bed box, garden box, storage box, or the like.

In closing, it is to be understood that although aspects of the present specification are highlighted by referring to specific embodiments, one skilled in the art will readily appreciate that these disclosed embodiments are only illustrative of the principles of the subject matter disclosed herein. Therefore, it should be understood that the disclosed subject matter is in no way limited to a particular methodology, protocol, and/or reagent, etc., described herein. As such, various modifications or changes to or alternative configurations of the disclosed subject matter can be made in accordance with the teachings herein without departing from the spirit of the present specification. Lastly, the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the scope of the present disclosure, which is defined solely by the claims. Accordingly, embodiments of the present disclosure are not limited to those precisely as shown and described.

Certain embodiments are described herein, including the best mode known to the inventors for carrying out the methods and devices described herein. Of course, variations on these described embodiments will become apparent to those of ordinary skill in the art upon reading the foregoing description. Accordingly, this disclosure includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, any combination of the above-described embodiments in all possible variations thereof is encompassed by the disclosure unless otherwise indicated herein or otherwise clearly contradicted by context.