U.S. patent application number 10/616432 was filed with the patent office on 2005-01-13 for collapsible reusable box.
This patent application is currently assigned to Kiva Plastics, Inc.. Invention is credited to Stafford, Ronald Thomas JR..
Application Number | 20050006446 10/616432 |
Document ID | / |
Family ID | 33564758 |
Filed Date | 2005-01-13 |
United States Patent
Application |
20050006446 |
Kind Code |
A1 |
Stafford, Ronald Thomas
JR. |
January 13, 2005 |
Collapsible reusable box
Abstract
A collapsible reusable box made of corrugated material with an
automatically lockable bottom includes a bottom side flap, which is
substantially equal in width to the width of the end walls of the
box, and which has a projection on the free end thereof for
extension into a slot at the bottom of the opposite side of the box
to maintain the shape of the box during initial erection and
filling of the box.
Inventors: |
Stafford, Ronald Thomas JR.;
(Glendale, AZ) |
Correspondence
Address: |
LaValle D. Ptak
Ste. B
28435 N. 42nd St.
Cave Creek
AZ
85331
US
|
Assignee: |
Kiva Plastics, Inc.
Woodruff Corporation
|
Family ID: |
33564758 |
Appl. No.: |
10/616432 |
Filed: |
July 9, 2003 |
Current U.S.
Class: |
229/117.04 ;
229/117.01; 229/157 |
Current CPC
Class: |
B65D 5/10 20130101; Y02W
30/80 20150501; B65D 5/3621 20130101; Y02W 30/807 20150501 |
Class at
Publication: |
229/117.04 ;
229/117.01; 229/157 |
International
Class: |
B65D 005/10; B65D
005/36 |
Claims
What is claimed is
1. A collapsible, reusable box including in combination: first and
second side walls and first and second end walls hingedly
interconnected together; first and second bottom end flaps hingedly
connected to the first and second end walls, respectively; first
and second bottom side flaps hingedly connected to the first and
second side walls, respectively, wherein the first bottom side flap
has a width less than the width of the first and second end walls,
and the second bottom side flap has a free edge and a width
substantially equal to the width of the first and second end walls;
a projection on the free edge of the second bottom side flap
extending outwardly therefrom; and a slot aligned with the
projection on the free edge of the second bottom slot flap and
located substantially at the connection of the first side wall and
the first bottom side flap, wherein with the box assembled, the
second bottom side flap overlies the first bottom side flap with
the projection extending into the slot.
2. A collapsible reusable box according to claim 1 wherein the box
is made of corrugated material.
3. A collapsible reusable box according to claim 2 wherein the
corrugated material is corrugated plastic.
4. A collapsible reusable box according to claim 3 wherein the
interconnections of the first and second side walls and the first
and second end walls are formed by foldable hinge lines.
5. The collapsible reusable box according to claim 4 wherein the
first and second bottom end flaps are connected by a foldable hinge
to the first and second end walls, respectively, and wherein the
first and second bottom side flaps are connected by a foldable
hinge to the first and second side walls, respectively.
6. A collapsible reusable box according to claim 5 wherein the
interconnections of the first and second side walls with the first
and second end walls, and the interconnections of the first and
second bottom end flaps with the first and second end walls, and
the interconnections of the first second bottom side flaps with the
first and second side walls are score lines in the material crushed
score lines, or perforated score lines.
7. The collapsible reusable box according to claim 6 wherein the
score lines are either crushed score lines, or perforated score
lines.
8. A collapsible reusable box according to claim 7 wherein the
first and second side walls, the first and second end walls, the
first and second bottom end flaps, and the first and second bottom
side flaps all are fabricated from a unitary of material.
9. A collapsible reusable box according to claim 8 further
including means for interconnecting the first bottom end flap with
the first bottom side flap and the second bottomed flap with the
second bottom side flap along diagonal hinge lines to form an
automatic lock bottom to the box.
10. A collapsible reusable box according to claim 1 wherein the
first and second side walls, the first and second end walls, the
first and second bottom end flaps, and the first and second bottom
side flaps all are fabricated from a unitary of material.
