Patent Publication Number: US-2023159214-A1

Title: Perforated collapsible box

Description:
REFERENCE TO RELATED APPLICATION 
     This application is a continuation of U.S. patent application Ser. No. 17/493,474, filed Oct. 4, 2021, which is a divisional of U.S. patent application Ser. No. 16/886,040, which issued as U.S. Pat. No. 11,230,404, filed May 28, 2020, which claims the benefit of U.S. Provisional Application No. 62/940,436, filed Nov. 26, 2019, which are each hereby specifically incorporated by reference herein in their entireties. 
    
    
     TECHNICAL FIELD 
     This disclosure relates to packaging. Specifically, this disclosure relates to collapsible packaging. 
     BACKGROUND 
     Consumers are increasingly relying on shipping, rather than in-store purchases, to buy goods. These goods are commonly shipped in containers, such as cardboard boxes. To recycle the cardboard boxes, the boxes are broken down, or collapsed, into substantially flat shapes. For many commonly available box types, the boxes are difficult to break down without first removing or cutting much or all of the tape that holds the box together. Removing and cutting the tape can be difficult or time consuming, so many people do not make the effort to do so, which can impede recycling of these boxes. 
     SUMMARY 
     It is to be understood that this summary is not an extensive overview of the disclosure. This summary is exemplary and not restrictive, and it is intended to neither identify key or critical elements of the disclosure nor delineate the scope thereof. The sole purpose of this summary is to explain and exemplify certain concepts of the disclosure as an introduction to the following complete and extensive detailed description. 
     Disclosed is a collapsible box comprising a top panel; a front panel hingedly attached to the top panel; a first side panel hingedly attached to the top panel and the front panel; a second side panel hingedly attached to the top panel and the front panel; a rear panel hingedly attached to the top panel, the first side panel, and the second side panel; and a bottom panel hingedly attached to the front panel, the rear panel, the first side panel, and the second side panel; and wherein a lateral hinge is defined extending at least partially across the front panel, the first side panel, the second side panel, and the rear panel, and wherein the lateral hinge is configured to collapse the collapsible box when a user presses inwards on the first side panel and the second side panel along the lateral hinge. 
     Also disclosed is a blank comprising a front panel defining a lower flap portion and a frame portion coupled together by a front line of weakness; a top subpanel coupled to the lower flap portion by a front hinge; a side panel coupled to the frame portion; and a rear panel coupled to the side panel; and wherein a lateral hinge extends at least partially across the front panel, the side panel, and the rear panel. 
     Also disclosed is a method for collapsing a collapsible box, the method comprising pressing inward on a first side panel and a second side panel of the collapsible box along a lateral hinge, the collapsible box defining the lateral hinge extending at least partially across a front panel, the first side panel, the second side panel, and a rear panel of the collapsible box; and pressing a top panel and a bottom panel of the collapsible box together until the collapsible box is substantially flattened, the top panel and the bottom panel being hingedly coupled to the rear panel. 
     Various implementations described in the present disclosure may include additional systems, methods, features, and advantages, which may not necessarily be expressly disclosed herein but will be apparent to one of ordinary skill in the art upon examination of the following detailed description and accompanying drawings. It is intended that all such systems, methods, features, and advantages be included within the present disclosure and protected by the accompanying claims. The features and advantages of such implementations may be realized and obtained by means of the systems, methods, features particularly pointed out in the appended claims. These and other features will become more fully apparent from the following description and appended claims, or may be learned by the practice of such exemplary implementations as set forth hereinafter. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The features and components of the following figures are illustrated to emphasize the general principles of the present disclosure. The drawings are not necessarily drawn to scale. Corresponding features and components throughout the figures may be designated by matching reference characters for the sake of consistency and clarity. 
         FIG.  1    is a perspective view of a collapsible box comprising a top panel, a front panel, a rear panel, a first side panel, a second side panel, and a bottom panel in accordance with one aspect of the present disclosure. 
         FIG.  2    is a front view of the front panel of the collapsible box of  FIG.  1   . 
         FIG.  3    is a perspective view of the collapsible box of  FIG.  1    with an access flap of the collapsible box articulated to reveal an inner cavity within the collapsible box. 
         FIG.  4    is a perspective view of the collapsible box of  FIG.  1    with the access flap articulated to reveal the inner cavity within the collapsible box. 
         FIG.  5    is a side view of the collapsible box of  FIG.  1    facing the second side panel. 
         FIG.  6    is a front view into the inner cavity of the collapsible box of  FIG.  1   . 
