Abstract:
A collapsible cardboard box and lid. The box sides each comprise an outer face and an inner face flap connected by a fold-over region. Mitered edges of adjacent fold-over regions align to define mitered corners of the box opening periphery. Intermediate side flaps connected to the outer shell bottom are sandwiched between the side outer faces and inner face flaps, and a locking flap connected to one of the sides defines an interior bottom. The lid top face is connected to a first set of outer side faces connected by a fold-over region to inner side faces. One inner side face is connected to a top locking liner flap that extends to an abutment with the inner side face to define the lid interior. A second set of outer side faces connects to intermediate flaps sandwiched between the first set of outer side faces and inner side faces.

Description:
BACKGROUND OF THE INVENTION 
     Storage boxes, such as cardboard boxes, of various shapes and designs are well known in the art, many of which may be assembled by the end user from a flat configuration into a fully assembled box. Such boxes are cut from a sheet of, for example, corrugated cardboard, such as with a metal die, forming a blank. The blank may further be constructed with various fold lines and perforations to assist in constructing the fully assembled box. In some instances, certain portions of the box may be pre-glued such that the unassembled box may still be shipped to or purchased by a user in a flattened form that takes less space in inventory than the fully constructed boxes, and which can be fully assembled by folding the box in a certain sequence along the pre-made fold lines or perforations. Such boxes typically have a box portion and a lid portion, both of which have a flat configuration and a fully assembled configuration. Such storage filing boxes, some of which are known by the brand name BANKERS BOX®, sold by Fellowes, Inc. of Itasca, Ill., are robust and capable of holding relatively heavy loads. Such boxes, however, are typically intended for storage in back rooms, where the aesthetic look and feel of the box is generally not important. 
     There is therefore a need for a box assembly that can provide the robustness of traditional storage filing boxes, flatness for transport and space conservation until needed, and easy of assembly, with an overall aesthetically pleasing look, such as a configuration that permits easy printing of designs on the box and that, when assembled, has smooth edges and corners. 
     SUMMARY OF THE INVENTION 
     One aspect of the invention comprises a collapsible box and lid assembly comprising a collapsible box portion and a collapsible lid portion. An exemplary collapsible box portion embodiment has a fully assembled configuration defined by an outer shell having four sides and a bottom ( 114 ), and an open top defined by top edges of the four sides, each of the four sides comprising an outer face ( 102 ,  104 ,  106 ,  108 ) and an inner face flap ( 120 ,  118 ,  122 ,  124 ) connected to the outer face by a fold-over region (between  174  and  176 ), in which the top edges of the four sides comprise the fold-over region. Each fold-over region comprises mitered edges ( 180 ,  182 ,  184 ,  186 ,  188 ,  190 ,  192 ,  194 ) that align with the mitered edges of adjacent fold over regions to define mitered corners. Two of the four sides comprise an intermediate side flap ( 110 ,  112 ) connected to an outer face of the outer shell bottom and sandwiched between the side outer face and the side inner face flap. The box portion further comprises a locking flap ( 116 ), connected to a remaining one of the four sides, that locks the box in the assembled configuration and defines an interior bottom of the box portion. 
     One collapsible lid portion embodiment has a fully assembled configuration defined by a top ( 200 ), a shell having four sides ( 202 ,  204 ,  214 ,  220 ), and an open bottom defined by top edges of the four sides. The top has an outer face connected to a first set of opposite outer side faces defining two of the sides ( 214 ,  220 ). The opposite outer side faces are connected by a fold-over region (between  248  and  249 ) to opposite inner side faces ( 216 ,  222 ). Inner side face  222  is connected at a fold line ( 254 ) to top liner flap ( 224 ), which extends from inner side face  222  to an abutment with inner side face  216 . The top liner flap defines an interior of the lid portion. The top outer face is connected to a second set of opposite outer side faces ( 202 ,  204 ) defining a remaining two of the four sides. The second set of opposite outer side faces is connected to opposite intermediate flaps ( 206 ,  208 ,  210 ,  212 ) sandwiched between the first set of opposite outer side faces and inner side faces. 
     The box in the fully assembled configuration may further comprise a flap ( 100 ) extending from one side, the flap having an outer face adhered face-to-face to an inner face of an adjacent side, the adhered flap sandwiched between the outer face and inner face of the adjacent side in the fully assembled configuration. 
     In some configurations, at least two of the inner side flaps of the box comprise tabs ( 130 .  132 ) biased against an interior face of the outer shell bottom in the fully assembled configuration and the locking flap comprises indents ( 150 ,  152 ) to accommodate the tabs. Similarly, in some configurations, the lid top liner flap comprises tabs ( 223 ,  225 ) that mesh with indents ( 215 ,  217 ) of the opposite inner side face ( 216 ), to lock the lid portion in the assembled configuration. 