11. A collapsible reusable box according to claim 10 further
including means for interconnecting the first bottom end flap with
the first bottom side flap and the second bottom end flap with the
second bottom side flap along diagonal hinge lines to form an
automatic lock bottom to the box.
12. A collapsible reusable box according to claim 1 wherein the
interconnections of the first and second side walls and the first
and second end walls are-formed by foldable hinge lines.
13. The collapsible reusable box according to claim 12 wherein the
first and second bottom end flaps are connected by a foldable hinge
to the first and second end walls, respectively, and wherein the
first and second bottom side flaps are connected by a foldable
hinge to the first and second side walls respectively.
14. A collapsible reusable box according to claim 1 wherein the
interconnections of the first and second side walls with the first
and second end walls, and the interconnections of the first and
second bottom end flaps with the first and second end walls, and
the interconnections of the first and second bottom side flaps with
the first and second side walls are score lines in the
material.
15. A collapsible reusable box according to claim 14 wherein the
first and second side walls, the first and second end walls, the
first and second bottom end flaps, and the first and second bottom
side flaps all are fabricated from a unitary of material.
16. The collapsible reusable box according to claim 15 wherein the
score lines are either crushed score lines, or perforated score
lines.
17. A collapsible reusable box according to claim 1 further
including means for interconnecting the first bottom end flap with
the first bottom side flap and the second bottom end flap with the
second bottom side flap along diagonal hinge lines to form an
automatic lock bottom to the box.
18. The collapsible reusable box according to claim 1 wherein the
first and second bottom end flaps are connected by a foldable hinge
to the first and second end walls, respectively, and wherein the
first and second bottom side flaps are connected by a foldable
hinge to the first and second side walls, respectively.
Description
BACKGROUND
[0001] Collapsible corrugated boxes made of paperboard and
corrugated plastic currently are extensively used. One form of such
boxes is known as an auto-bottom box; and it is constructed by
means of hinged-together bottom panels, with diagonal hinges
interconnecting bottom panels from the ends of the box with bottom
panels folded from the sides of the box to automatically form a
strong bottom for the box when it is opened or set up. Auto-bottom
boxes are particularly useful for packing and shipping goods at a
central distribution warehouse for shipment to end users in the
form of retail outlets and the like. After the box is unpacked at
the end user, it is collapsed back to a flat configuration and
shipped back to the original warehouse distribution center,
whereupon it once again may be filled and returned to the end
user.
[0002] Auto-bottom boxes, or other types of reusable boxes, cause
substantial savings in the cost of materials to be realized by the
business or other entity employing such reusable boxes over boxes
or containers which are designed only for one time use between a
distribution center and the end user, whereupon they are destroyed
or recycled. In addition to the substantial monetary savings
realized by reusing boxes, significant conservation of raw
materials also is achieved. In view of the awareness of the high
impact of throw-away materials on the environment, reusable
collapsible boxes are achieving widespread acceptance.
[0003] A popular material for reusable collapsible boxes of the
auto-bottom type is corrugated plastic, because of its relatively
greater life expectancy over that of corrugated paperboard.
[0004] Corrugated plastic boxes, however, have some disadvantages
when this material is employed in auto-bottom boxes, inasmuch as
the plastic has a greater memory retention or stiffness compared
with corrugated paperboard.
[0005] A typical corrugated plastic auto-bottom box is disclosed in
the United States patent to Dowd No. 6,349,876. The structure of
this box is typical of the structure of auto-bottom boxes; and the
patent discloses the use of cut or perforated score lines where the
bottom panels interconnect with the side and end panels in order to
reduce the memory of the plastic in assisting the stability of the
box when it initially is erected or set up. Even so, boxes
manufactured in accordance with the disclosure of this patent tend
to skew toward their flattened condition when they are opened up.
This occurs in part because the bottom flaps connected to the sides
are designed to extend less than the full width of the box, in
order to facilitate the collapsing of the box after it has been
emptied and is to be re-shipped back to the original source. This
problem is exacerbated as the thickness and ply of the corrugated
plastic increases, even though double score lines and/or perforated
score lines are employed in an effort to reduce the memory of the
plastic material. It has been found that when a box of this
construction initially is erected for filling, the person filling
the box frequently must use one hand to hold the box in its open
configuration until a certain amount of product has been placed in
the box, whereupon it gains stability.
