U.S. patent application number 15/829170 was filed with the patent office on 2018-05-10 for foldable box.
The applicant listed for this patent is IdeaStream Consumer Products, LLC. Invention is credited to Benjamin Hietanen, Jinyuan Li, Zhenghong Li, Daniel V. Perella, Jensen Tuen.
Application Number | 20180127140 15/829170 |
Document ID | / |
Family ID | 62065309 |
Filed Date | 2018-05-10 |
United States Patent
Application |
20180127140 |
Kind Code |
A1 |
Perella; Daniel V. ; et
al. |
May 10, 2018 |
Foldable Box
Abstract
A foldable box having a first, substantially flat and unfolded
configuration which can be easily and conveniently transformed into
a second, three-dimensional configuration capable of retaining one
or more items.
Inventors: |
Perella; Daniel V.;
(Cleveland, OH) ; Hietanen; Benjamin; (Cleveland,
OH) ; Li; Zhenghong; (Shenzhen City, CN) ;
Tuen; Jensen; (Fanling, HK) ; Li; Jinyuan;
(Shenzhen City, CN) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
IdeaStream Consumer Products, LLC |
Cleveland |
OH |
US |
|
|
Family ID: |
62065309 |
Appl. No.: |
15/829170 |
Filed: |
December 1, 2017 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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29583811 |
Nov 9, 2016 |
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15829170 |
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29583815 |
Nov 9, 2016 |
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29583811 |
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29585394 |
Nov 23, 2016 |
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29583815 |
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29585399 |
Nov 23, 2016 |
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29585394 |
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29610397 |
Jul 12, 2017 |
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29585399 |
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29611998 |
Jul 27, 2017 |
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29610397 |
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29612002 |
Jul 27, 2017 |
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29611998 |
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29611995 |
Jul 27, 2017 |
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29612002 |
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29611992 |
Jul 27, 2017 |
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29611995 |
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29623678 |
Oct 26, 2017 |
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29611992 |
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29623680 |
Oct 26, 2017 |
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29623678 |
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29623683 |
Oct 26, 2017 |
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29623680 |
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29623686 |
Oct 26, 2017 |
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29623683 |
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29623688 |
Oct 26, 2017 |
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29623686 |
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29623689 |
Oct 26, 2017 |
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29623688 |
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29623693 |
Oct 26, 2017 |
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29623689 |
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29627144 |
Nov 22, 2017 |
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29623693 |
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29613487 |
Aug 10, 2017 |
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29627144 |
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29613491 |
Aug 10, 2017 |
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29613487 |
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62428602 |
Dec 1, 2016 |
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62428606 |
Dec 1, 2016 |
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62476914 |
Mar 27, 2017 |
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62485091 |
Apr 13, 2017 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B65D 2313/04 20130101;
B65D 5/3642 20130101; B65D 5/241 20130101; B65D 5/3657 20130101;
B65D 5/48002 20130101; B65D 5/365 20130101; B65D 2313/02 20130101;
B65D 2313/08 20130101 |
International
Class: |
B65D 5/36 20060101
B65D005/36; B65D 5/48 20060101 B65D005/48; B65D 5/24 20060101
B65D005/24 |
Claims
1. A foldable box having a plurality of interchangeable
configurations, the box comprising: a first configuration wherein
the box is substantially flat; and a second configuration wherein
the box is an assembled three-dimensional shape; wherein the first
and second configurations are interchangeable.
2. The foldable box of claim 1, wherein the box further comprises a
first set of panels and a second set of panels, each set of panels
comprising one or more panels having a length and a width.
3. The foldable box of claim 2, wherein each panel comprises a
single piece of panel material.
4. The foldable box of claim 3, wherein the box further comprises a
lining material extending over at least a portion of the first and
second set of panels, the lining material forming a foldable
attachment portion connecting at least a first and a second
panel.
5. The foldable box of claim 4, wherein the at least first and
second panels further comprise a second attachment portion.
6. The foldable box of claim 5, wherein the second attachment
portion comprises at least one of a hook, loop fastener, tack,
staple, latch, snap, releasable adhesive, magnet, and button.
7. The foldable box of claim 5, wherein the second attachment
portion of the at least first and second panels forms a reversible
connection between the first and second panels.
8. The foldable box of claim 2, wherein the box further comprises a
third set of panels, the third set of panels comprising one or more
panels having a length and a width.
9. The foldable box of claim 2, wherein the one or more panels
includes at least one of a: left end panel, left side panel, bottom
panel, right side panel, right end panel, back panel, top panel,
top end panel, and front panel.
10. The foldable box of claim 3, wherein the panel material
comprises at least one of a: heavy weight cardboard, heavy weight
paperboard, medium weight cardboard, fiberboard, plastic, composite
material, metal, or wood.
10. The foldable box of claim 9, wherein the box further comprises
a third configuration wherein the box is substantially flat and one
or more of the panels is layered on top of at least one other
panel.
11. A method for manufacturing a foldable box having a plurality of
interchangeable configurations, the method comprising: selecting a
material suitable for use in a foldable box; cutting the selected
material into a desired number of panels, each panel having a
desired size and shape; optionally applying a first liner material
to at least one surface of the panels; forming at least one
attachment portion and at least one foldable connector on the
panels; and optionally applying a second liner material to at least
a second surface of the panels.
12. The method of claim 11, wherein method further comprising
forming a second attachment portion on one or more of the panels,
the second attachment portion comprising at least one of a hook,
loop fastener, tack, staple, latch, snap, releasable adhesive,
magnet, and button; wherein the first liner material forms a
foldable attachment portion connecting at least a first and a
second panel.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the priority benefit of U.S.
Provisional Patent Application Ser. No. 62/428,602, filed Dec. 1,
2016, U.S. Provisional Patent Application Ser. No. 62/428,606,
filed Dec. 1, 2016, U.S. Provisional Patent Application Ser. No.
62/476,914, filed Mar. 27, 2017; U.S. Provisional Patent
Application Ser. No. 62/485,091, filed Apr. 13, 2017; and is a
continuation-in-part of U.S. patent application Ser. No. 29/583,811
filed Nov. 9, 2016; U.S. patent application Ser. No. 29/583,815
filed Nov. 9, 2016; U.S. patent application Ser. No. 29/585,394
filed Nov. 23, 2016; U.S. patent application Ser. No. 29/585,399
filed Nov. 23, 2016; U.S. patent application Ser. No. 29/610,397
filed Jul. 12, 2017; U.S. patent application Ser. No. 29/611,998
filed Jul. 27, 2017; U.S. patent application Ser. No. 29/612,002
filed Jul. 27, 2017; U.S. patent application Ser. No. 29/611,995
filed Jul. 27, 2017; U.S. patent application Ser. No. 29/611,992
filed Jul. 27, 2017; U.S. patent application Ser. No. 29/623,678
filed Oct. 26, 2017; U.S. patent application Ser. No. 29/623,680
filed Oct. 26, 2017; U.S. patent application Ser. No. 29/623,683
filed Oct. 26, 2017; U.S. patent application Ser. No. 29/623,686
filed Oct. 26, 2017; U.S. patent application Ser. No. 29/623,688
filed Oct. 26, 2017; U.S. patent application Ser. No. 29/623,689
filed Oct. 26, 2017; U.S. patent application Ser. No. 29/623,693
filed Oct. 26, 2017; U.S. patent application Ser. No. 29/627,144
filed Nov. 22, 2017; U.S. patent application Ser. No. 29/613,487
filed Aug. 10, 2017; and U.S. patent application Ser. No.