     The inner side flaps and intermediate side flaps on at least two sides each may comprise handle openings ( 138 ,  140 ,  134 ,  136 ), and at least two of the outer sides may each comprise a handle flap ( 142 ,  144 ) for folding into the handle openings. 
     In another lid embodiment, instead of a locking flap  224  extending from one of the short side inner liners, a pair of locking flap liners  302  and  304  may be provided extending from each of the short sides, with the overall length of the pair of locking flap liners together being such that their leading edges  303  and  305  snugly abut one another inside the lid to form a 2-piece lid liner. 
     Another aspect of the invention comprises the box portion as described above, with or without a lid portion as described herein. Still another aspect of the invention comprises a collapsible lid having a fully assembled configuration defined by a top, a shell having four sides, and an open bottom defined by top edges of the four sides, the top having an outer face connected to a first set of opposite outer side faces defining two of said sides. The opposite outer side faces are connected by a fold-over region to opposite inner side faces, with at least one inner side face connected at a fold line to a top locking liner flap that extends from the attached inner side face to an abutment with the opposite inner side face or an opposing top locking liner flap to lock said lid portion in said assembled configuration, the at least one top liner flap defining an interior of the lid portion. The top outer face is further connected to a second set of opposite outer side faces defining a remaining two of the four sides, and the second set of opposite outer side faces is connected to opposite intermediate flaps sandwiched between the first set of opposite outer side faces and the inner side faces. 
     Still other aspects of the invention include the box, the lid embodiments, and box and lid assembly embodiments depicted in  FIGS. 11-20 . 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a plan view of a blank for an exemplary box portion of an exemplary box assembly in an unassembled configuration. 
         FIG. 2  is a plan view of a blank for an exemplary lid portion for use with the exemplary box portion of  FIG. 1 , in an unassembled configuration. 
         FIG. 3  is a perspective view illustrating initial steps in an exemplary process for folding the lid portion of  FIG. 2  from an unassembled into an assembled configuration. 
         FIG. 4  is a perspective view illustrating steps after those illustrated in  FIG. 3 , for folding the lid portion of  FIG. 2  from an unassembled into an assembled configuration. 
         FIG. 5  is a perspective view illustrating steps after those illustrated in  FIG. 4 , for folding the lid portion of  FIG. 2  from an unassembled into an assembled configuration. 
         FIG. 6  is a perspective view illustrating initial steps in an exemplary process for folding the box portion of  FIG. 1  from an unassembled into an assembled configuration. 
         FIG. 7  is a perspective view illustrating steps after those illustrated in  FIG. 6 , for folding the box portion of  FIG. 1  from an unassembled into an assembled configuration. 
         FIG. 8  is a perspective view illustrating steps after those illustrated in  FIG. 7 , for folding the box portion of  FIG. 1  from an unassembled into an assembled configuration. 
         FIG. 9  is a perspective view illustrating steps after those illustrated in  FIG. 8 , for folding the box portion of  FIG. 1  from an unassembled into an assembled configuration. 
         FIG. 10  is a perspective view illustrating steps after those illustrated in  FIG. 9 , for folding the box portion of  FIG. 1  from an unassembled into an assembled configuration. 
         FIG. 11  is a 3-D rendering of a perspective view of the box and lid assembly with the lid on the box. 
         FIG. 12  is a rendering of a plan view of the box portion blank of  FIG. 1 . 
         FIG. 13  is a rendering of a plan view of the lid portion blank of  FIG. 2 . 
         FIG. 14  is a rendering of a top view of the box portion showing the interior of the box portion. 
         FIG. 15  is a rendering of a plan view of the long side of the box portion. 
         FIG. 16  is a rendering of a plan view of the short side of the box portion. 
         FIG. 17  is a rendering of a bottom view of the lid portion showing the interior of the lid. 
         FIG. 18  is a rendering of a plan view of the long side of the lid portion. 
         FIG. 19  is a rendering of a plan view of the short side of the box portion. 
         FIG. 20  is a 3-D perspective rendering of an exemplary box and an alternative embodiment lid assembly, with the lid separated from the box, showing an exemplary pattern printed on thereon. 
         FIG. 21  is a plan view of a blank for the exemplary lid embodiment depicted in  FIG. 20 . 
         FIG. 22  is a perspective view illustrating initial steps in an exemplary process for folding the lid portion embodiment of  FIG. 21  from an unassembled into an assembled configuration. 