         FIG.  7    is a perspective view of a first step in collapsing the collapsible box of  FIG.  1   . 
         FIG.  8    is another perspective view of the first step in collapsing the collapsible box of  FIG.  1   . 
         FIG.  9    is a perspective view of a second step in collapsing the collapsible box of  FIG.  1   . 
         FIG.  10    is another perspective view of the second step in collapsing the collapsible box of  FIG.  1   . 
         FIG.  11    is another perspective view of the second step in collapsing the collapsible box of  FIG.  1   . 
         FIG.  12    is a plan view of a blank in accordance with another aspect of the present disclosure. 
     
    
    
     DETAILED DESCRIPTION 
     The present disclosure can be understood more readily by reference to the following detailed description, examples, drawings, and claims, and the previous and following description. However, before the present devices, systems, and/or methods are disclosed and described, it is to be understood that this disclosure is not limited to the specific devices, systems, and/or methods disclosed unless otherwise specified, and, as such, can, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular aspects only and is not intended to be limiting. 
     The following description is provided as an enabling teaching of the present devices, systems, and/or methods in its best, currently known aspect. To this end, those skilled in the relevant art will recognize and appreciate that many changes can be made to the various aspects of the present devices, systems, and/or methods described herein, while still obtaining the beneficial results of the present disclosure. It will also be apparent that some of the desired benefits of the present disclosure can be obtained by selecting some of the features of the present disclosure without utilizing other features. Accordingly, those who work in the art will recognize that many modifications and adaptations to the present disclosure are possible and can even be desirable in certain circumstances and are a part of the present disclosure. Thus, the following description is provided as illustrative of the principles of the present disclosure and not in limitation thereof. 
     As used throughout, the singular forms “a,” “an” and “the” include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to “an element” can include two or more such elements unless the context indicates otherwise. 
     Ranges can be expressed herein as from “about” one particular value, and/or to “about” another particular value. When such a range is expressed, another aspect includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent “about,” it will be understood that the particular value forms another aspect. It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint, and independently of the other endpoint. 
     For purposes of the current disclosure, a material property or dimension measuring about X or substantially X on a particular measurement scale measures within a range between X plus an industry-standard upper tolerance for the specified measurement and X minus an industry-standard lower tolerance for the specified measurement. Because tolerances can vary between different materials, processes and between different models, the tolerance for a particular measurement of a particular component can fall within a range of tolerances. 
     As used herein, the terms “optional” or “optionally” mean that the subsequently described event or circumstance can or cannot occur, and that the description includes instances where said event or circumstance occurs and instances where it does not. 
     The word “or” as used herein means any one member of a particular list and also includes any combination of members of that list. Further, one should note that conditional language, such as, among others, “can,” “could,” “might,” or “may,” unless specifically stated otherwise, or otherwise understood within the context as used, is generally intended to convey that certain aspects include, while other aspects do not include, certain features, elements and/or steps. Thus, such conditional language is not generally intended to imply that features, elements and/or steps are in any way required for one or more particular aspects or that one or more particular aspects necessarily include logic for deciding, with or without user input or prompting, whether these features, elements and/or steps are included or are to be performed in any particular aspect. 
     Disclosed are components that can be used to perform the disclosed methods and systems. These and other components are disclosed herein, and it is understood that when combinations, subsets, interactions, groups, etc. of these components are disclosed, that while specific reference of each various individual and collective combinations and permutations of these may not be explicitly disclosed, each is specifically contemplated and described herein, for all methods and systems. This applies to all aspects of this application including, but not limited to, steps in disclosed methods. Thus, if there are a variety of additional steps that can be performed it is understood that each of these additional steps can be performed with any specific aspect or combination of aspects of the disclosed methods. 
     Disclosed is a collapsible box and associated methods, systems, devices, and various apparatus. The collapsible box can comprise a top panel, a front panel, a rear panel, a first side panel, a second side panel, and a bottom panel. It would be understood by one of skill in the art that the disclosed collapsible box is described in but a few exemplary aspects among many. No particular terminology or description should be considered limiting on the disclosure or the scope of any claims issuing therefrom. 