29/613,491 filed Aug. 10, 2017, all of which are incorporated
herein by reference.
BACKGROUND ON THE INVENTION
[0002] Boxes are used every day for many purposes such as storage
and shipping. Typically, when boxes are manufactured by a
manufacturing company, the boxes are manufactured and shipped in a
three-dimensional form. The manufacturing company then must pay for
additional shipping cost for empty space within the box.
Additionally, the boxes are also more susceptible to damage when
shipped in this fashion. To overcome the high shipping cost and
inefficient shipping of such boxes, box designers have made
collapsible boxes. These boxes are designed to be shipped flat and
need to be constructed by the end user of the box. End user
construction of these boxes often requires time-consuming processes
such as the application of additional or extra materials (e.g.,
glue, tape, etc.). These actions can be complicated,
time-consuming, and labor intensive to the end user, thereby making
the assembly of such boxes undesirable.
[0003] Non-limiting examples of such prior art foldable boxes
include U.S. Patent Publication Nos. 2004/0140345; 2006/0151856;
2010/0006632; 2011/0121062; 2012/0037693 and 2014/0231495, and U.S.
Pat. Nos. 2,957,617; 6,568,586; 8,573,471; 8,960,527 and RE 46563,
all of which are incorporated herein by reference.
[0004] In view of the current state of foldable boxes, there is a
need for a foldable box having one or more interchangeable
configurations, and which can be easily and conveniently
transformed between such interchangeable configurations thereby
minimizing the time required for assembly and/or disassembly of the
foldable box.
SUMMARY OF THE INVENTION
[0005] The present invention is directed to a foldable box having
one or more interchangeable configurations, and which can be easily
and conveniently transformed between such interchangeable
configurations, thereby minimizing the time required for assembly
and/or disassembly of the foldable box.
[0006] In one non-limiting aspect of the present invention, there
is provided a foldable box having a plurality of interchangeable
configurations. In one non-limiting aspect of the present
invention, there is provided a foldable box having a first,
unfolded configuration in which the foldable box is substantially
flat, and a second, folded and/or three-dimensional configuration
in which the foldable box is fully assembled. As described above,
the first and second configurations of the foldable box are
interchangeable. For example, the first configuration (i.e., the
flat, unfolded foldable box) can be easily and conveniently
transformed into the second configuration (i.e., the folded,
three-dimensional foldable box), and, similarly, the second
configuration can be easily and conveniently transferred into the
first configuration; however, this is not required.
[0007] The materials used to form the foldable box are
non-limiting. The foldable box can be formed from a single type of
material; however, this is not required. As can be appreciated, the
foldable box can be formed from one or more types of material.
Generally, the foldable box is formed from a moderately rigid
material such as, for example, a heavy weight cardboard material or
paperboard material; however, this is not required. As can be
appreciated the foldable box can be formed from other or
alternative materials (e.g., flexible materials, semi-rigid
materials, medium weight cardboard, fiberboard, rigid plastic,
flexible plastic, composite materials, metal, wood, etc.). The
material of the foldable box is typically selected so as to allow
folding, bending, or other manipulations of the foldable box
without losing the structural integrity of the material; however,
this is not required. In one non-limiting configuration, the
thickness of the material used to form the foldable box can be from
about 0.01 mm to about 10 mm, more particularly about 2 mm;
however, this is not required.
[0008] In another and/or alternative non-limiting aspect of the
present invention, the material of the foldable box can be lined
with one or more additional types of material; however, this is not
required. In one non-limiting embodiment, the material of the
lining is a laminate material; however, other or alternative liners
can be used (e.g., cloth, cloth-like materials, tape, tape-like
materials, plastic material, fabric material, etc.). Generally, the
lining (when used) is designed to completely cover at least a first
surface of the foldable box; however, this is not required. In one
non-limiting configuration, the lining completely covers a first
surface of a portion of the foldable box, wraps around the
perimeter thereof, and terminates at a position at or near the
perimeter on a second surface of the portion of the foldable box;
however, this is not required. The lining can be used to provide an
aesthetically pleasing appearance to one or more users of the
foldable box; however, this is not required. As such, the lining
can include designs, surface structures, etc. on a surface thereof;
however, this is not required. The lining (when used) typically has
a thickness less than or equal to the material used to form the
foldable box; however, this is not required. As such, the lining
can be designed to provide support to the foldable box; however,
this is not required. The lining can be used to connect together
one or more pieces of the foldable box (e.g., connect together
multiple pieces of paperboard panels that are used to form one or
more sides of the foldable box, etc.), and/or be used to form a
hinge or foldable region between two or more pieces of the foldable
box; however, this is not required.
[0009] The shape of the foldable box is non-limiting. In one
non-limiting configuration, the shape of the top plan view of the
foldable box in its first, unfolded configuration is rectangular or
square; however, the shape of the top plan view foldable box in its
first, unfolded configuration can have other shapes. In another
and/or alternative non-limiting configuration, the shape of the top
plan view of the foldable box in its second, three-dimensional
configuration is rectangular or square; however, the shape of the
top plan view of the foldable box in its second, three-dimensional
configuration can have other shapes. Similarly, the size of the
foldable box in its folded and unfolded configuration is
non-limiting. In one specific non-limiting configuration, when the
foldable box in the folded configuration has a top plan rectangular
shape, the dimensions of the foldable box can be about 1-6 inches
in height by about 2-20 inches in width by about 1-18 inches in
length; however, the foldable box can have other dimensions. In one
specific non-limiting configuration, when the foldable box in the
folded configuration has a top plan square shape, the dimensions of
the foldable box can be about 1-6 inches in height by about 2-20
inches in width by about 2-20 inches in length; however, the
foldable box can have other dimensions.
[0010] In one non-limiting aspect of the present invention, there
is provided a foldable box having a first set of panels and a
second set of panels; however, this is not required. The second set
of panels is designed to be foldably connected to the first set of
panels; however, this is not required. This non-limiting
configuration provides a non-limiting advantage in that all
components of the foldable box are connected such that no further
assembly is required by the end user, a common disadvantage of many
existing foldable box types in which at least one component must
typically be assembled separately and connected to the remaining
portion of a box. This non-limiting configuration also has the
advantage that the foldable box, after being assembled into its
folded configuration, can later be unassembled into its original
unfolded position. Foldable boxes that require the permanent
connection of one or more components during assembly cannot
thereafter be unassembled into its original unfolded position
without having to damage one or more portions of the foldable
box.
[0011] In another and/or alternative non-limiting aspect of the
present invention, the first set of panels further comprises a
front panel, a bottom panel, a back panel, a top panel and a top
end panel arranged in a predetermined sequence; however, this is
not required. In one non-limiting configuration, the front panel,
bottom panel, back panel, top panel, and top end panel are defined
portions in a single piece of material; however, this is not
required. In such a configuration, the front panel, bottom panel,
back panel, top panel and top end panel can be defined via cutting,
scoring, creasing and/or folding; however, other or alternative
methods can be used. The cutting, scoring, creasing and/or folding
(when used) also provides the foldable connections between adjacent
panels of the first set of panels. The size and shape of the
foldable connections are non-limiting. Generally, the foldable
connections are designed to permit from about 1.degree. to about
180.degree. angles of relative rotation between adjacent panels;
however, this is not required. For example, from a flat, unfolded
configuration, the connection arrangements can permit the front
panel to be rotated about 90.degree. relative to the bottom panel,
the back panel to be rotated about 90.degree. relative to the
bottom panel, the back panel to be rotated about 90.degree.
relative to the top panel, and the top end panel to be rotated
about 90.degree. relative to the top panel; however, this is not
required. As such, when the foldable box is in its first, unfolded
configuration, the front panel, bottom panel, back panel, top panel
and top end panel are designed to lay substantially flat and, in
its second, three-dimensional configuration, the foldable box can
be folded such that the top end panel is parallel to the front and
back panels, and the top panel is parallel to the bottom panel.
