Abstract:
A one-piece container includes a single sheet of corrugated material, including: four walls, a bottom, and a lid, the lid being hingedly and integrally connected to one of the four walls. The bottom and the four walls define a storage area for housing articles therein. The lid is configured to transition between an open position, an intermediate position, and a closed position. The one-piece container includes a mechanism for maintaining the lid in a closed position. In some embodiments, the mechanism biases the lid toward a closed position when in the closed position, an open position when in the open position, and an intermediate position when in the intermediate position. In other embodiments, the mechanism includes tabs and slots for retaining the lid in the closed position. Other embodiments include a combination of these features. The container may be a cardboard box.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     The present application is a nonprovisional patent application of, and claims priority under 35 U.S.C. §119(e) to, U.S. provisional patent application Ser. No. 61/452,640, filed Mar. 14, 2011, which &#39;640 application is incorporated herein by reference. Furthermore, the appendix hereto includes the disclosure of the &#39;640 application relevant to the present application, which disclosure of the appendix is incorporated by reference herein. 
    
    
     COPYRIGHT STATEMENT 
     All of the material in this patent document is subject to copyright protection under the copyright laws of the United States and other countries. The copyright owner has no objection to the facsimile reproduction by anyone of the patent document or the patent disclosure, as it appears in official governmental records but, otherwise, all other copyright rights whatsoever are reserved. 
     BACKGROUND OF THE INVENTION 
     The present invention generally relates to a one piece box with an integrally connected lid. One-piece boxes with integrally connected lids are generally well-known. However, it is thought that these containers generally do not remain closed without a separate mechanism for retaining the lids in a closed position. Accordingly, it is believed that a need exists for improvement in one-piece boxes with integrally connected lids. This, and other needs, are addressed by one or more aspects of the present invention. 
     SUMMARY OF THE INVENTION 
     The present invention includes many aspects and features. Moreover, while many aspects and features relate to, and are described in, the context of a once-piece box with an integrally connected lid, the present invention is not limited to use only in such one-piece boxes, as will become apparent from the following summaries and detailed descriptions of aspects, features, and one or more embodiments of the present invention. 
     Accordingly, one aspect of the present invention relates to a one-piece container with a hingedly connected lid as substantially shown and described. 
     In an aspect of the invention, a blank for forming a container by folding comprises a single sheet of material. The single sheet of material comprises a bottom section; four side wall sections; four side wall attachment portions; and a lid section. Fold lines in the sheet of material preferably define these elements therebetween. Additionally, the lid section comprises a top portion, a left side portion having a plurality of lid fold lines (preferably three lid fold lines), a right side portion having a plurality of lid fold lines (preferably three lid fold lines), a front portion having a two slots, a left side tab portion, and a right side tab portion. The lid fold lines of the left side portion of the lid and the lid fold lines of the right side portion of the lid are located such that, when the blank is folded and glued to form the container, the fold lines collectively bias the lid to maintain a stable open position of the container when in such open position; a stable intermediate position when in such intermediate position, and a stable closed position when in such closed position. 
     In a feature, the single sheet of material comprises a generally planar sheet of corrugated material. 
     In a feature, the single sheet of material comprises cardboard. 
     In another feature, the blank further comprise a decorative element applied to an exterior surface of the single sheet of material. The decorative element may be adhered to a surface of the single sheet of material using adhesives, or the decorative element may be printed directly on a surface of the single sheet of material. 
     In another aspect of the invention, a method of forming a container by folding a blank comprising a single sheet of material includes the step of providing a single sheet of material. The sheet of material that is provided comprises a bottom section; four side wall sections; four side wall attachment portions; and a lid section. The lid section comprises a top portion; a left side portion having three lid fold lines; a right side portion having three lid fold lines; a front portion having a two slots; a left side tab portion; and a right side tab portion. The method further includes the steps of folding each of the side wall sections perpendicular to the bottom section; attaching the outer surfaces of the four side wall attachment portions to the inner surfaces of the side wall sections; folding the lid section such that the left side portion, the right side portion, and the front portion are folded downward and perpendicular to the top portion; folding the left side tab portion and the right side tab portion perpendicular to the left side portion and right side portion, respectively; and inserting the left side tab portion and the right side tab portion into respective slots of the front portion. The steps are performed such that the three lid fold lines of the left side portion of the lid and the three lid fold lines of the right side portion of the lid collectively bias the lid to maintain a stable open position of the container when in such open position; a stable intermediate position when in such intermediate position; and a stable closed position when in such closed position. 
