Abstract:
Box designs, blanks for forming boxes by folding, collapsible and non-collapsible boxes formed thereby, and manufacturing methods therefor are disclosed. An exemplary box is formed from folding a single sheet of material having fold lines therein. The assembled box includes a lid comprising a top panel having top side panels that extend partially within the interior of the box and partially on the exterior of the box when the box is assembled and the lid is closed. Overlapping side panels of the box define openings through which the top side panels extend in crossing over from the exterior of the box to the interior of the box. In a feature, the openings defined in the sides of the box are covered by the top side panels when extending there through. In another feature, the box is collapsible when in the assembled state.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     The present application is a continuation of, and claims the benefit under 35 U.S.C. §120 to, U.S. nonprovisional patent application Ser. No. 14/318,574 filed Jun. 27, 2014, which is hereby incorporated herein by reference in its entirety, and which is a nonprovisional of, and claims the benefit under 35 U.S.C. §119(e) to, U.S. provisional patent application 61/840,460 filed Jun. 27, 2013, which is hereby incorporated herein by reference in its entirety. 
    
    
     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 box designs, blanks for forming boxes by folding, collapsible and non-collapsible boxes formed thereby, and manufacturing methods therefor. 
     SUMMARY OF THE INVENTION 
     The present invention includes many aspects and features. In one aspect of the invention, a box is formed from folding a single sheet of material having fold lines therein. The assembled box includes a lid comprising a top panel having top side panels that extend partially within the interior of the box and partially on the exterior of the box when the box is assembled and the lid is closed. Overlapping side panels of the box define openings through which the top side panels extend in crossing over from the exterior of the box to the interior of the box. In a feature, the openings defined in the sides of the box are covered by the top side panels when extending therethrough. In another feature, the box is collapsible when in the assembled state. 
     Another aspect comprises a box blank for making the above-described box by folding of the box blank along fold lines formed in the box blank. 
     Another aspect comprises a method of making the above-described box from a box blank by folding of the box blank along fold lines formed in the box blank. 
     Additional aspects and features are disclosed below and in the drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       One or more preferred embodiments of the present invention now will be described in detail with reference to the accompanying drawings. 
         FIG. 1  is a plan view of a preferred embodiment of a box blank  10  in accordance with an aspect of the invention. 
         FIG. 2  is a plan view of a preferred embodiment of another box blank  50  in accordance with an aspect of the invention. 
         FIG. 3  is a perspective view of an assembled box  100  wherein the cover is closed. 
         FIG. 4  is a perspective view of a first side of the assembled box  100  wherein the cover is closed. 
         FIG. 5  is a perspective view of a second, opposite side of the assembled box  100  wherein the cover is closed. 
         FIG. 6  is a perspective view of the second side of the assembled box  100  wherein the cover is partially closed. 
         FIG. 7  is a perspective view of the first side of the assembled box  100  wherein the cover is partially closed. 
         FIG. 8  is a perspective view of the assembled box  100  wherein the cover is open and the box is configured to receive one or more articles therein. 
         FIG. 9  is a perspective view of the inside of the box looking down at the bottom of the box and perhaps best shows the score lines s 1  and s 2  and fold line f 13  formed in the bottom panel  12 . 
         FIG. 10  is a perspective view of the second side of the assembled box  100  from inside of the box, wherein the cover is open. 
         FIG. 11  is a perspective view of the second side of the assembled box  100  from inside of the box, wherein the cover is open. 
         FIG. 12  is a perspective view of the assembled box  100  in a collapsed state, the box  100  having been folded along fold line f 13 . 
         FIG. 13  is a perspective view of the first side of the assembled box  100  in the collapsed state. 
         FIG. 14  is a perspective view of the assembled box  100  in the collapsed state with a view into the interior of the box. 
         FIG. 15  is a perspective view of the second side of the assembled box  100  in the collapsed state. 
         FIG. 16  is another perspective view of the assembled box  100  in a collapsed state. 
         FIG. 17  is a perspective view of the box in a disassembled state, reduced back to a generally planar form, and serves to illustrate areas at which panels are adhered to maintain the assembled box  100  in the assembled state. 
         FIG. 18  is a similar view to that of  FIG. 17 , but of the opposite planar side, and also serves to illustrate areas at which panels are adhered to maintain the assembled box  100  in the assembled state. 