Thus, the front panel, bottom panel, back panel, top panel and top
end panel of the first set of panels are foldably connected in a
predetermined sequence along a crease and/or fold; however, this is
not required. In such a configuration, the front panel is foldably
connected to the bottom panel along a first crease, the back panel
is foldably connected to the bottom panel along a second crease,
the back panel is foldably connected to the top panel along a third
crease, and the top end panel is foldably connected to the top
panel along a fourth crease; however, this is not required. As can
be appreciated, when a liner or a separate hinge or a hinge
material is used, the liner or the separate hinge or the hinge
material can be used to allow separate panels to be connected
together and folded with respect to one another; however, this is
not required.
[0012] The size and shape of each of the panels in the first set of
panels is non-limiting. In one non-limiting configuration, each of
the panels in the first set of panels is rectangular or square,
thereby providing a substantially rectangular or square box when
folded/assembled and viewed from the top plan view; however, this
is not required. The first set of panels of the foldable box can
include panels of one or more different sizes; however, this is not
required. In one non-limiting configuration, the first set of
panels comprises a bottom panel and a top panel which are greater
in size that the front panel, the back panel and the top end panel;
however, this is not required. In another and/or alternative
non-limiting configuration, the front panel, back panel and top end
panel are the same or similar in size and shape; however, this is
not required.
[0013] In another and/or alternative non-limiting aspect of the
present invention, the second set of panels further comprises a
left side panel and a right side panel. Generally, the left and
right side panels are formed from separate pieces of material;
however, this is not required. The size and shape of the left and
right side panels are non-limiting. In one non-limiting
configuration, the left and right side panels are rectangular in
shape and formed from the same material as the first set of panels;
however, this is not required. The second set of panels are
designed to be adhesively and/or foldably connected to the first
set of panels; however, this is not required. As can also be
appreciated, the second set of panels can be designed to be snap
connected to the first set of panels; however, this is not
required.
[0014] A lining material can optionally be applied to the left and
right side panels; however, this is not required. The lining
material can be applied such that a portion of the lining material
extends at least partially over the lengthwise edge of the left and
right side panels, thereby forming an attachment portion suitable
for facilitating attachment of the left and right side panels to
the first set of panels; however, this is not required. For
example, the attachment portion of the left and right side panels
can be connected (e.g., glue, tape, adhesive, tack, staple, melted
connection, hook and loop fastener, snap, etc.) at or near
oppositely disposed edges of the bottom panel of the first set of
panels; however, this is not required. As such, the attachment
portion of the second set of panels provides a foldable and
adhesive connection to the first set of panels. As can be
appreciated, the attachment portion of the second set of panels can
include a snap connection to the first set of panels
[0015] In another and/or alternative non-limiting aspect of the
present invention, the foldable box optionally incorporates a
plurality of foldable connectors. In one non-limiting
configuration, the lining material is applied to the left and right
side panels such that the lining material extends at least
partially over the side edges of the left and right side panels,
thereby forming a plurality of foldable connectors. The plurality
of foldable connectors can be foldable relative to the side edges
of the left and right side panels, and provide a connection means
wherein the left and right side panels can be connected to the
first set of panels; however, this is not required. The inherent
flexibility, durability and flexibility of lining materials
provides a suitable hinge and/or foldable connection; however, this
is not required. The connection arrangements are designed to
connect the left and right side panels to the front and back panels
to facilitate lifting of the front and back panels when the left
and right side panels are lifted; however, this is not required. As
such, the front panel, back panel and left and right side panels
can be lifted in unison to an upright position relative to the
bottom panel; however, this is not required and the work required
by the end user of the box is significantly minimized. Furthermore,
the end user does not need to apply any additional glue and/or tape
to the foldable box.
[0016] The shape and size of each of the plurality of foldable
connectors are non-limiting. Generally, all the foldable connectors
are the same in size and shape; however, this is not required. In
one non-limiting configuration, each foldable connector comprises a
generally square shape having a diagonal crease and/or groove
thereby providing a first and second connectable section. The
outside surface of a first connectable section can be designed to
be connected to an interior surface of the front and/or back panel.
In one specific non-limiting configuration, a first connectable
section of a first foldable connector of the right side panel is
connected to the back panel, a first connectable section of a
second foldable connector of the right side panel is connected to
the front panel, a first connectable section of a first foldable
connector of the left side panel is connected to the back panel,
and a first connectable section of a second foldable connector of
the left side panel is connected to the front panel; however, this
is not required. The type of connection used is non-limiting. For
example, the outside surface of the first connectable section can
be connected to the interior surface of the front and/or back panel
via an adhesive such as, for example, glue, tape, hook and loop
fastener, melted connection, staple, tack, snap, etc.; however,
this is not required. The second connectable section can be
designed to be connected along an edge to a side edge of the left
and/or right side panel.
[0017] In another and/or alternative non-limiting configuration,
the outside surface of the second connectable section can also be
designed to be connected to the interior surface of the front
and/or back panel; however, this is not required. In one
non-limiting configuration, the outside surface of the second
connectable section of each foldable connector can include an
adhesive material; however, this is not required. The adhesive
material (when used) can be positioned on or closely adjacent to
one or more edges of the second connectable region and can cover a
majority of the second connectable region; however, this is not
required. Generally, the adhesive material is a preapplied material
that includes a removable top protective release liner that, when
removed, exposes a top adhesive surface of the adhesive material.
One non-limiting advantage to providing a preapplied adhesive
material is that the end user does not need to apply any additional
materials to the foldable box prior to its use. When exposed, the
top adhesive surface of the adhesive material is designed to bond
with a portion of the front and/or back panels that is positioned
at or near the second connectable section; however, this is not
required. In such a configuration, when the foldable box is
converted into its second, three-dimensional structure, the
adhesive material on the outside surface of the second connectable
section can at least partially hold the foldable box in a
three-dimensional configuration; however, this is not required. As
can be appreciated, other or alternative releasable connection
arrangements can optionally be used to connect the second
connectable region of each foldable connector to the front and/or
back panels; however, this is not required. As can be appreciated,
the adhesive connection can be designed to form a permanent
connection with a portion of the front and/or back panels that is
positioned at or near the second connectable section so as to
permanently hold the foldable box in the three-dimensional
configuration; however, this is not required. As can also be
appreciated, the adhesive connection can be designed to form a
releasable and reusable connection with a portion of the front
and/or back panels that is positioned at or near the second
connectable section so the foldable box can be unfolded from the
three-dimensional configuration back to the unfolded configuration;
however, this is not required.
[0018] In another and/or alternative non-limiting aspect of the
present invention, the foldable box includes a protective material
provided on one or more surfaces of the foldable box; however, this
is not required. The type of protective material is non-limiting.