     In a feature, the step of attaching the outer surfaces of the four side wall attachment portions to the inner surfaces of the side wall sections is performed using an adhesive. 
     In another aspect, a container comprising a single sheet of material, the single sheet of material comprising a bottom section; four side wall sections; four side wall attachment portions; and a lid section. The lid section in turn comprises atop portion; a left side portion having three lid fold lines; a right side portion having three lid fold lines; a front portion having a two slots; a left side tab portion; and a right side tab portion. The three lid fold lines of the left side portion of the lid and the three lid fold lines of the right side portion of the lid are located such that the fold lines collectively bias or urge the lid to maintain a stable open position of the container when in such open position; a stable intermediate position when in such intermediate position, and a stable closed position when in such closed position. 
     In a feature, the single sheet of material comprises a generally planar sheet of corrugated material that is folded. 
     In a feature, the single sheet of material comprises cardboard. 
     In a feature, the container further comprises a decorative element applied to an exterior surface of the single sheet of material. The decorative element may be adhered to a surface of the single sheet of material using adhesives, or the decorative element may be printed directly on a surface of the single sheet of material. 
     In additional features, each of the side wall sections extend generally perpendicular to the bottom section; the outer surfaces of the four side wall attachment portions are attached to the inner surfaces of the side wall sections; the left side portion, the right side portion, and the front portion extend generally perpendicular to the top portion; the left side tab portion and the right side tab portion extend generally perpendicular to the left side portion and right side portion, respectively; and the left side tab portion and the right side tab portion extend into respective slots of the front portion. Furthermore, the outer surfaces of the four side wall attachment portions preferably are attached to the inner surfaces of the side wall sections with an adhesive such as glue. 
     In another aspect, a one-piece container comprises a single, folded sheet of material. The single, folded sheet of material comprises a bottom section; four wall sections, including a first wall section having a first slotted opening, and a second wall section, opposite to the first wall section, having a second slotted opening; a first flap section, integrally and hingedly attached to a third wall section; and a second flap section, integrally and hingedly attached to a fourth wall section, opposite to the third wall section, the second cover portion having a first side with a first tab and a second side, opposite to the first side, with a second tab. The bottom section and the four wall sections define a storage area adapted to house articles therein; the first flap section and second flap section together define a cover for the storage area; and the second flap section is secured in a covering orientation by inserting the first tab into the first slotted opening and the second tab into the second slotted opening, and the first flap section is secured in a covering orientation by the second flap section. 
     In a feature, the first flap section is secured in a covering orientation by the second flap section by a portion of the second flap section extending over and abutting the first flap section. 
     In a feature, the single sheet of material comprises a generally planar sheet of corrugated material that is folded. 
     In another aspect, a blank for forming a one-piece container when folded comprise a single sheet of material, which in turn, comprises: a bottom section; four wall sections, including a first wall section having a first slotted opening, and a second wall section, opposite to the first wall section, having a second slotted opening; a first flap section, integrally and hingedly attached to a third wall section; and a second flap section, integrally and hingedly attached to a fourth wall section, opposite to the third wall section, the second cover portion having a first side with a first tab and a second side, opposite to the first side, with a second tab. The bottom section and the four wall sections define a storage area adapted to house articles therein when the blank is folded. Furthermore, the first flap section and second flap section together define a cover for the storage area when the blank is folded; and the second flap section is secured in a covering orientation by inserting the first tab into the first slotted opening and the second tab into the second slotted opening, and the first flap section is secured in a covering orientation by the second flap section when the blank is folded. 
     In yet another aspect, a one-piece container includes a single sheet of corrugated material, including four walls, a bottom, and a lid, the lid being hingedly and integrally connected to one of the four walls. Furthermore, the bottom and the four walls define a storage cavity or storage area for housing articles therein, and the lid is configured to transition between an open position, an intermediate position, and a closed position. 