         FIG. 19  is a perspective view of the box  200  wherein the cover is open. 
         FIG. 20  is another perspective view of the box  200  wherein the cover is open. 
         FIG. 21  is a perspective view of a first side of the box  200  wherein the cover is open. 
         FIG. 22  is a perspective view of the first side of the box  200  wherein the cover is closed. 
         FIG. 23  is perspective view of the first side of the box  200  wherein the cover is partially open. 
         FIG. 24  is perspective view of the first side of the box  200  wherein the cover is open. 
         FIG. 25  is a CAD drawing representative of a third embodiment of an assembled box and illustrates a box blank  300 . 
     
    
    
     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, three preferred embodiments  100 , 200 , 300  of the present invention are shown. 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. 
     Turning now to  FIG. 1 , a preferred embodiment of a box blank  10  in accordance with an aspect of the invention is illustrated. The box blank  10  comprises a bottom panel  12 ; a first side panel  14 ; a second side panel  16 ; a front panel  18 ; a back panel  20 ; a first overlapping side panel  22 ; a second overlapping side panel  24 ; a third overlapping side panel  26 ; and a fourth overlapping side panel  28 . The box blank  10  further comprises a top cover panel  30 ; a first top side panel  32 ; a second top side panel  34 ; and a top front panel  36 . The top cover panel  30  and top side panels  32 , 34  and top front panel form a lid of the box  100 . 
     The panels of the box blank  10  are integrally formed as part of a generally planar single sheet of material, such as cardboard, and are defined and separated by fold lines. The panels so defined and separated are folded relative to each other about such fold line during assembly of a box from the blank  10 . In this respect, a “blank” is considered to be a box in an unassembled, flat condition, with the box being assembled by folding of the blank. 
     In particular, fold line f 1  extends between and delineates bottom panel  12  and first side panel  14 ; fold line f 2  extends between and delineates bottom panel  12  and second side panel  16 ; fold line f 3  extends between and delineates bottom panel  12  and front panel  18 ; fold line f 4  extends between and delineates bottom panel  12  and back panel  20 . 
     Additionally, fold line f 5  extends between and delineates back panel  20  and first overlapping side panel  22 ; fold line f 6  extends between and delineates back panel  20  and third overlapping side panel  26 ; fold line f 7  extends between and delineates front panel  18  and second overlapping side panel  24 ; fold line f 6  extends between and delineates front panel  18  and fourth overlapping side panel  28 . 
     Fold line f 7  extends between and delineates top cover panel  30  and back panel  20 ; fold line f 8  extends between and delineates top cover panel  30  and first top side panel  32 ; fold line f 9  extends between and delineates top cover panel  30  and second top side panel  34 ; fold line f 10  extends between and delineates top cover panel  30  and top front panel  36 . 
       FIG. 2  illustrates a preferred embodiment of another box blank  50  in accordance with an aspect of the invention. The box blank  50  is the same as box blank  10  except that box blank  50  includes a fold line f 11  generally bisecting side panel  14 ; a fold line f 12  generally bisecting side panel  16 ; a folding line f 13  generally bisecting bottom panel  12 ; and minor score lines s 1  and minor score lines s 2 . It will be appreciated by the Ordinary Artisan that these additional fold lines and score lines enable a box assembled from folding of the box blank  50  to be collapsed for storage and transport while in the assembled state. 
       FIGS. 3 through 11  show an embodiment of a box  100  assembled from a box blank that is represented by box blank  50 . 
     Specifically,  FIG. 3  is a perspective view of the assembled box  100  wherein the cover is closed. 
       FIGS. 4 and 5  are additional perspective views of the assembled box  100  wherein the cover is closed;  FIG. 4  is a perspective view of a first side of the box  100  and  FIG. 5  is a perspective view of a second, opposite side of the box  100 . 
       FIGS. 6 and 7  are additional perspective views of the assembled box  100  wherein the cover is partially closed;  FIG. 6  is a perspective view of the second side of the box  100  and  FIG. 7  is a perspective view of the first side of the box  100 . 
       FIG. 8  is a perspective view of the assembled box  100  wherein the cover is open and the box is configured to receive one or more articles therein. 