         FIG. 23  is a perspective view illustrating steps after those illustrated in  FIG. 22 , for folding the lid portion embodiment of  FIG. 21  from an unassembled into an assembled configuration. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Turning now to the figures, which illustrate an exemplary embodiment of the invention,  FIGS. 1 and 2  show the box blank  100  and lid blank  200 , respectively, and  FIGS. 3-10  illustrate the exemplary steps for folding the blanks into the fully assembled configuration, which is depicted in  FIG. 11 .  FIGS. 12 and 13  show renderings of a top view of the box and lid blanks in the same orientation as  FIGS. 1 and 2 , respectively. It should be understood that the bottom views of said blanks are essentially a mirror image of the views shown in  FIGS. 12 and 13  and that from the side, these blanks resemble any sheet of cardboard stock, with the lines associated with each contour of the cut shape of the blank projected onto those side views.  FIGS. 14-16  illustrate, from various views, the fully assembled box and  FIGS. 17-19  illustrate, from various views, the fully assembled lid. It should be understood that although only one short or long side of the box or lid are shown in  FIGS. 15 ,  16 ,  18  and  19 , the opposite side view of each is identical. Similarly, it should be understood that a bottom view of the box portion and a top view of the lid portion are essentially identical rectangular shapes. Finally, it should be understood that the relative dimensions of the box and lid assembly are not necessarily to scale, and that the various parts of the assembly may be of any size or shape. One exemplary embodiment, such as the one depicted herein, may have an approximate width of 12 inches, length of 15 inches, and depth of 10 inches, and may be constructed of corrugated cardboard stock. 
     Box portion blank as shown in  FIG. 1  comprises a number of faces and flaps, separated by fold lines, cuts, or perforations between adjacent areas. As shown in  FIG. 11 , the fully assembled box assembly is rectangular in shape. While box assemblies according to the invention are not limited to a rectangular shape, for purposes of illustration, the rectangular shape of the exemplary box and lid shown herein permits reference to a “short side” and a “long side” of the box, and thus such reference will be made herein. It should be understood, however, that in other embodiments, all sides may be of equal length. For ease of discussion, the following are the faces and flaps of the box portion blank as illustrated in  FIG. 1 . 
       101 —affixation flap 
       102 ,  104 —box outer shell long sides 
       106 ,  108 —box outer shell short sides 
       110 ,  112 —sandwiched side flaps 
       114 —bottom 
       116 —locking flap 
       118 ,  120 —long side inner liner flaps 
       122 ,  124 —short side inner liner flaps 
     An exemplary sequence for folding the box portion blank will now be discussed with reference to  FIGS. 6-10 . Prior to the steps shown in  FIG. 6 , the box portion is folded along fold lines  162 ,  164 , and  166  so that the adjacent faces lie in perpendicular planes to one another, and the outer surface (the side facing the viewer in  FIG. 1 ) of affixation flap  101  is then affixed to the inner surface (the side facing away from the viewer of  FIG. 1 ) of outer shell long side face  102 , creating the assembly shown in  FIG. 6 . Affixation flap  101  may be affixed to face  102  by any means known in the art, such as by gluing, stapling (or affixing with any type of mechanical fastener not limited to a staple), melting (for materials of construction, such as plastic resins, that permit melting of parts together), or some combination thereof, or by any means of affixation suitable for creating a bond that will withstand the designed load for the box. The partially formed box portion so created now has an exterior (defined by the portions of faces  102  and  108  visible in  FIG. 6 ) and an interior (defined by the portions of faces  104  and  106  visible in  FIG. 6 ). It should be noted that affixation flap  101  may be affixed to face  102  as described above before sale of the box portion to a consumer. The resulting partially constructed blank can still lie flat with all of the faces lying along a singular plane (or, more precisely, two parallel, planes spaced apart only by the distance of the cardboard thickness) for easy storage and transport, and then can be assembled by the end user only by folding as described herein next. 
     As shown in  FIG. 6 , locking flap  116  is first folded along fold line  168 , as illustrated by arrow A, so that it rests in the interior of the box. Then, sandwiched side flaps  110  and  112  are folded along fold lines  170  and  172 , as shown by arrows B and C, such that their faces are substantially parallel to the face of bottom  114 . It should be noted that lines  109  and  115  separating flap  110  from face  106  and flap  112  from face  108 , respectively, as shown in  FIG. 1 , are cut lines (illustrated in solid lines) rather than fold lines (illustrated with dashed lines). The substantially parallel faces/flaps  110 ,  112 , and  114  are then folded along fold line  171  so that bottom  114  rests in a plane perpendicular to the planes of faces  102 ,  104 ,  106 , and  108 . As illustrated in  FIG. 7 , the box portion may then, most conveniently but not as a matter of necessity, be placed so that the box rests on bottom face  114  such that the opening framed by the sides the box faces toward the assembler. 