     In a feature of this aspect, the lid comprises a plurality of fold lines adapted to cause the lid to maintain either the open position, the intermediate position, or the closed position. 
     In a variation of this feature, the plurality of fold lines includes three fold lines on a left side of the lid and three fold lines on a right side of the lid. 
     Another aspect of the present invention relates to a one-piece container comprising a single sheet of corrugated material, including a bottom, four walls, including a first wall having a first slotted opening, and a second wall, opposite the first wall, having a second slotted opening, a first flap, integrally and hingedly attached to a third wall, and a second flap, integrally and hingedly attached to a fourth wall, opposite the third wall, the second cover portion having a first side with a first tab and a second side, opposite the first side, with a second tab. Furthermore, the bottom and the four walls define a storage area adapted to house articles therein, the first flap and second flap together define a cover for the storage area, and the second flap is secured in a covering orientation by inserting the first tab into the first slotted opening and the second tab into the second slotted opening, and the first flap is secured in a covering orientation by the second flap. 
     In addition to the aforementioned aspects and features of the present invention, it should be noted that the present invention further encompasses the various possible combinations and subcombinations of such aspects and features. Thus, for example, any aspect may be combined with an aforementioned feature in accordance with the present invention without requiring any other aspect or feature. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of a preferred embodiment of a one-piece box in accordance with one or more aspects of the present invention, showing the lid being maintained in a stable, open position. 
         FIG. 2  is a top view of a single sheet of corrugated material, or blank, that is used to make the box of  FIG. 1  by folding along the fold lines. 
         FIGS. 3A and 3B  are perspective and side views of the box of  FIG. 1  showing the lid being maintained in a stable, intermediate position. 
         FIGS. 4A and 4B  are perspective and side views of the box of  FIG. 1  showing the lid being maintained in a stable, closed position. 
         FIG. 5  is a front view of the box of  FIG. 1 . 
         FIG. 6  is a right side view of the box of  FIG. 1 . 
         FIG. 7  is a photograph of a front view of a one-piece box in accordance with one or more embodiments of the present invention, which generally corresponds to the box of  FIGS. 1-6 . 
         FIG. 8  is a photograph of a right side view of the box of  FIG. 7 . 
         FIG. 9  is a photograph of a bottom view of the box of  FIG. 7 . 
         FIG. 10  is a photograph of the box of  FIG. 7  with the lid in the intermediate position. 
         FIG. 11  is a photograph of the box of  FIG. 7  with the lid in the open position. 
         FIG. 12  is a photograph of the box of  FIG. 7 , showing the left and right side tabs removed from the slots in the front of the lid. 
         FIG. 13  is a perspective view of another preferred embodiment of a one-piece box in accordance with one or more aspects of the present invention. 
         FIG. 14  is a top view of a single sheet of corrugated material, or blank, that is used to make the box of  FIG. 13  by folding along the fold lines. 
         FIG. 15  is a top view of the box of  FIG. 13  with the first and second lid portions open. 
         FIG. 16  is a top view of the box of  FIG. 13  with the first lid portion open and the second lid portion closed. 
         FIG. 17  is a top view of the box of  FIG. 13  with the first and second lid portions closed. 
         FIG. 18  is a side perspective view of the box of  FIG. 13 . 
         FIG. 19  is a photograph of a one-piece box in accordance with one or more embodiments of the present invention, which generally corresponds to the box of  FIGS. 13-18 . 
         FIG. 20  is a photograph of a side view of the box of  FIG. 19 . 
         FIG. 21  is a photograph of the side of the box of  FIG. 19 , showing a tab completely inserted into a slot. 
         FIG. 22  is a photograph of the side of the box of  FIG. 19 , showing a tab partially inserted into a slot. 
         FIG. 23  is a photograph of the side of the box of  FIG. 19 , showing a tab completely removed from a slot. 
         FIG. 24  is a photograph of the box of  FIG. 19 , with the first and second lid portions partially open. 
         FIG. 25  is a photograph of a top view of the box of  FIG. 19 , with the first and second lid portions partially open. 
