Abstract:
A collapsible, automatically locking box is appropriately sized for transporting the typically five to seven reels of film of a complete movie, and includes the reinforced bottom and top necessary to support the weight of the complete movie.

Description:
BACKGROUND OF THE INVENTION 
   1. Field of the Invention 
   The present invention provides a collapsible box having an automatically locking bottom for transporting reels of movie film. The present invention further provides a method of transporting movies. 
   2. Description of the Prior Art 
   The reels of film on which movies are typically supplied to theaters weigh approximately 10 pounds each, and are presently transported using metal or plastic film cans, with each film can holding up to four reels of film. The cans typically weigh approximately eight pounds, and do not collapse when empty. Therefore, the use of these cans not only increases the cost of shipping a movie by increasing the total weight that must be shipped, but also increase the cost of shipping the empty containers, and the amount of space required to store empty containers. Furthermore, a typical movie requires five to seven reels of film, requiring two film cans to hold an entire movie. The use of more than one film can increases the risk that only part of a movie will arrive at its desired destination. Lastly, each of these film cans is expensive, costing over $22.00 each. 
   Some examples of presently available collapsible boxes having automatically locking bottoms include U.S. Pat. Nos. 6,102,279 and 6,102,280, having the same inventor and assignee as the present invention. Although these boxes perform their intended applications quite well, the references fail to teach or suggest the specific reinforcements necessary to carry the 50–70 pounds that a typical series of film reels for a movie will weigh. 
   Accordingly, there is a need for a box having a collapsible, automatically locking bottom, capable of containing and supporting the weight of a complete movie. 
   SUMMARY OF THE INVENTION 
   The present invention provides a collapsible box having an automatically locking bottom, capable of holding the five to seven 10-pound reels of 35 mm. film or other media typically used to contain a single movie (although the box could be sized to hold different numbers of reels). Further, the present invention provides a box capable of supporting the weight of the movie. Lastly, the present invention provides a method of transporting the movie. 
   The box includes a collapsible, automatically locking bottom having four panels. A first bottom panels extends substantially across all of the bottom. A second bottom panel and third bottom panel are each adjacent to the first bottom panel. A fourth bottom panel is located between the second and third bottom panels. The second bottom panel includes a live hinge defining a flap, with the flap being secured to the first bottom panel. Likewise, the third bottom panel includes a live hinge defining a flap, with the third flap being secured to the fourth bottom panel. A fifth bottom panel, covering substantially the entire bottom, may be placed atop the first, second, third and fourth bottom panels. To support the weight of a movie, it is not only preferable to reinforce the bottom, but also the top. The top of the box includes a first top panel, a second top panel adjacent to the first top panel, a third top panel on the other side of the first top panel, and a fourth panel between the second and third top panels. The first top panel includes a pair of openings dimensioned and configured to receive a handle. A reinforcement plate having corresponding openings is secured beneath the first top panel. A preferred handle has a T-shaped end passing through each of these openings, securing the first top panel, reinforcing panel, and handle together. Each of the second, third, and fourth top panels define openings structured to receive the handle. When all four top panels are folded over the top of the box to close the box, the handle thereby passes through all four panels, so that all four panels are supporting the weight of the box and its contents. 
   The box is preferably dimensioned and configured so that the five to seven film reels required for a complete movie may fit within the box. Preferably, these reels fit within the box standing on their edge, thereby permitting visual verification that the box contains the correct reels without the need to remove any of the reels from the box. 
   Accordingly, it is an object of the present invention to provide a collapsible, automatically locking bottom for a box for transporting movies, and capable of supporting the weight of an entire movie. 
   It is another object of the invention to provide a box dimensioned and configured to contain an entire movie. 
   It is a further object of the present invention to provide a box for transporting movies having a reinforced top so that the box will support the weight of a movie when carried by a handle secured to the top. 
   It is another object of the present invention to provide a box dimensioned and configured to contain the multiple reels of film for a complete movie with the reels standing on their edge, facilitating verification of the contents of the box. 