The protective material can be the same or different than the
lining (when used); however, this is not required. In one
non-limiting configuration, the protective material is a durable
paper material; however, other or alternative types of materials
can be used (e.g., fabric, composition material, plastic, metal,
wood, fiberglass, etc.). In one non-limiting configuration, the
protective material can be applied to a second surface of the first
set of panels via an adhesive (e.g., glue, tape, etc.); however,
other or alternative connection arrangements can be used (melted
connection, tack, staple, snap, etc.). Alternatively, the
protective material can be a layer of tape; however, this is not
required. The protective material (when used) is designed to cover
a majority of the second surface of the first set of panels;
however, this is not required. In one non-limiting configuration,
the protective material is applied to the second surface of the
first set of panels such that the protective material extends at
least partially over the portion of the lining which terminates at
or near the perimeter of the first set of panels; however, this is
not required. In addition to providing improved durability and
structural rigidity to the panels of the foldable box, the
protective material also provides improved support at or near the
foldable connections (i.e., creases and/or folds) between panels of
the first set of panels. Optionally, all of the panels includes a
protective material; however, this is not required.
[0019] In another and/or alternative non-limiting aspect of the
present invention, the foldable box can include a connection
arrangement provided between the top end panel and the front panel
such that, when the foldable box is transformed into its second,
three-dimensional configuration, the top end panel can releasably
connect to the front panel; however, this is not required. As such,
the connection arrangement between the top end panel and the front
panel is capable of at least partially retaining the foldable box
in its second, three-dimensional configuration; however, this is
not required.
[0020] The type of connection arrangement used between the top end
panel and the front panel is non-limiting. In one non-limiting
configuration, a magnetic connection arrangement is used; however,
this is not required. In such a configuration, the top end panel
can include one or more magnets (or magnetically attractive
materials) and the front panel can include one or more magnets (or
magnetically attractive materials) corresponding to the one or more
magnets (or magnetically attractive materials) of the top end
panel; however, this is not required. As can be appreciated, other
connection arrangements can be used (e.g., releasable adhesive,
hook and loop fastener, latch, snap, button, etc.). When two or
more magnets are used, the magnets generally have opposite
polarity. In one non-limiting configuration, the magnets are
positioned within the material of the front panel and the top end
panel, spaced apart from the edge of the front and top end panels
and the lining; however, this is not required. This size, shape and
configuration of the magnets are non-limiting. In one non-limiting
configuration, the thickness of each magnet is selected to be about
the same or less than the thickness of the material of the panels
such that the magnets are completely enclosed; however, this is not
required. As such, the magnets are provided within the material of
the front and top end panels so that the magnets are not visible to
a user. In another configuration, one panel includes one or more
magnets and the other panel includes a material that is
magnetically attracted to a magnetic (e.g., iron material,
etc.).
[0021] In another and/or alternative non-limiting aspect of the
present invention, the foldable box is designed to be easily and
conveniently converted from a flat, unfolded configuration to a
three-dimensional configuration. In operation, a user can lift the
left and right side panels upward towards a vertical orientation.
In doing so, the front and back panels will be also be caused to be
rotated or pivot upwards to a vertical orientation via the
plurality of connection arrangements connecting the right and left
side panels of the second set of panels to the front and back
panels of the first set of panels; however, this is not required.
As such, the foldable box can be easily and conveniently changed
from an unfolded position to a three-dimensional configuration.
When the foldable box is in its three-dimensional configuration,
the foldable box can be filled with one or more items to be stored
and/or held within the foldable box.
[0022] In another and/or alternative non-limiting aspect of the
present invention, the foldable box can optionally be folded from
its flat, unfolded configuration into a space-saving, compact
configuration; however, this is not required. The compact
configuration (when used) can facilitate space-saving storage
and/or transport of one or more foldable boxes; however, this is
not required. In one non-limiting configuration, when the compact
configuration is used, the gap between the top panel and the back
panel is generally designed to permit about 180.degree. rotation,
thereby accommodating the combined thicknesses of the back panel,
the top panel and the left and/or right side panels; however, this
is not required.
[0023] In another and/or alternative non-limiting aspect of the
present invention, the first set of panels of the foldable box can
optionally comprise a plurality of individual panels which can be
attached (e.g., glued, taped, melted connection, hook and loop
fastener, etc.) to one surface of a liner (e.g., cover, laminate
material, etc.) with small gaps and/or spaces between adjacent
individual panels; however, this is not required. The small gaps
and/or spaces (when used) can provide the foldable connection
between individual panels of the first set of panels; however, this
is not required. In such a configuration, the first and second sets
of panels can optionally be laminated together; however, this is
not required. In such a configuration, the left and right side
panels are spaced apart from the bottom panel; however, this is not
required. The small gap and/or space between the left and right
side panels can be designed to provide the foldable connection
between the left and right side panels and the bottom panel of the
foldable box; however, this is not required. In one non-limiting
configuration, the left and right side panels are foldably
connected at or near the side edges of the bottom panel; however,
this is not required. In one specific non-limiting embodiment, the
left and right side panels are spaced inward a predetermined
distance from the side edges of the bottom panel; however, this is
not required. Generally, the space between the left and/or right
side panels and the bottom panel is designed to permit the left
and/or right side panels to rotate about 70-150.degree. relative to
the bottom panel; however, this is not required. As such, in a
three-dimensional configuration, the left and right side panels can
be moved to be parallel to each other; however, this is not
required.
[0024] In another and/or alternative non-limiting aspect of the
present invention, there is provided a method for manufacturing a
foldable box in accordance with the present invention. As described
above, the foldable box can be formed from a first set of panels
and a second set of panels; however, this is not required. The
method for manufacturing the foldable box of the present invention
can include: 1) selecting a material suitable for use in a foldable
box, 2) cutting the selected material into a first and second set
of panels having a desired size and shape, 3) optionally applying a
lining material to at least a first surface of the first set of
panels, 4) optionally applying a lining material to at least a
first surface of the second set of panels forming at least one
attachment portion and at least one foldable connector, 5)
optionally applying a protective cover to at least a first surface
of the first and/or second set of panels, 6) defining one or more
panels within the first set of panels, 7) forming foldable
connections between the one or more panels defined within the first
set of panels by some means (e.g., cutting, scoring, folding the
first set of panels, forming a hinge between the first set of
panels, etc.), and/or 8) connecting the second and third set of
panels to the first set of panels. The method for manufacturing a
foldable box can further comprise the steps of: a) connecting a
first portion of the at least one foldable connector to the first
set of panels, and/or b) applying a snap or an adhesive having a
removable protective liner or use some other type of connector to a
second portion of the at least one foldable connector.
[0025] In another and/or alternative non-limiting aspect of the
present invention, there is provided a method for transforming the
foldable box of the present invention from its first, unfolded
configuration to its second, three-dimensional configuration.
Initially, the foldable box is provided in an unfolded
configuration wherein the first set of panels is substantially flat
(i.e., the front panel, bottom panel, back panel, top panel and top
end panel foldable connections are all at approximately
180.degree.), and the second set of panels lays on top of the first
set of panels. The left and right side panels can be lifted
upwards, thereby rotating the left and right side panels relative
to the bottom panel. In lifting the left and right side panels
upwards, the back and front panels of the first set of panels are
caused to lift upwards, thereby also rotating the back and front
panels relative to the bottom panel. The protective release liner
(when used) can be removed from the preapplied adhesive material,
thereby exposing the adhesive surface of the adhesive material of
the foldable connectors. The left and right side panels are lifted
upwards until they reach an approximately vertical position (i.e.,
about 90.degree. relative to the bottom panel) wherein the adhesive
surface of the adhesive material contacts and bonds with a portion
of the front and/or back panels. A snap arrangement can also or
alternatively be used. The top panel can then be rotated relative
to the back panel such that the top panel covers the opening formed
by the bottom panel, left side panel, right side panel, back panel
and front panel. The top end panel can be rotated relative to the
top panel to form a releasable connection. For example, when one or
more magnets are provided in the top end panel and/or front panel
and are caused to approach one or more connectors (e.g., magnet,
hook and loop fastener, etc.) provided on or in the other panel of
the foldable box, the magnetic force between the one or more
magnets on the top end panel and/or the front panel is sufficient
to releasably and securely close the foldable box in a
three-dimensional configuration.