     
    
    
     DETAILED DESCRIPTION 
     As a preliminary matter, it will readily be understood by one having ordinary skill in the relevant art (“Ordinary Artisan”) that the present invention has broad utility and application. As should be understood, any embodiment may incorporate only one or a plurality of the above-disclosed aspects of the invention and may further incorporate only one or a plurality of the above-disclosed features. Furthermore, any embodiment discussed and identified as being “preferred” is considered to be part of a best mode contemplated for carrying out the present invention. Other embodiments also may be discussed for additional illustrative purposes in providing a full and enabling disclosure of the present invention. As should be understood, any embodiment may incorporate only one or a plurality of the above-disclosed aspects of the invention and may further incorporate only one or a plurality of the above-disclosed features. Moreover, many embodiments, such as adaptations, variations, modifications, and equivalent arrangements, will be implicitly disclosed by the embodiments described herein and fall within the scope of the present invention. 
     Accordingly, while the present invention is described herein in detail in relation to one or more embodiments, it is to be understood that this disclosure is illustrative and exemplary of the present invention, and is made merely for the purposes of providing a full and enabling disclosure of the present invention. The detailed disclosure herein of one or more embodiments is not intended, nor is to be construed, to limit the scope of patent protection afforded the present invention, which scope is to be defined by the claims and the equivalents thereof. It is not intended that the scope of patent protection afforded the present invention be defined by reading into any claim a limitation found herein that does not explicitly appear in the claim itself. 
     Thus, for example, any sequence(s) and/or temporal order of steps of various processes or methods that are described herein are illustrative and not restrictive. Accordingly, it should be understood that, although steps of various processes or methods may be shown and described as being in a sequence or temporal order, the steps of any such processes or methods are not limited to being carried out in any particular sequence or order, absent an indication otherwise. Indeed, the steps in such processes or methods generally may be carried out in various different sequences and orders while still falling within the scope of the present invention. Accordingly, it is intended that the scope of patent protection afforded the present invention is to be defined by the appended claims rather than the description set forth herein. 
     Additionally, it is important to note that each term used herein refers to that which the Ordinary Artisan would understand such term to mean based on the contextual use of such term herein. To the extent that the meaning of a term used herein—as understood by the Ordinary Artisan based on the contextual use of such term—differs in any way from any particular dictionary definition of such term, it is intended that the meaning of the term as understood by the Ordinary Artisan should prevail. 
     Regarding applicability of 35 U.S.C. §112, ¶6, no claim element is intended to be read in accordance with this statutory provision unless the explicit phrase “means for” or “step for” is actually used in such claim element, whereupon this statutory provision is intended to apply in the interpretation of such claim element. 
     Furthermore, it is important to note that, as used herein, “a” and “an” each generally denotes “at least one,” but does not exclude a plurality unless the contextual use dictates otherwise. Thus, reference to “a picnic basket having an apple” describes “a picnic basket having at least one apple” as well as “a picnic basket having apples.” In contrast, reference to “a picnic basket having a single apple” describes “a picnic basket having only one apple.” 
     When used herein to join a list of items, “or” denotes “at least one of the items,” but does not exclude a plurality of items of the list. Thus, reference to “a picnic basket having cheese or crackers” describes “a picnic basket having cheese without crackers”, “a picnic basket having crackers without cheese”, and “a picnic basket having both cheese and crackers.” Finally, when used herein to join a list of items, “and” denotes “all of the items of the list.” Thus, reference to “a picnic basket having cheese and crackers” describes “a picnic basket having cheese, wherein the picnic basket further has crackers,” as well as describes “a picnic basket having crackers, wherein the picnic basket further has cheese.” 
     Referring now to the drawings, one or more preferred embodiments of the present invention are next described. The following description of one or more preferred embodiments is merely exemplary in nature and is in no way intended to limit the invention, its implementations, or uses. 
       FIG. 1  is a perspective view of a foldable box  10  in accordance with one or more preferred embodiments of the present invention. An exemplary such box  10  comprises a single sheet  12  of material or blank, as shown in  FIG. 2 , and preferably, comprises a corrugated material or cardboard and may be single-ply or multiply in thickness.  FIG. 2  is a top view of the inner surface of the single sheet  12  of corrugated material. To form a box  10  from the single sheet  12  of corrugated material, the single sheet  12  of corrugated material is folded along various fold lines and glued. As an alternative, or in addition to, gluing, portions of the single sheet  12  of corrugated material may be formed into tabs and slots, the tabs adapted to be inserted in to the slots to form the box  10 . 