       FIG.  1    is a perspective view of a collapsible box  100  in a closed configuration in accordance with one aspect of the present disclosure. The collapsible box  100  can comprise a top panel  112 , a front panel  114 , a rear panel  116 , a first side panel  118 , a second side panel  120  (shown in  FIG.  2   ), and a bottom panel  122  (shown in  FIG.  3   ). The top panel  112  can comprise a first top subpanel  124   a  and a second top subpanel  124   b . The first top subpanel  124   a  can be hingedly attached to the front panel  114  by a front hinge  126   a . The second top subpanel  124   b  can be hingedly attached to the rear panel  116  by a rear hinge  126   b.    
     The first top subpanel  124   a  can be coupled to the second top subpanel  124   b  by a top tape strip  132  to form the top panel  112 . The first top subpanel  124   a  can define a top hinge  128  between the top tape strip  132  and the front hinge  126   a . The portion of the first top subpanel  124   a  positioned between the front hinge  126   a  and the top hinge  128  can define an upper flap portion  130 . 
     The front panel  114 , the rear panel  116 , the first side panel  118 , and the second side panel  120  can together define a pair of lateral hinges  140   a,b . The lateral hinges  140   a,b  can extend at least partially across each of the front panel  114 , the rear panel  116 , the first side panel  118 , and the second side panel  120 . 
       FIG.  2    is a front view of the front panel  114  of the collapsible box  100  of  FIG.  1   . The front panel  114  can define a lower flap portion  212  and a frame portion  214 , as demarcated by a front line of weakness  216 . The lower flap portion  212  can be attached to the top panel  112  by the front hinge  126   a . The lower flap portion  212  and the upper flap portion  130  (shown in  FIG.  1   ) can together define an access flap  230  of the collapsible box  100 . 
     The frame portion  214  can extend along the intersections with the side panels  118 , 120  and the bottom panel  122 , and the frame portion  214  can be coupled to the side panels  118 , 120  and the bottom panel  122 . The front line of weakness  216  can comprise a pair of side portions  218   a,b , a base line portion  220 , and a finger cutout portion  222 . The side portions  218   a,b  can extend downwards and inwards from the front hinge  126   a  to the base line portion  220 . The base line portion  220  can extend substantially laterally and substantially parallel to the lateral hinges  140   a,b . The finger cutout portion  222  can extend downwards from the base line portion  220  in a shape of a widened “U” or a bathtub shape. 
     The lower flap portion  212  can define a main portion  226  and a finger portion  224 . The main portion  226  can be substantially defined between the front hinge  126   a , the side portions  218   a,b , and the base line portion  220 , and the main portion  226  can define a substantially trapezoidal shape that can taper from the front hinge  126   a  towards the bottom panel  122 . The finger portion  224  can be defined between the main portion  226  and the finger cutout portion  222 , as though the base line portion  220  extended unbroken across the lower flap portion  212 . The finger portion  224  can define a substantially trapezoidal shape. In some aspects, corners of either or both of the main portion  226  and the finger portion  224  can be rounded, as demonstrated by the trapezoidal shape of the finger portion  224  in the present aspect. In other aspects, either or both of the main portion  226  and the finger portion  224  can define a different shape, such as rectangular for example and without limitation. 
     In the present aspect, the side portions  218   a,b  and the base line portion  220  of the front line of weakness  216  can be perforations that are partially cut, but that partially connect the lower flap portion  212  to the frame portion  214 . In the present aspect, the finger cutout portion  222  can be a complete cut, or thru-cut, that extends completely through the front panel  114 . The complete cut can facilitate a user in pressing the finger portion  224  inwards or pulling the finger portion  224  outwards so that the user can grasp the finger portion  224  and pull upon it to tear the perforations of the side portions  218   a,b  and the base line portion  220 . Such an arrangement can facilitate opening of the collapsible box  100  without cutting the top tape strip  132  or a bottom tape strip  532  (shown in  FIG.  5   ). 
     Once the perforations are torn, the access flap  230  can then be articulated upwards about the front hinge  126   a  and the top hinge  128  (shown in  FIG.  1   ) to reveal an inner cavity  300  within the collapsible box  100  in an open configuration, as shown in  FIG.  3   . 
       FIG.  3    is a front perspective view of the collapsible box  100  of  FIG.  1    with the access flap  230  articulated upwards to reveal the inner cavity  300  in the open configuration. The inner cavity  300  can be defined within the collapsible box  100  by the top panel  112 , the front panel  114 , the rear panel  116 , the first side panel  118 , and the second side panel  120 , and the bottom panel  122 . The inner cavity  300  can be enclosed, or concealed, in the closed configuration and exposed, or revealed, in the open configuration. 