[0026] These and other objects and advantages will become apparent
to those skilled in the art upon reading and following the
description taken together with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] Reference may now be made to the drawings which illustrate
various non-limiting embodiments that the invention may take in
physical form and in certain parts and arrangement of parts
wherein:
[0028] FIG. 1 is a top perspective illustration of a foldable box
in a flat configuration in accordance with one non-limiting aspect
of the present invention;
[0029] FIG. 2 is a bottom perspective illustration of the foldable
box of FIG. 1 in its transition from a flat, unfolded configuration
into its folded, three-dimensional configuration;
[0030] FIG. 3 is a perspective illustration of the foldable box of
FIGS. 1-2 in its transition from a flat, unfolded configuration
into its folded, three-dimensional configuration;
[0031] FIG. 4 is a perspective illustration of the foldable box of
FIGS. 1-3 in its folded, assembled three-dimensional configuration
with the lid open;
[0032] FIG. 5 is a perspective illustration of the foldable box of
FIGS. 1-4 in its folded, assembled three-dimensional configuration
with the lid closed;
[0033] FIG. 6 is a cross-sectional perspective illustration of the
foldable box taken along line 6-6 of FIG. 5;
[0034] FIG. 7 is a top plan illustration of a foldable box in
accordance with another non-limiting aspect of the present
invention;
[0035] FIGS. 8-9 is a perspective illustration of the foldable box
of FIG. 7 in its transition from flat, unfolded configuration into
its folded, three-dimensional configuration;
[0036] FIG. 10 is a back perspective illustration of the assembled
foldable box of FIGS. 7-9; and
[0037] FIG. 11 is a front perspective illustration of the assembled
foldable box of FIGS. 7-10.
[0038] FIG. 12 is a top plan illustration of a foldable box in
accordance with another non-limiting aspect of the present
invention;
[0039] FIG. 13 is a perspective illustration of the foldable box of
FIGS. 1-2 in its transition from a flat, unfolded configuration
into its folded, three-dimensional configuration;
[0040] FIG. 14 is a perspective illustration of the foldable box of
FIGS. 12-13 in its folded, assembled three-dimensional
configuration with the lid open;
[0041] FIG. 15 is a perspective illustration of the foldable box of
FIGS. 12-14 in its folded, assembled three-dimensional
configuration with the lid closed; and,
[0042] FIG. 16 is a cross-sectional perspective illustration of the
foldable box taken along line 16-16 of FIG. 15.
DETAILED DESCRIPTION
[0043] The present invention is directed to a foldable box having
one or more interchangeable configurations, and which can be easily
and conveniently transformed between such interchangeable
configurations, thereby minimizing the time required for assembly
and/or disassembly of the foldable box.
[0044] The foldable box has a plurality of interchangeable
configurations. In one non-limiting aspect of the present
invention, there is provided a foldable box having a first,
unfolded configuration in which the foldable box is substantially
flat, and a second, folded and/or three-dimensional configuration
in which the foldable box is fully assembled. As described below,
the first and second configurations of the foldable box are
interchangeable. For example, the first configuration (i.e., the
flat, unfolded foldable box) can be easily and conveniently
transformed into the second configuration (i.e., the folded,
three-dimensional foldable box), and, similarly, the second
configuration can be easily and conveniently transferred into the
first configuration; however, this is not required.
[0045] With reference to FIGS. 1-6, there is illustrated a foldable
box in accordance with the present invention. As illustrate din
FIG. 1, the foldable box 10 is illustrated in a partially unfolded
configuration. When the foldable box is in the fully folded
position, side panels 12, 14 and 16, 18 are folded under panels 20,
22. FIG. 1 illustrates that the foldable box 10 includes a
plurality of panels 12, 14, 16, 18, 20, 22, 24, 26, 28. Generally,
the panels are foldable with respect to one another; however, this
is not required.
[0046] With reference to FIG. 2, another configuration of the
foldable box 10 is illustrated, wherein the foldable box 10 is
partially unfolded but still substantially flat.
[0047] With reference to FIGS. 1-2, the first, second, and third
sets of panels of the foldable box 10 may comprise a left end panel
12, a left side panel 14, a right end panel 16, a right side panel
18, a back panel 20, a top panel 22, a top end panel 24, a front
panel 26, and a bottom panel 28.
[0048] Each panel of the foldable box 10 can be formed from a
single type of material, or from one or more types of material. The
foldable box 10 may formed from a moderately rigid material such
as, for example, a heavy weight cardboard material or paperboard
material. The foldable box 10 can be formed from other or
alternative materials, such as, for example, a flexible material,
semi-rigid material, medium weight cardboard, fiberboard, rigid
plastic, flexible plastic, composite materials, metal, or wood. The
panel material may be selected so as to allow folding, bending,
and/or other manipulations of the foldable box 10 without losing
the structural integrity of the panel material. In particular
embodiments, the thickness of the material used to form the panels
12, 14, 16, 18, 20, 22, 24, 26, 28 may be from about 0.01 mm to
about 10 mm. In further embodiments, the thickness of the material
used to form the panels 12, 14, 16, 18, 20, 22, 24, 26, 28 may be
about 2 mm.
[0049] In particular embodiments, the panel material of the
foldable boxes 10 can be lined with one or more additional types of
lining materials. The material of the lining is a laminate
material; however, other or alternative liners can be used (e.g.,
cloth, cloth-like materials, tape, tape-like materials, plastic
material, fabric material, etc.). Generally, the lining (when used)
is designed to partially and/or completely cover at least a first
surface of the foldable box 10. In some embodiments, the lining
completely covers a first surface of a portion of the foldable box
10, wraps around the perimeter thereof, and terminates at a
position at or near the perimeter on a second surface of the
portion of the foldable box 10. The lining can be used to provide
an aesthetically pleasing appearance to one or more users of the
foldable box; however, this is not required. As such, the lining
can include designs, surface structures, etc. on a surface thereof;
however, this is not required. The lining (when used) typically has
a thickness less than or equal to the material used to form the
foldable box; however, this is not required. As such, the lining
can be designed to provide support to the foldable box; however,
this is not required. The lining can be used to connect together
one or more pieces of the foldable box (e.g., connect together
multiple pieces of paperboard panels that are used to form one or
more sides of the foldable box, etc.), and/or be used to form a
hinge or foldable region between two or more pieces of the foldable
box. The lining can be designed to provide support to the foldable
box; however, this is not required. The lining can be used to
connect together one or more pieces of the foldable box (e.g.,
connect together multiple pieces of paperboard panels that are used
to form one or more sides of the foldable box, etc.), and/or be
used to form a hinge or foldable region between two or more pieces
of the foldable box.