     Next, as illustrated in  FIG. 8 , locking flap  116  is further folded along line  168 , as shown by arrow D, such that flap  116  is parallel to face  102  within the interior of the box portion, and sandwiched side flaps  110  and  112  are then folded along lines  170  and  172 , as shown by arrows E and F, respectively, such that they lie parallel to faces  106  and  108 , respectively, within the interior of the box portion. Then, as shown in  FIG. 9 , locking flap  116  is folded as shown by arrow G such that it lies parallel to bottom face  114 . Finger hole  117  in locking flap  116  provides an opening through which a user can insert his or her finger to pull up locking flap to disassemble the box, if later desired. 
     Next, as illustrated in  FIG. 10 , long side inner liner flaps  118 ,  120  and short side inner liner flaps  122 ,  124  are folded inward toward the interior of the box along fold line  174  and fold lines  178 ,  176 ,  177 , and  179 , as shown by arrows H, I, J, and K. respectively. The preferred sequence is to fold along arrows H and I first, and then fold along arrows J and K, so that tabs  130  and  132  interface with the slots that are defined by indents  150  and  152  of locking flap  116  and the adjacent faces of sides  108  and  106  in the assembled configuration. Fold lines  178 ,  176 ,  177 , and  179  are displaced from fold line  174  by a distance necessary to wrap around the thickness of sandwiched flaps  110  and  112 , which then become sandwiched between faces  106  and  122  and between faces  108  and  124 , respectively. Thus, areas  180 ,  181 ,  182 , and  183  between fold line  174  and fold lines  176 ,  177 ,  178 , and  179 , respectively, define a cooperating set of flat top edges that define the top periphery surrounding the opening of the fully assembled box portion. The cooperating flat top edges create an aesthetically pleasing look, which is further enhanced by the mitered corners  185  of each edge portion that abut adjacent mitred corners of adjacent edge portions at each intersection along the periphery. This aesthetically pleasing configuration is best shown in  FIG. 14 . 
     Box portion preferably has handle cutouts for easy transport of the box by users. Thus, for example, cuts  139  and  141  create holes  138  and  140  in faces  110  and  112  respectively, and cuts  135  and  137  create holes  134  and  136  in faces  122  and  124 , respectively. Furthermore, cuts  143  and  145  create flaps  143  and  144  in faces  106  and  108 , such that when in the assembled configuration shown in  FIG. 10 , flap  143  and holes  138  and  134  align with one another and flap  144  and holes  140  and  136  align with one another, permitting the flaps to be folded toward the box interior along fold lines  195  and  196  for flap  142  and long fold lines  197  and  198  for flap  144 , permitting a user to insert his or her hands within the holes to grab the box, with the smooth surface of the flaps protecting the user&#39;s hands from the roughness of the cut cardboard. 
     Lid portion as shown in  FIG. 2  also has a number of faces, separated by fold lines (dashed lines), cuts (solid lines), or perforations between adjacent faces. As shown in  FIG. 11 , the fully assembled lid assembly is rectangular in shape. While lid assemblies according to the invention are not limited to a rectangular shape, for purposes of illustration, the rectangular shape of the exemplary lid embodiments depicted herein permit labeling of a “short side” and a “long side” of the lid, and thus reference will be made to such sides herein. It should be understood, however, that for a square lid, all sides will be of equal length. For ease of discussion, the following are the faces of the lid portion blank as illustrated in  FIG. 2 . 