[0006] It is desirable to provide an improved collapsible reusable
box which overcomes the disadvantages of the prior art, and which
has a desired stable configuration immediately upon set-up when the
box still is empty.
SUMMARY OF THE INVENTION
[0007] It is an object of this invention to provide an improved
collapsible reusable box.
[0008] It is another object of this invention to provide an
improved collapsible reusable corrugated box of the auto-bottom
type.
[0009] It is an additional object of this invention to provide an
improved collapsible reusable box made of corrugated material which
maintains its desired shape immediately upon set-up, without
collapsing on itself.
[0010] It is a further object of this invention to provide an
improved collapsible reusable box made of corrugated material which
employs a locking tab end and mating slot on the bottom of the box
to facilitate set-up of the box.
[0011] In accordance with a preferred embodiment of the invention,
a collapsible reusable box has first and second side walls and
first and second end walls hingedly interconnected together. First
and second bottom end flaps are hingedly connected to the first and
second end walls, respectively; and first and second bottom side
flaps are hingedly connected to the first and second side walls,
respectively. The first bottom side flap has a width which is less
than the width of the first and second end walls; and the second
bottom side flap has a free edge and a width which is substantially
equal to the width of the first and second end walls. The free edge
of the second bottom slide side flap which is opposite the hinged
interconnection of the second side wall has a projection which
extends outwardly from that edge. When the box is set up, the
projection extends into a mating slot located at the junction of
the first side all and the first bottom side flap to maintain the
desired shape of the box after initial set-up and during filling of
the box.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is a plan view of a blank for an auto-bottom box in
accordance with a preferred embodiment of the invention;
[0013] FIG. 2 is a top perspective view of a collapsible
auto-bottom box of a preferred embodiment of the invention, FIGS. 3
and 4 are cross-sectional views taken along the lines 3/4 of FIG. 2
illustrating features of the preferred embodiment of the invention;
and FIG. 5 is a top view of the box shown in FIG. 2 illustrating
features of a preferred embodiment of the invention.
DETAILED DESCRIPTION
[0014] Reference now should be made to the drawings, in which the
same reference numbers are used throughout the different figures to
designate the same or similar components. FIG. 1 is a plan view of
a unitary blank for the construction of a collapsible auto-bottom
box made of corrugated material, preferably corrugated plastic. As
shown in FIG. 1, the blank includes a pair of side walls 11 and 21,
which form the opposite sides for the length of the box, and end
walls 36 and 46, which constitute opposite ends of the box when the
blank is formed into a finished box.
[0015] A full width bottom flap 10 is hingedly attached to the side
wall 11, and a shorter bottom flap 20 is hingedly attached to the
side wall 21. The end walls 36 and 46 have bottom flaps 30 and 40
attached to them, along with corresponding glue flaps or attaching
flaps 32 and 42, which are attached to the bottom end flaps 30 and
40 at diagonal hinge lines 34 and 44, respectively.
[0016] The top of the box is formed by top side flaps 12 and 22,
which are folded down, respectively, from the tops of the side
walls 11 and 21, and end top flaps 38 and 48, which are hingedly
attached to the tops of the end walls 36 and 46, respectively. Fold
lines or creases 39 and 49 are formed in the flaps 38 and 48,
respectively; and these are used to assist in the insertion of
these flaps into L-shaped slots 60 (on the top flap 22) and 70 (on
the top flap 12) to releasably close the top of the box formed from
the blank after it is filled with material for shipping and
handling.
[0017] A vertical flap 50 is attached by a fold line or crease 51
at the edge of the side wall 21. The flap 50 is designed to be
joined to the left-hand edge of the end wall 46 when the box is
constructed. This joining may be by means of ultrasonic bonding,
melt bonding, or an adhesive. Similarly, the flap 32 is joined to
the bottom side flap 20; and the flap 42 is joined to the bottom
side flap 10 by means of melt bonding, ultrasonic bonding, or
adhesive, to form the standard configuration of an auto-bottom
box.