[0050] The foldable box 10 may be formed such that all components
of the foldable box 10 are connected, and no further assembly in
required by the end user in order to transform the foldable box 10
into a second or third configuration. In some embodiments, the
foldable box 10 may also be disassembled after back into the first
configuration or a previous configuration without compromising the
structural integrity of the foldable box 10. That is, all of the
components (e.g. panels, connectors, and attachment portions) the
foldable box 10 may reversibly folded and/or connected. Put another
way, the foldable box 10 may not contain a permanent connector of
one or more of the panels.
[0051] As also seen in FIGS. 1-2, the shape of the foldable box 10
(in a top plan view) may be, in some embodiments, a T-shaped, a
square, or a rectangle. The foldable box 10 in its second,
three-dimensional configuration, may be rectangular or square;
however, the shape of the top plan view of the foldable box 10 in
its second, three-dimensional configuration can have other shapes.
When the foldable box 10 in the folded configuration and has a top
plan rectangular shape, the dimensions of the foldable box 10 can
be about 1-6 inches in height by about 2-20 inches in width by
about 1-18 inches in length; however, the foldable box 10 can have
other dimensions. In one specific non-limiting configuration, when
the foldable box 10 in the folded configuration has a top plan
square shape, the dimensions of the foldable box 10 can be about
1-6 inches in height by about 2-20 inches in width by about 2-20
inches in length.
[0052] The foldable box 10 has a first set of panels, a second set
of panels 20, 22, 24 and a third set of panels, wherein the second
and third sets of panels are designed to be adhesively and/or
foldably connected to the first set of panels. This non-limiting
configuration provides a non-limiting advantage in that all
components of the foldable box are connected such that no further
assembly is required by the end user, a common disadvantage of many
existing foldable box types in which at least one component must
typically be assembled separately and connected to the remaining
portion of a box. This non-limiting configuration also has the
advantage that the foldable box, after being assembled into its
folded configuration, can later be unassembled into its original
unfolded position. Foldable boxes that require the permanent
connection of one or more components during assembly cannot
thereafter be unassembled into its original unfolded position
without having to damage one or more portions of the foldable
box.
[0053] With reference to FIG. 3, in another and/or alternative
non-limiting aspect of the present invention, the first set of
panels further comprises a left end panel, a left side panel, a
bottom panel, a right side panel and a right end panel arranged in
a predetermined sequence. In one non-limiting configuration, the
left end panel, left side panel, bottom panel, right side panel and
right end panel are defined portions in a single piece of material.
In such a configuration, the left end panel, left side panel,
bottom panel, right side panel and right end panel can be defined
via cutting, scoring, creasing and/or folding of the material;
however, other or alternative methods can be used. The cutting,
scoring, creasing and/or folding (when used) also provides the
foldable connections between adjacent panels of the first set of
panels. For example, as seen in FIG. 1, foldable connections 30,
32, 34, 36, and 38 may separate and connect individual panels of
the foldable box 10. The size and shape of the foldable connections
30, 32, 34, 36, and 38 are non-limiting. In some embodiments, the
foldable connections 30, 32, 34, 36, and 38 are designed to permit
from about 1.degree. to about 360.degree. angles of relative
rotation between adjacent panels. For example, from a flat,
unfolded configuration, the foldable connections 30, 32, 34, 36,
and 38 can permit the left end panel 12 to be rotated about
1-180.degree. relative to the left side panel 14, the left side
panel 14 to be rotated about 1-360.degree. relative to the bottom
panel 28, the right side panel 18 to be rotated about 1-360.degree.
relative to the bottom panel 28, and the right end panel 16 to be
rotated about 1-180.degree. relative to the right side panel 16. As
such, when the foldable box 10 is in its unfolded configuration,
the left end panel 12, left side panel 14, bottom panel 28, right
side panel 18 and right end panel 16 are designed to lay
substantially flat and, in its three-dimensional configuration, the
foldable box 10 can be folded such that the left end panel 12, left
side panel 14, right side panel 18 and right end panel 16 are
parallel and are oriented approximately perpendicular (e.g., about
85-95.degree.) to the bottom panel 28. Thus, each of the left end
panel 12, left side panel 14, bottom panel 28, right side panel 18
and right end panel 16 of the first set of panels are foldably
connected together in a predetermined sequence along a crease
and/or fold. In such a configuration, the left end panel 12 is
foldably connected to the left side panel 14 along a first crease
30, the left side panel 14 is foldably connected to the bottom
panel 28 along a second crease 40, the right side panel 18 is
foldably connected to the bottom panel 28 along a third crease 42,
and the right end panel 16 is foldably connected to the right side
panel 18 along a fourth crease 32. As can be appreciated, when a
liner or a separate hinge or a hinge material is used, the liner or
the separate hinge or the hinge material can be used to allow
separate panels to be connected together and folded with respect to
one another; however, this is not required.
[0054] The size and shape of each of the panels in the first set of
panels is non-limiting. In one non-limiting configuration, for a
rectangular shaped box, each of the panels in the first set of
panels is rectangular, thereby providing a substantially
rectangular box when folded/assembled and viewed from the top plan
view. The first set of panels of the foldable box can include
panels of one or more different sizes. In one non-limiting
configuration, the first set of panels comprises a bottom panel
greater in size than the left end panel, left side panel, right
side panel and right end panel. In another and/or alternative
non-limiting configuration, the left end panel, left side panel,
right side panel and right end panel are the same or similar in
size and shape. For a square shaped box, each of the panels in the
first set of panels is square, thereby providing a substantially
square box when folded/assembled and viewed from the top plan
view.
[0055] In another and/or alternative non-limiting aspect of the
present invention, any one of the panels in the first, second
and/or third sets of panels can include a hole and/or cutout 46, as
seen in FIGS. 1 and 2. Generally, the hole and/or cutout 46 (when
used) is provided at or near an edge of a panel. As can be
appreciated, the hole and/or cutout can be spaced apart from the
edge of a panel. In one non-limiting configuration, the left and
right end panels can include a hole and/or cutout 46 along the edge
of the left and right end panels 12, 16 opposite the edge foldably
connected to the left and right side panels 14, 18, respectively.
In another and/or alternative non-limiting configuration, the front
end panel can include a hole and/or cutout along the edge of the
front end panel opposite the edge foldable connected to the top
panel. The size, shape and orientation of the hole and/or cutout 46
are non-limiting. The hole and/or cutout 46 (when provided on the
left and/or right end panels) is generally designed to permit easy
and convenient disassembly of the three-dimensional configuration
of the foldable box into its flat, unfolded configuration; however,
this is not required. Additionally and/or alternatively, the hole
and/or cutout 46 (when provided on the top end panel) is designed
to permit easy and convenient lifting of the top end panel from the
front panel, thereby disconnecting the connection arrangement
connecting the front panel and top end panel.
[0056] In another and/or alternative non-limiting aspect of the
present invention, the left and right end panels in the first set
of panels can optionally be formed from separate panels of material
than the left side panel, bottom panel and right side pane. In such
a configuration, the left and right end panels can be incorporated
into the first set of panels by being connected such as, for
example, via an adhesive, to the liner material with a small gap
and/or space between adjacent panels. As can be appreciated, other
connection arrangement can be used (e.g., hinge, etc.). The small
gap and/or space (when used) can provide the foldable connection
between panels of the first set of panels of the foldable box.