     In the aspect shown, the entire access flap  230  can be folded back about the top hinge  128  to expose the inner cavity  300 . Doing so exposes a third top subpanel  324   a  and a fourth top subpanel  324   b  of the top panel  112 . The third top subpanel  324   a  can be attached to the first side panel  118 , and the fourth top subpanel  324   b  can be attached to the second side panel  120 . The third and fourth top subpanels  324   a,b  can be positioned beneath the first and second top subpanels  124   a,b  (shown in  FIG.  1   ). As shown, the third and fourth top subpanels  324   a,b  can each taper rearward towards the rear panel  116  as each extends inward from the respective side panel  118 , 120 . These tapered edges provide additional access to the inner cavity  300  for removing contents from the collapsible box  100 . 
     Optionally, a user may only fold back the lower flap portion  212  about the front hinge  126   a  to expose the inner cavity  300 . By folding the entire access flap  230  about the top hinge  128 , the user is provided greater clearance and access to the inner cavity  300 . 
     As shown, the bottom panel  122  can comprise a first bottom subpanel  312   a , a second bottom subpanel  312   b , a third bottom subpanel  314   a , and a fourth bottom subpanel  314   b . The first bottom subpanel  312   a  can be coupled to the front panel  114 . The second bottom subpanel  312   b  can be coupled to the rear panel  116 . The third bottom subpanel  314   a  and the fourth bottom subpanel  314   b  can be respectively coupled to the first side panel  118  and the second side panel  120 . The third bottom subpanel  314   a  and the fourth bottom subpanel  314   b  can be disposed inward from and be covered by the first bottom subpanel  312   a  and the second bottom subpanel  312   b . The first bottom subpanel  312   a  can be coupled to the second bottom subpanel  312   b  by the bottom tape strip  532 , as shown in  FIG.  5   . 
       FIG.  4    is a front perspective view of the collapsible box  100  of  FIG.  1    with the access flap  230  folded fully backwards about the top hinge  128 . 
       FIG.  5    is a side view of the collapsible box  100  of  FIG.  1    showing the second side panel  120  and the lateral hinges  140   a,b , as well as the tape strips  132 ,  532 . 
       FIG.  6    is a front view of the inner cavity  300  of the collapsible box  100  of  FIG.  1   . In the present aspect, the rear panel  116  can define a center subpanel  680  disposed at a center of the rear panel  116 . The center subpanel  680  can be substantially rectangular in shape, as defined by lines of weakness. The lateral hinges  140   a,b  can extend between the center subpanel  680  and each side panel  118 , 120 , and the lateral hinges  140   a,b  can extend across the rear panel  116 , with the exception of within the center subpanel  680 . 
     Four corner fold lines  684   a - d  can extend between the corners of the center subpanel  680  and the nearest respective corners of the rear panel  116 . A plurality of V-shaped fold lines  686   a - h  can extend between the corners of the rear panel  116  and the lateral hinges  140   a,b . The V-shaped fold lines  386   a - d  can extend between the corners of the rear panel  116  formed with the first side panel  118 . The V-shaped fold lines  686   a - d  can be defined between the corner fold lines  684   a  and  684   d . The V-shaped fold lines  686   e - h  can extend between the corners of the rear panel  116  formed with the second side panel  120 . The V-shaped fold lines  686   e - h  can be defined between the corner fold lines  684   b  and  684   c . The center subpanel  680 , the lateral hinges  140   a,b , the corner fold lines  684   a - d , and the V-shaped fold lines  686   a - h  can cooperate to collapse the collapsible box  110  and to provide the rear panel  116  with a truncated pyramidal shape when collapsed, as further discussed below with respect to  FIGS.  7 - 11   . 
     The collapsible box  110  can be configured to quickly and easily collapse, such as for disposal or recycling, without having to cut or tear the collapsible box  110  or remove any tape. As shown in  FIG.  7    and  FIG.  8   , the first step in collapsing the collapsible box  110  can comprise a user  1000  pressing inward on the side panels  118 , 120  (side panel  118  shown in  FIG.  1   ) along the lateral hinges  140   a,b .  FIG.  7    demonstrates the user  1000  collapsing the collapsible box  100  towards the chest of the user  1000 .  FIG.  8    demonstrates the user  1000  collapsing the collapsible box  100  on a ground surface  800 . 
     As the user  1000  presses inwards on the side panels  118 , 120  along the lateral hinges  140   a,b , the side panels  118 , 120  begin to collapse inwards, and the rear panel  116  begins to take a truncated pyramidal shape with the center subpanel  680  forming the truncated point of the pyramid. 