       200 —lid outer shell top 
       202 ,  204 —lid long sides 
       214 ,  220 —lid outer shell short sides 
       216 ,  222 —lid inner liner short sides 
       224 —lid locking flap 
       216 ,  214 —lid short side inner liner flaps 
       206 ,  208 ,  210 ,  212 —lid sandwiched side flaps 
     An exemplary sequence for folding the lid portion blank will now be discussed with reference to  FIGS. 3-5 . First, as shown in  FIG. 3 , the lid long sides  202  and  204  are folded along lines  234  and  240 , respectively, as illustrated by arrows L and M, such that they lie in a plane perpendicular to the lid outer shell top  200 . Lid sandwiched side flaps  206 ,  208 ,  210 ,  212  (which are separated from adjacent flaps  214  and  220  by cuts  207 ,  209 ,  211 , and  213 , are folded along fold lines  238 ,  236 ,  232 , and  230 , respectively such that they lie in planes perpendicular to both the bottom  200  and their respective attached long sides. Lid outer shell short sides  214  and  220  are folded along lines  242  and  247  respectively, and locking flap  224  is then folded toward the center of the opening defined by the lid. As shown in  FIG. 4 , lid locking flap folds along both of fold lines  248  and  249 , leaving a smooth edge between the fold lines and further folds along line  254 , which separates lid inner liner short side  222  from locking flap  224 . Line  254  may preferably be a perforated line, rather than a creased line, to facilitate locking flap  224  remaining parallel to the top  200  rather than it having some tendency to want to fold away from the top. Cuts  250  and  252  define flaps attached to lid locking flap  224 . Locking flap  224  is folded along arrows N and O such that lid sandwiched side flaps  208  and  212  are sandwiched between lid outer shell short side  220  and lid inner liner short side  222  and such that the edge formed by fold line  254  abuts the inside (the side facing the viewer in  FIG. 3 ) of lid outer shell top  200  and locking flap  224  lies parallel to lid outer shell top  200 , thus forming an inner liner for the top of the lid. 
     Then, as shown in  FIG. 5 , lid outer shell short side is folded along fold line  242  such that it lies parallel to lid sandwiched side flaps  206  and  210 , and lid short side inner liner  216  is folded along lines  243  and  244  as illustrated by arrow P, such that lid sandwiched side flaps  206  and  210  are sandwiched between lid outer shell short side  220  and lid inner liner short side  222  and such that the edge of flap  216  abuts the inside of lid outer shell top  200 . Indents  215  and  217  create slots between the edge of flap  216  and top  200  which accommodate tabs  223  and  225 , respectively, thus creating a more secure locked configuration. 
     It should be understood that while illustrated with indents and tabs in certain places in the design, other indents or slot and tab configurations may be provided to further secure the box and lid assembly in their respective assembled configurations. It should be further understood, that to the extent the embodiment depicted herein is rectangular, features described herein located on the “short side” could also be located on the “long side,” and vice versa. For example, although the lid portion is depicted herein with has sandwiched side flaps connected to the long sides and the locking tab connected to one of the short side inner liner flaps, in another embodiment the locking tab may be located on the long side and the side flaps attached to the short sides. Similarly, the box portion may have the locking flap connected to the short side and the inner liner flaps provided on the long side. 
     Box assemblies constructed in accordance with this invention are strong, yet aesthetically pleasing around the upper periphery of the box portion because of the smooth mitred edges on all four sides, and are easily assembled by users. The layout of the blanks also facilitates coating the box material or printing patterns such that the assembled box may be more aesthetically pleasing than a traditional cardboard box. The box configuration is not limited to any particular patterns or coatings. Although ideally constructed of cardboard, any material suitable for folding may be used. It should be understood that although the box portion and lid portion having the configurations discussed herein are ideally suited to one another, a box portion as described herein may be matched with a lid portion having a different configuration, and vice versa. 
     In the configuration of the blank shown in  FIG. 1 , although  115  is a cut line separating flap  112  from face  108 , a small perforated attachment  190 , such as, for example, ⅛ inch attaching sections separated by ⅛ inch perforations, may be provided to better keep the blank in a planar configuration without undesired folding of certain portions, until the user desires to assemble the box. Thus, the user may need to break the attachment at perforation  190  before beginning to assemble the box. It should be understood that other such attachments may be provided, with or without perforations, for keeping cut sections of the blank in a flat configuration when desired. 
     In an alternate lid embodiment, depicted in  FIGS. 20-23 , instead of a locking flap  224  extending from one of the short side inner liners, a pair of locking flap liners  302  and  304  may be provided extending from each of the short sides, with the overall length of the pair of locking flap liners together being such that their leading edges  303  and  305  snugly abut one another inside the lid to form a 2-piece lid liner. In all other respects, this lid embodiment is essentially the same as the embodiment shown and described elsewhere herein. The embodiment shown elsewhere herein is preferred over this alternate embodiment because in this embodiment there may be a tendency for the two locking flap liners to separate. A piece of adhesive tape, however, may optionally be used to keep the locking flaps together. 
       FIG. 20 , in addition to depicting this alternate lid embodiment, also depicts the box and lid with the lid separated from the box, and also depicts an aesthetically pleasing pattern printed on the box. The box and lid assembly is not limited to this pattern or to any pattern, and use of such a pattern is not limited to use for any particular lid or box embodiment. 
     Although the invention is illustrated and described herein with reference to specific embodiments, the invention is not intended to be limited to the details shown. Rather, various modifications may be made in the details within the scope and range of equivalents of the claims and without departing from the invention.