[0057] The second set of panels comprises a back panel 20, a top
panel 22 and a top end panel 24. In some embodiments, the back
panel 20, top panel 22 and top end panel 24 are formed from a
single piece of material. The size and shape of the second set of
panels are non-limiting. In one non-limiting configuration, the
back panel 20, top panel 22 and top end panel 24 are each
substantially rectangular in shape and formed from the same
material as the first set of panels; however, other shapes can be
used (e.g., square, etc.). The second set of panels are designed to
be adhesively and/or foldably connected to the first set of panels.
As can be appreciated, other types of connection arrangements can
be used (e.g., hook and loop fastener, tack, staple, melted
connection, snap, etc.). In one non-limiting configuration, the
back panel 20, top panel 22 and top end panel 24 are foldably
connected in sequence along a crease and/or fold. In such a
configuration, the back panel 20 is foldably connected to the
bottom panel 28 along a fifth crease 36, the top panel 22 is
foldably connected to the back panel 20 along a sixth crease 34,
and the top end panel 24 is foldably connected to the top panel 22
along a seventh crease 38. As such, when the foldable box 10 is in
its first, unfolded configuration, the back panel 20, top panel 22
and top end panel 24 are designed to lay substantially flat.
[0058] The size and shape of each of the panels in the second set
of panels is non-limiting. In one non-limiting configuration, each
of the panels in the second set of panels is rectangular, thereby
providing a substantially rectangular box when folded/assembled;
however, other shapes can be used (e.g., square, etc.). In one
non-limiting configuration, the second set of panels includes
panels of two different sizes; however, this is not required. In
such a configuration, the second set of panels can comprise a top
panel greater in size than the back panel and the top end panel. In
another and/or alternative non-limiting configuration, the back
panel and the top end panel are the same in size and shape.
[0059] In another and/or alternative non-limiting aspect of the
present invention, the back panel, top panel and top end panel can
be defined in the second set of panels by cutting, scoring and/or
folding the material. As can be appreciated, the back panel 20, top
panel 22 and top end panel 24 are can be individual, separate
panels joined together via the liner material, hinge, etc.;
however, this is not required.
[0060] In another and/or alternative non-limiting aspect of the
present invention, the cutting, scoring and/or folding of the
second set of panels or hinge (when used) can provide foldable
connections between the panels in the second set of panels of the
foldable box. The size and shape of the foldable connections are
non-limiting. In one non-limiting configuration, the foldable
connection is designed to permit limited rotation between two
adjacent panels. In one non-limiting configuration, the foldable
connections are designed to permit from about 1.degree. to about
360.degree. rotation about the foldable connection; however, this
is not required. For example, in one specific non-limiting
embodiment, the top end panel can be rotated from about
1-360.degree. relative to the top panel, the back panel can be
rotated about 1-360.degree. relative to the top panel, and the back
panel can be rotated about 1-180.degree. relative to the bottom
panel. In such a configuration, when the second set of panels is
folded, the second set of panels can be caused to move to a
configuration wherein both the back panel and the top end panel
extend approximately perpendicularly (e.g., about 85-95.degree.)
from opposing edges of the top panel; however, this is not
required.
[0061] In another and/or alternative non-limiting aspect of the
present invention, the third set of panels of the foldable box
further comprises at least a front panel; however, this is not
required. The size and shape of the front panel are non-limiting.
In one non-limiting configuration, the shape of the front panel is
rectangular; however, other shapes can be used (e.g., square,
etc.). In another and/or alternative non-limiting aspect of the
present invention, the third set of panels also includes a laminate
material. The front panel can be adhesively and/or foldably
connected to the bottom panel of the first set of panels forming an
eighth crease.
[0062] A lining material can optionally be applied to the first,
second and/or third sets of panels. In one non-limiting
configuration, the lining material can be applied to panels of the
foldable box such that a portion of the lining material extends at
least partially over the lengthwise edge of the front and back
panels, thereby forming an attachment portion suitable for
facilitating attachment of the front (i.e., the third set of
panels) and back (i.e., the second set of panels) panels to the
bottom panel (i.e., the first set of panels). For example, the
attachment portion of the front and back panels can be connected
(e.g., glue, tape, adhesive, melted connection, hook and loop
fastener, tack, staple, etc.) at or near oppositely disposed edges
of the bottom panel of the first set of panels. In one specific
non-limiting embodiment, an attachment portion of the back panel
can be connected at or near the edge of the bottom portion forming
the fifth crease, and an attachment portion of the front panel can
be connected at or near the edge of the bottom portion forming the
eighth crease; however, this is not required. As such, the
attachment portions of the second and third sets of panels provide
a foldable and adhesive connection or some other type of connection
to the first set of panels.
[0063] In another and/or alternative non-limiting aspect of the
present invention, the foldable box incorporates a plurality of
foldable connectors. In one non-limiting configuration, the lining
material is optionally applied to the front and back panels of the
foldable box such that the lining material extends at least
partially over the side edges thereof, thereby forming a plurality
of foldable connectors. The plurality of foldable connectors can be
foldable relative to the side edges of the front and back panels,
and provide a connection means wherein the front and back panels
can be connected to the first set of panels. The inherent
flexibility, durability and flexibility of optional lining
materials provides a suitable hinge and/or foldable connection. The
foldable connectors are designed to connect the front and back
panels to the left and right side panels of the first set of panels
to facilitate lifting of the left and right side panels when the
front and back panels are lifted. As such, the front panel, back
panel and left and right side panels can be lifted in unison to an
upright position relative to the bottom panel; however, this is not
required. In such a configuration, the work required by the end
user of the box can be significantly minimized. Furthermore, the
end user does not need to apply and/or remove any additional glue,
tape, or other materials during assembly and/or disassembly of the
foldable box.
[0064] The shape and size of each of the plurality of foldable
connectors are non-limiting. In some embodiments, all foldable
connectors are the same in size and shape. In one non-limiting
configuration, each foldable connector comprises a generally square
shape having a diagonal crease and/or groove thereby providing a
first and second connectable section. The outside surface of a
first connectable section can be designed to be connected to an
interior surface of the left or right side panel. In one specific
non-limiting configuration, a first connectable section of a first
foldable connector of the front panel is connected to the left side
panel, a first connectable section of a second foldable connector
of the front panel is connected to the right side panel, a first
connectable section of a first foldable connector of the back panel
is connected to the left side panel, and a first connectable
section of a second foldable connector of the back panel is
connected to the right side panel; however, this is not required.
The type of connection used is non-limiting. For example, the
outside surface of the first connectable section can be connected
to the interior surface of the left and/or right side panels via an
adhesive, such as, for example, glue, tape, hook and loop fastener,
a tack, and/or a staple. The second connectable section can be
designed to be connected along an edge to a side edge of the front
and/or back panel.
[0065] With reference to FIGS. 7-11, the outside surface of the
second connectable section can also be designed to be connected to
the interior surface of the left and/or right side panels in
accordance another and/or alternative non-limiting configuration.
In one non-limiting configuration, the outside surface of the
second connectable section of each foldable connector can include
snaps that are used to connect one panel to another panel during
the assembly of the box.
[0066] In another and/or alternative non-limiting aspect of the
present invention, the first, second and third sets of panels can
be individually laminated; however, this is not required. As can be
appreciated, the foldable box can be formed from a single set of
panels wherein the single set of panels is laminated. In
embodiments where the first, second and third sets of panels are
separately laminated, the first, second and third sets of panels
can be connected together via an adhesive (e.g., glue, tape, etc.).
In one non-limiting configuration, the second and third sets of
panels are connected to the top surface of the first set of panels.