     As shown in  FIGS. 1 and 2 , the single sheet  12  of corrugated material includes a bottom  14 , four side walls  16 , 17 , four side wall attachment portions  18 , and a lid  20 . The lid includes a top  22 , a left side  24  having three lid fold lines  36 , 37 , 38 , a right side  26  having three lid fold lines  46 , 47 , 48 , a front  28  having a two slots  30 , a left side tab  32 , and a right side tab  34 . 
     In at least one preferred embodiment, the single sheet  12  of corrugated material is shipped as blank in order to save space. Furthermore, multiple blanks can be packaged and shipped together. These blanks then may be assembled into boxes upon receipt, after shipping, when needed. 
     To form the box  10  from the single corrugated sheet  12 , each of the side walls  16 , 17  is folded perpendicular to the base  14 , and the outer surfaces of the four side wall attachment portions  18  are attached to the inner surfaces of the side walls  16  using an adhesive or other suitable attachment method. Next, the lid  20  is formed such that the left side  24 , the right side  26 , and the front  28  are folded downward and perpendicular to the top  22 . The left side tab  32  and right side tab  34  are folded perpendicular to the left side  24  and right side  26 , respectively, and are each inserted into their respective slots  30 . The box  10  shown in  FIG. 1  is thus assembled from the blank of  FIG. 2 . 
     Once formed, the box  10  includes a storage portion  50 , defining an opening, and adapted to house objects therein, and a lid  20  hingedly connected and integral with the storage portion  50 . In at least one preferred embodiment, the lid  20  is adapted to transition between an open position, an intermediate position, and a closed position. The open, intermediate, and closed positions are distinct and discrete from each other. The lid  20  includes a biasing mechanism that that encourages the lid  20  to remain in either the open, intermediate or closed position until acted upon by a force large enough to overcome the force exerted by the biasing mechanism. In at least one preferred embodiment, the biasing mechanism comprises a plurality of fold lines  36 , 37 , 38 , 46 , 47 , 48  on left and right sides of the lid  20 . 
       FIG. 1  illustrates the box  10  in the open position. In the open position, the top of the lid  20  is perpendicular to the base  14  and the contents of the box  10  are exposed. Furthermore, it is noted that the left side  24  and right side  26  are not folded along any of the fold lines  36 , 37 , 38 , 46 , 47 , 48 . 
       FIGS. 3A and 3B  illustrate the box  10  of  FIG. 1  in the intermediate position. In the intermediate position, the top  22  of the lid  20  is at an angle between zero and ninety degrees relative to the base  14 . In the intermediate position, the left side  24  is folded 180 degrees along fold  36  and the right side  26  is folded 180 degrees along fold  46 . Furthermore, the left and right sides  24 , 26  are folded substantially less than 180 degrees along fold lines  37 , 38 , 47 , 48 . This is perhaps best illustrated in  FIG. 3B , showing the hidden fold line  36  in dashed lines. 
       FIGS. 4A and 4B  illustrate the box  10  of  FIG. 1  in the closed position. In the closed position, the top  22  of the lid  20  is parallel to the base  14 , and lid  20  completely covers the opening of the storage portion  50 . In the closed position, the left side  24  is folded 180 degrees along both fold line  36  and fold line  38 , and the right side  26  is folded 180 degrees along both fold line  46  and fold line  48 . This is perhaps best illustrated in  FIG. 4B , showing the hidden fold line  37  in dashed lines. 
       FIGS. 5 and 6  are front and right side views, respectively, of the box  10  in the closed position. 
     An exemplary embodiment of the box  10  is shown in  FIGS. 7-12 . In particular,  FIG. 7  is a photograph of a front view of a box in accordance with one or more embodiments of the present invention;  FIG. 8  is a photograph of a right side view of the box of  FIG. 7 ;  FIG. 9  is a photograph of a bottom view of the box of  FIG. 7 ;  FIG. 10  is a photograph of the box of  FIG. 7  with the lid in the intermediate position;  FIG. 11  is a photograph of the box of  FIG. 7  with the lid in the open position; and  FIG. 12  is a photograph of the box of  FIG. 7 , showing the left and right side tabs removed from the slots in the front of the lid. 