   It is a further object of the present invention to provide a box for transporting movies that resist the entrance of water therein when closed. 
   It is another object of the present invention to provide a box for transporting movies that is inexpensive to purchase. 
   It is a further object of the present invention to provide a box for transporting movies that reduces the cost of transporting the movies. 
   It is a further object of the present invention to provide a box for transporting movies that permits the entire movie to be shipped in a single container, thereby reducing the likelihood that a portion of the movie will not reach its destination. 
   These and other objects of the invention will become more apparent through the following description and drawings. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is an isometric top view of a box according to the present invention. 
       FIG. 2  is a top view of a corrugated plastic panel forming a box according to the present invention, prior to securing the various panels together. 
       FIG. 3  is a top isometric view of bottom reinforcement panel for a box according to the present invention. 
       FIG. 4  is a top view of a handle for a box according to the present invention. 
       FIG. 5  is a top view of a handle reinforcing panel for a box according to the present invention. 
       FIG. 6  is a top view of a box according to the present invention. 
       FIG. 7  is a bottom view of a first top panel for a box according to the present invention. 
       FIG. 8  is a bottom view of a box according to the present invention. 
       FIG. 9  is a top view of a box according to the present invention containing a movie and showing the top open. 
   

   Like reference characters denote like elements through the drawings. 
   DESCRIPTION OF THE PREFERRED EMBODIMENTS 
   Referring to  FIG. 1 , the present invention provides a box  10  for transporting the film reels of a movie. 
   Referring to  FIGS. 1 and 2 , the box includes a plurality of sides  12 ,  14 ,  16 ,  18 . In the illustrated embodiment, a glue flap  20  extends from the side  18  for securing the side  18  to the side  12 . A first bottom panel  22  depends from the side panel  16 , and in some preferred embodiments defines a live hinge  24 . A second bottom panel  26  depends from the side  18 , having a live hinge  28  defining a flap  30 . A third bottom panel  32  depends from the side  14 , having a live hinge  34  defining a flap  36 . A fourth bottom panel  38  depends from the side  12 . The first bottom panel  22  may be dimensioned and configured to extend across substantially all of the bottom of the assembled box. Although the bottom panels should remain in the same sequence with respect to each other, any of the bottom panels  22 ,  26 ,  32 ,  38  may depend from any of the sides  12 ,  14 ,  16 ,  18  as long as the relationship of the other bottom panels  22 ,  26 ,  32 ,  38  is preserved. Referring briefly to  FIG. 3 , a fifth bottom panel  40  may be provided atop the bottom panels  22 ,  26 ,  32 ,  38  as described in greater detail below. The fifth bottom panel  40  serves as a reinforcing panel and preferably covers substantially the entire bottom of the box  10 , but may provide a finger-receiving cut-out to facilitate removal of the panel  40  from the box  10 . 
   Referring back to  FIGS. 1 and 2 , a first top panel  44 , second top panel  46 , third top panel  48 , and fourth top panel  50 , extending upward from the sides  14 ,  16 ,  12 ,  18 , respectively. The top panels  44 ,  46 ,  48 ,  50  may be arranged in any order with respect to each other and with respect to the side panels  12 ,  14 ,  16 ,  18 . In the illustrated embodiment, the first top panel  44  defines a pair of handle-receiving openings  52 . The second top panel  46  defines an opening  54  dimensioned and configured to receive a handle (described below) and also includes a live hinge  56  defining an end flap  58 . The second top panel  46  may also define a slot  60  along the live hinge  56 , and one or more finger tabs  62  extending outward pass the end flap  58 . The third top panel  48  also defines an opening  64  dimensioned and configured to receive a handle, and a live hinge  66  defining an end flap  68 . A closure securing tab, dimensioned and configured to fit within the slot  60 , may be defined within the side  12  and third top panel  48 . A finger tab  72  may extend outward from a live hinge  74  defined within the securing tab  70 , thereby permitting easy withdrawal of the tab  70  from the slot  60 . A slot  76 , dimensioned and configured to receive the end flap  58 , may also be defined between the side panel  12  and third top panel  48 . The fourth top panel  50  includes an opening  78  dimensioned and configured to receive a handle, and may also include a recessed section  81  dimensioned and configured to accommodate the end flap  58 . 