       FIG. 9  is a perspective view of the inside of the box looking down at the bottom of the box and perhaps best shows the score lines s 1  and s 2  formed in the bottom panel  12 . 
       FIGS. 10 and 11  are perspective views of the assembled box  100  from inside of the box, wherein the cover is open;  FIG. 10  is a perspective inside view of the second side of the box  100  and  FIG. 11  is a perspective inside view of the first side of the box  100 . 
     It will be appreciated from  FIGS. 3-11  that side panels  22 , 24  overlap with side panel  14  and that side panels  26 , 28  overlap with side panel  16  when the box  100  is in the assembled state; however, the overlap is such that the side panels  22 , 24  do not overlap each other and instead are spaced apart, and side panels  26 , 28  do not overlap each other and instead are spaced apart. Moreover, side panels  22 , 24  extend above and beyond side panel  14 , and side panels  26 , 28  extend above and beyond side panel  16  when the box  100  is in the assembled state. Consequently, the side panels  22 , 24  are in spaced relation to each other and define a gap or opening  40  therebetween in extending beyond the side wall  14 , and the side panels  26 , 28  are in spaced relation to each other and define a gap  42  or opening therebetween in extending beyond the side wall  16 . It is these openings  40 , 42  that the top side panels  32 , 34  extend through, respectively, when the lid is closed. 
       FIGS. 12-16  illustrate the assembled box  100  when in a collapsed state. 
     It is believed that the top side panel  32  of the lid extending between the inside and outside of the box inbetween the first pair of spaced side walls  22 , 24 , and the top side panel  34  of the lid extending between the inside and outside of the box inbetween the second pair of spaced side walls  26 , 28  together create a secure engagement for keeping the box  100  closed and, further, provide greater stacking strength of the box  100  when closed. 
     Specifically,  FIG. 12  is a perspective view of the assembled box  100  in a collapsed state, the box  100  having been folded along fold line f 13 . 
       FIG. 13  is a perspective view of the first side of the assembled box  100  in the collapsed state. 
       FIG. 14  is a perspective view of the assembled box  100  in the collapsed state with a view into the interior of the box. 
       FIG. 15  is a perspective view of the second side of the assembled box  100  in the collapsed state. 
       FIG. 16  is another perspective view of the assembled box  100  in a collapsed state. 
       FIG. 17  is a perspective view of the box in a disassembled state, reduced back to a generally planar form, and serves to illustrate areas at which panels are adhered to maintain the assembled box  100  in the assembled state. 
       FIG. 18  is a similar view to that of  FIG. 17 , but of the opposite planar side, and also serves to illustrate areas at which panels are adhered to maintain the assembled box  100  in the assembled state. In particular, the assembled box  100  is held in the assembled position with glue or other fastening means that may be conventional. The glued areas are revealed at  1002 , 1004 , 1006 , 1008  in  FIG. 17  and at  1010 , 1012 , 1014 , 1016  in  FIG. 18  with reference to the box blank  1000  shown, wherein the assembled box  100  has been pulled apart after being assembled. The single sheet of material preferably is a corrugated cardboard material, as revealed in  FIG. 17  wherein at  1011  a portion of the top surface of the sheet of material has been removed to reveal an interior section of the material. 
       FIGS. 19-24  show a second embodiment of an assembled box  200 , wherein the openings defined in the sides of the box extend lower than in the assembled box  100 . 
     Specifically,  FIG. 19  is a perspective view of the box  200  wherein the cover is open. 
       FIG. 20  is another perspective view of the box  200  wherein the cover is open. 
       FIG. 21  is a perspective view of a first side of the box  200  wherein the cover is open. 
       FIG. 22  is a perspective view of the first side of the box  200  wherein the cover is closed. 
       FIG. 23  is perspective view of the first side of the box  200  wherein the cover is partially open. 
       FIG. 24  is perspective view of the first side of the box  200  wherein the cover is open. 
     A third embodiment of an assembled box is represented by the CAD drawing of a box blank  300  in  FIG. 25 . Fold lines are illustrated, the folding of which forms an assembled box. Furthermore, dimensions are provided for context, are illustrative in nature only, and should not been seen as limiting scope of the broader aspects of the invention. 
     Vents, while not shown, may optionally be added. 
     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.