       FIG. 13  is a perspective view of a box  110  in accordance with a preferred embodiment of another aspect of the present invention. The box  110  comprises a single sheet  112  of corrugated material and, preferably, corrugated material or cardboard and may be single-ply or multiply in thickness To assemble the box  110  from the single sheet  112  of corrugated material, the single sheet  112  of corrugated material is folded along various fold lines and attached at various places using an adhesive or other appropriate attachment means. As an alternative, or in addition to, gluing, portions of the single sheet  112  of corrugated material may be formed into tabs and slots, the tabs adapted to be inserted in to the slots. 
       FIG. 14  is a top view of the sheet  112  of corrugated material in a flat, pre-assembled configuration. In at least one preferred embodiment, the single sheet  112  of corrugated material is shipped as a flat sheet in order to save space. Furthermore, multiple single sheets can be packaged and shipped together. These flat sheets may be assembled into boxes after shipping is complete. 
     As shown in  FIG. 14 , the boundary of the sheet  112  of corrugated material is shown in solid lines and fold lines are shown as dashed lines. The single sheet comprises a base  114 , four side walls  116 , 117 , four side wall attachment portions  118 , a first lid portion  120 , a second lid portion  122 , and two side portions  124 , each with a tab  126 . Two opposing side walls  116  include a slot  128 . Each tab  126  is adapted to slide into and be retained within one of the slots  128  to seal the first lid portion  120  and the second lid portion  122  in a closed position. 
     To assemble the box  110  from the single sheet  112  of corrugated material, each of the side walls  116 , 117  is folded perpendicular to the base  114 , and the outer surfaces of the four side wall attachment portions  118  are attached to the inner surfaces of side walls  116 . The assembled box  110  is shown in  FIGS. 13 and 15 . 
     To seal the box  110  closed, the second lid portion  122  is folded over the opening, as seen in  FIG. 16 . Next, as seen in  FIGS. 17 and 18 , the first lid portion  120  is folded down over the opening to cover at least part of the second lid portion  122 , securing the second lid portion  122  closed. Finally, as shown in  FIG. 18 , the tabs  126  are inserted into the slots  128  to hold the first lid portion  120 , and therefore the second lid portion  122 , in place, sealing the contents of the box  110 . 
     An exemplary embodiment of the box  110  is shown in  FIGS. 19-25 . In particular,  FIG. 19  is a photograph of a box in accordance with one or more preferred embodiments of the present invention.  FIG. 20  is a photograph of a side view of the box of  FIG. 19 .  FIG. 21  is a photograph of the side of the box of  FIG. 19 , showing a tab completely inserted into a slot.  FIG. 22  is a photograph of the side of the box of  FIG. 19 , showing a tab partially inserted into a slot.  FIG. 23  is a photograph of the side of the box of  FIG. 19 , showing a tab completely removed from a slot.  FIG. 24  is a photograph of the box of  FIG. 19 , with the first and second lid portions partially open; and  FIG. 25  is a photograph of a top view of the box of  FIG. 19 , with the first and second lid portions partially open. 
     Based on the foregoing description, it will be readily understood by those persons skilled in the art that the present invention is susceptible of broad utility and application. Many embodiments and adaptations of the present invention other than those specifically described herein, as well as many variations, modifications, and equivalent arrangements, will be apparent from or reasonably suggested by the present invention and the foregoing descriptions thereof, without departing from the substance or scope of the present invention. 
     Accordingly, while the present invention has been described herein in detail in relation to one or more preferred embodiments, it is to be understood that this disclosure is only illustrative and exemplary of the present invention and is made merely for the purpose of providing a full and enabling disclosure of the invention. The foregoing disclosure is not intended to be construed to limit the present invention or otherwise exclude any such other embodiments, adaptations, variations, modifications or equivalent arrangements, the present invention being limited only by the claims appended hereto and the equivalents thereof.