   The side panels  12 ,  14 ,  16 ,  18 , bottom panels  22 ,  26 ,  32 ,  38 , and top panels  44 ,  46 ,  48 ,  50 , are preferably cut from a single sheet of suitable material, for example, corrugated plastic, resulting in the sheet illustrated in  FIG. 2 . Using a water-resistant material such as corrugated plastic provides the additional advantage of making the box resist the entrance of water. The sheet is then folded into the final shape of the box, with the glue flap  20  secured to the side panel  12 , preferably by a suitable adhesive. Next, the flap  30  is secured to the first bottom panel  22 , preferably by a suitable adhesive. The flap  36  is likewise secured to the fourth bottom panel  38 , also preferably by a suitable adhesive. 
   The handle  79  is illustrated in  FIG. 4 . The handle  79  includes a grasping portion  80  having a tapered portion  82  at each end. A handle-securing tab  84  is secured substantially perpendicular to each of the tapered portions  82 . Some preferred embodiments of the handle  79  may include reinforcing ribs  86 . 
     FIG. 5  illustrates a reinforcement plate  88  for use with the handle  79 . The reinforcement plate  88  defines a pair of openings  90  corresponding to the openings  52  in the first top panel  44 . Referring to  FIGS. 6 and 7 , the reinforcement plate  88  is placed underneath the first top panel  44 , with the openings  90  aligned with the openings  52 . The tabs  84  are then inserted through the openings  52 ,  90 , so that the tapered portions  82  are retained within these openings. The handle  79  is thereby secured to the first top panel  44 . 
   In use, the box  10  may be collapsed by pushing the bottom panels  22 ,  26 ,  32 ,  38  upward into the box  10 , while simultaneously pushing the sides  16 ,  18  closer together, and the sides  12 ,  14  closer together. To expand the box, the sides  16 ,  18  and the sides  12 ,  14  are pulled apart, while simultaneously pushing downward on the bottom panels  22 ,  26 ,  32 ,  38 . The live hinge  24  within the first bottom panel  22  facilitates the movement of this panel without interference with the side  18 . In the expanded position, the bottom will resemble  FIG. 8 . 
   Referring to  FIG. 9 , movie reels  92  are placed within the box  10 , above the bottom panels  22 ,  26 ,  32 ,  38  and the fifth bottom panel  40 . The reels  92  are preferably placed in the box  10  with their edge resting on the panel  40 . As can be seen in  FIG. 9 , placing the reels  92  in the box  10  in this manner permits easy verification that the box contains the proper reels without the need to remove the reels  92  from the box. To close the box, the first top panel  44  is first lowered over the box  10 . Next, the fourth top panel  50  is lowered over the first top panel  44 , and the handle  79  is passed through the opening  78 . The third top panel  48  is next lowered over the fourth top panel  50 , with the end flap  68  inserted between the panels  44 ,  50 , and the side  16 . The handle is passed through the opening  64 . Lastly, the second top panel  46  is lowered over the third top panel  48 . The handle is passed through the opening  54 . The end flap  58  is passed into the slot  76 . The tab  70  is inserted into the slot  60  to secure the box in its closed position. 
   The box  10  of the present invention therefore provides an automatically locking, collapsible box for transporting movie reels  92 . The box  10  provides the proper reinforced bottom and top to support the weight of the movie reels  92 , and is dimensioned and configured to hold a sufficient number of movie reels  92  for an entire movie. By collapsing the box when not in use, the volume taken up by the box during storage and shipment is drastically reduced, thereby reducing the costs associated with each. 
   While a specific embodiment of the invention has been described in detail, it will be appreciated by those skilled in the art that various modifications and alternatives to those details could be developed in light of the overall teachings of the disclosure. Accordingly, the particular arrangements disclosed are meant to be illustrative only and not limiting as to the scope of the invention which is to be given the full breadth of the appended claims and any and all equivalents thereof.