       FIGS.  9 - 11    demonstrate the next step in collapsing the collapsible box  100 , which can be for the user to press the top panel  112  (shown in  FIG.  1   ) and the bottom panel  122  together until the collapsible box  100  is substantially flattened. In this state, the side panels  118 , 120  can be folded substantially in half such that portions of the respective side panel  118 , 120  on opposite sides of the lateral hinges  140   a,b  (shown in  FIG.  1   ) can be positioned together in facing engagement. In this state, the rear panel  116  can be substantially in the shape of a truncated rectangular pyramid.  FIG.  10    demonstrates the user  1000  pressing the collapsible box  100  upon the ground surface  800  to collapse the collapsible box  100 . 
     As shown, the collapsible box  100  can be manually collapsed without having to remove the tape strips  132 , 532  (shown in  FIG.  5   ). The collapsible box  100  can also be machine collapsible. The ability to collapse the collapsible box  100  without removing tape strips  132 , 532  (or any other tape) can facilitate recycling of the collapsible box  100 . 
       FIG.  12    shows a blank  1200  in accordance with another aspect of the present disclosure. The collapsible box  100  of  FIG.  1    can be constructed from the blank  1200 . The blank  1200  can comprise the front panel  114 , the rear panel  116 , the first side panel  118 , the second side panel  120 , the subpanels  124   a,b , 324   a,b  of the top panel  112  (shown in  FIG.  1   ), and the subpanels  312   a,b , 314   a,b  of the bottom panel  122  (shown in  FIG.  3   ). The blank  1200  can further comprise an end tab  1202 , which in the present aspect can be attached to an end of the blank  1200 , in this aspect to the rear panel  116  opposite from the second side panel  120 . During construction of the collapsible box  100 , the end tab  1202  can be coupled to the first side panel  118 , such as with an adhesive. In other aspects, a different panel  114 , 116 , 118 , 120  can define the end of the blank  1200 , and the end tab  1202  can be attached to one of the panels defining the end of the blank  1200 . 
     Additionally, the lateral hinges  140   a,b  can extend at least partially across each of the front panel  114 , the rear panel  116 , the first side panel  118 , and the second side panel  120  of the blank  1200  to facilitate collapse of the collapsible box  100  (shown in  FIG.  1   ). Measurements shown on the blank  1200  are for exemplary purposes only, and the measurements are not intended to be limiting. The various panels and subpanels can be larger or smaller than indicated, and the ratios between different measurements can vary. 
     In the present aspect, the blank  1200  and the collapsible box  100  can comprise corrugated cardboard. In other aspects, the blank  1200  and/or the collapsible box  100  can comprise a different material, such as paperboard, plastic sheeting, or any other suitable material. The various hinges, fold lines, and lines of weakness identified within the specification can be formed by techniques such as scoring, perforation, pre-creasing, cutting, or any other suitable method. 
     The blank  1200  can be formed through processes such as die-cutting, for example and without limitation. The collapsible box  100  can also be processed with a case erector during construction of the collapsible box  100  form the blank  1200 . 
     One should note that conditional language, such as, among others, “can,” “could,” “might,” or “may,” unless specifically stated otherwise, or otherwise understood within the context as used, is generally intended to convey that certain embodiments include, while other embodiments do not include, certain features, elements and/or steps. Thus, such conditional language is not generally intended to imply that features, elements and/or steps are in any way required for one or more particular embodiments or that one or more particular embodiments necessarily include logic for deciding, with or without user input or prompting, whether these features, elements and/or steps are included or are to be performed in any particular embodiment. 
     It should be emphasized that the above-described embodiments are merely possible examples of implementations, merely set forth for a clear understanding of the principles of the present disclosure. Any process descriptions or blocks in flow diagrams should be understood as representing modules, segments, or portions of code which include one or more executable instructions for implementing specific logical functions or steps in the process, and alternate implementations are included in which functions may not be included or executed at all, may be executed out of order from that shown or discussed, including substantially concurrently or in reverse order, depending on the functionality involved, as would be understood by those reasonably skilled in the art of the present disclosure. Many variations and modifications may be made to the above-described embodiment(s) without departing substantially from the spirit and principles of the present disclosure. Further, the scope of the present disclosure is intended to cover any and all combinations and sub-combinations of all elements, features, and aspects discussed above. All such modifications and variations are intended to be included herein within the scope of the present disclosure, and all possible claims to individual aspects or combinations of elements or steps are intended to be supported by the present disclosure.