[0018] Each of the end walls 36 and 46 also has a corresponding
handle flap 80 and 90 formed in it in the shape of an inverted
U-shaped cut to form gripping or carrying handles in the box at
opposite ends, as shown most clearly in FIG. 2. The vertical dotted
lines 51,54,56 and 58 and the double dotted line 52 and the single
dotted line 59 all are fold lines or crease lines, which are formed
by conventional techniques into the blank, to allow the various
parts to be folded together to form the completed box shown in FIG.
2.
[0019] Because of the memory inherent in corrugated plastic, when
corrugated plastic material is used for the blank of FIG. 1, it is
preferable to use a double parallel fold line or perforated line 52
along the bottom flaps of the box, since when the box is collapsed
into its shipping or storage configuration, these flaps are folded
substantially 180.degree. against the corresponding side and end
walls 11, 21,36 and 46. All of the score lines or fold lines, as
described previously, are made to be repeatedly folded and opened
to allow the box to be formed in the configuration shown in FIG. 2,
and then once again flattened for shipping subsequent to emptying
of the box at its point of use.
[0020] In order to prevent the inherent memory in corrugated
materials, particularly corrugated plastic material, from tending
to skew or flatten the box when it is initially set up, prior to
filling, the bottom side flap 10 is constructed, as shown most
clearly in FIG. 5, with a width established by the edge 15 which is
substantially equal to the width of the end walls 36 and 46 of the
box; so that the flap 10 extends entirely across the bottom of the
box to cause the free edge 13 of the flap 10 to lie immediately
adjacent the bottom edge of the opposite side wall 21 when the box
is opened to its erected position. This is in contrast to
conventional auto-bottom boxes, in which a bottom flap most nearly
corresponding to the bottom side flap 10 has a width which is less
than the full width of the box. In addition, it should be noted
that the edge 15 is designed to lie parallel to and immediately
adjacent the side wall 36 while the edge 14 is tapered to
facilitate subsequent collapsing of the box.
[0021] The configuration described above for the bottom side panel
10 in and of itself substantially reduces the tendency for the box
to collapse into a flattened configuration when it immediately is
set up. In addition, however, the free edge 13 of the bottom side
flap 10 has a projection 17 located in it. This projection is
aligned with a slot 24 in the bottom side wall 21. Consequently,
when the 14 box is erected and the bottom side flap 10 is pushed
downwardly in the direction of the arrow shown in FIG. 3, it causes
the projection 17 to pop into the slot 24 to hold the bottom side
flap 10 in its downward position. This, in turn, holds down the
bottom side flap 20; and the entire box is stable in its erected
configuration, as shown in FIG. 2. FIG. 4 shows the extension of
the projection 17 into the slot 24 for the assembled box.
[0022] After the box has been emptied of its contents, and it
desired to flatten the box, a return to the diagonally flattened
condition readily is effected by a slight outward pressure on the
inside of the side wall 21 to release the projection 17 from the
slot 24. This may be accompanied by lifting of the edge 14 of the
bottom side flap 10; although the natural memory of the corrugated
material, particularly plastic corrugation, is such that once the
projection 17 is released from the slot 24, the bottom side flap 10
tends to raise upwardly in the opposite direction of the arrow of
FIG. 3 to the position shown in FIG. 3 to facilitate the subsequent
re-flattening or collapse of the box.
[0023] The incorporation of the projection 17 on a substantially
full-width bottom side flap 10 and the utilization of a
corresponding mating slot 24 to modify an otherwise standard blank
for an auto-bottom box requires no change to the box making
machinery. However, a significant improvement in the performance of
auto-bottom boxes, particularly made of corrugated plastic
material, is achieved. At the same time, the reusable
characteristics of the auto-bottom box have not been compromised;
and the construction allows for multiple cycles of erection and
collapsing of the box, employing all of the advantages present in
such auto-bottom box constructions.
[0024] The foregoing description of the preferred embodiment of the
invention is to be considered as illustrative and not as limiting.
Various changes and modifications will occur to those skilled in
the art for performing substantially the same function, in
substantially the same way, to achieve substantially the same
result, without departing from the true scope of the invention as
defined in the appended claims.
* * * * *