As can be appreciated, other connection arrangements can be used
(e.g., melted connection, staple, tack, hook and loop fastener,
etc.). In one specific non-limiting embodiment, the second and
third sets of panels are connected to the bottom panel of the first
set of panels; however, this is not required.
[0067] In another and/or alternative non-limiting aspect of the
present invention, the foldable box includes a second liner
material; however, this is not required. In one non-limiting
configuration, the second liner material is a protective material;
however, this is not required. The protective material can be
applied to one or more surfaces of the foldable box; however, this
is not required. The type of protective material is non-limiting.
The protective material can be the same or different than the first
liner material (as described earlier). In one non-limiting
configuration, the protective material (when used) is a durable
paper material; however, other or alternative types of materials
can be used (e.g., plastic, metal, wood, composite material, etc.).
The protective material can be applied to a second surface of the
first, second and/or third set of panels via an adhesive (e.g.,
glue, tape, etc.); however, other or alternative connection
arrangements can be used (e.g., hook and loop fastener, melted
connection, tack, staple, etc.). Alternatively, the protective
material can be a layer of tape; however, this is not required. The
protective material (when used) is designed to cover a majority of
the second surface of the first, second and/or third sets of
panels; however, this is not required. In one non-limiting
configuration, the protective material is applied to the second
surface of the first and second sets of panels such that the
protective material extends at least partially over the portion of
the first liner material which terminates at or near the perimeter
of the first and second sets of panels. In addition to providing
improved durability and structural rigidity to the panels of the
foldable box, the protective material also provides improved
support at or near the foldable connections (i.e. creases and/or
folds) between panels of the first and second sets of panels.
Optionally, the third set of panels includes a protective
material.
[0068] In another and/or alternative non-limiting aspect of the
present invention, the foldable box can include a connection
arrangement provided between the top end panel and the front panel
such that, when the foldable box is transformed into its second,
three-dimensional configuration, the top end panel can releasably
connect to the front panel. As such, the connection arrangement
between the top end panel and the front panel is capable of at
least partially retaining the foldable box in its second,
three-dimensional configuration; however, this is not required.
[0069] The type of connection arrangement used between the top end
panel and the front panel is non-limiting. In one non-limiting
configuration, a magnetic connection arrangement is used; however,
this is not required. In such a configuration, the top end panel
can include one or more magnets (or magnetically attractive
materials) and the front panel can include one or more magnets (or
magnetically attractive materials) corresponding to the one or more
magnets (or magnetically attractive materials) of the top end
panel; however, this is not required. As can be appreciated, other
connection arrangements can be used (e.g., releasable adhesive,
hook and loop fastener, latch, snap, button, etc.). When two or
more magnets are used, the magnets generally have opposite
polarity. In one non-limiting configuration, the magnets are
positioned within the material of the front panel and the top end
panel, spaced apart from the edge of the front and top end panels
and the lining. This size, shape and configuration of the magnets
are non-limiting. In one non-limiting configuration, the thickness
of each magnet is selected to be about the same or less than the
thickness of the material of the panels such that the magnets are
completely enclosed. As such, the magnets are provided within the
material of the front and top end panels so that the magnets are
not visible to a user. In another configuration, one panel includes
one or more magnets and the other panel includes a material that is
magnetically attracted to a magnetic (e.g., iron material,
etc.).
[0070] In another and/or alternative non-limiting aspect of the
present invention, the foldable box is designed to be easily and
conveniently converted from a flat, unfolded configuration to a
three-dimensional configuration. In operation, a user can lift the
front and back panels upward towards a vertical orientation. In
doing so, the left and right side panels will be also be caused to
be rotated upwards to a vertical orientation via the plurality of
foldable connectors connecting the front and back panels to the
left and right side panels; however, this is not required. As such,
the foldable box can be easily and conveniently changed from an
unfolded position to a three-dimensional configuration. When the
foldable box is in its three-dimensional configuration, the
foldable box can be filled with one or more items to be stored
and/or held within the foldable box.
[0071] In another and/or alternative non-limiting aspect of the
present invention, the foldable box can optionally be folded from
its flat, unfolded configuration into a space-saving, compact
configuration; however, this is not required. The compact
configuration (when used) can facilitate space-saving storage
and/or transport of one or more foldable boxes; however, this is
not required. In one non-limiting configuration, when the compact
configuration is used, the gap between the top panel and the back
panel is generally designed to permit about 180.degree. rotation,
thereby accommodating the combined thicknesses of the back panel,
the top panel and the left and/or right side panels; however, this
is not required.
[0072] In another and/or alternative non-limiting aspect of the
present invention, the first, second and/or third set of panels of
the foldable box can optionally comprise a plurality of individual
panels which can be attached (e.g., glued, taped, melted
connection, hook and loop connection, tack, staple, etc.) to one
surface of a liner (e.g., cover, laminate material, etc.) with
small gaps and/or spaces between adjacent individual panels;
however, this is not required. The small gaps and/or spaces (when
used) can provide the foldable connection between individual panels
of the first, second and/or third sets of panels; however, this is
not required. In such a configuration, the first, second and third
sets of panels can optionally be laminated together; however, this
is not required. The small gap and/or space between the individual
panels can be designed to provide the foldable connection between
adjacent panels of the foldable box; however, this is not
required.
[0073] In another and/or alternative non-limiting aspect of the
present invention, there is provided a method for manufacturing a
foldable box in accordance with the present invention. As described
above, the foldable box can be formed from a first set of panels, a
second set of panels and a third set of panels; however, this is
not required. A method for manufacturing a foldable box in
accordance with the present invention can include: 1) selecting a
material suitable for use in a foldable box, 2) cutting the
selected material into a desired number of panels (e.g., a first,
second and third set of panels), each panel having a desired size
and shape, 3) optionally applying a first liner material (e.g., a
laminate material) to at least one surface of the first, second and
third set of panels, 4) forming at least one attachment portion and
at least one foldable connector on the second and third set of
panels, 6) optionally applying a second liner material (e.g., a
protective cover) to at least one surface of the first and/or
second set of panels, 7) defining one or more panels within the
first set of panels, second set of panels and/or third set of
panels, 8) forming foldable connections between the one or more
panels defined within the first, second and/or third sets of panels
by cutting, scoring and/or folding the first, second and/or third
sets of panels, and/or 9) connecting the second and third set of
panels to the first set of panels.
[0074] In another and/or alternative non-limiting aspect of the
present invention, there is provided a method for transforming a
foldable box of the present invention from a first, unfolded
configuration to a second, three-dimensional configuration.
Initially, a foldable box is provided in an unfolded configuration
wherein the first set of panels is substantially flat (i.e., the
left end panel, left side panel, bottom panel, right side panel,
and right end panel foldable connections are all at approximately
180.degree.), and the second and third sets of panels lays on top
of the first set of panels. The foldable connectors connecting the
second and third sets of panels to the first set of panels can be
configured to be folded and/or unfolded. The front and back panels
can be lifted upwards such that the front and back panels are
relative to the bottom panel. In lifting the front and back panels
upwards, the left and right side panels of the first set of panels
are caused to lift upwards, thereby also rotating the left and
right side panels upwards relative to the bottom panel. In such a
configuration, the front and back panels are lifted away from a
middle portion of the bottom panel while the left and right side
panels are caused to move towards a middle portion of the bottom
panel. The front and back panels (and therefore also the left and
right side panels) are lifted upwards until they reach an
approximately vertical position (i.e. about 85-95.degree.) relative
to the bottom panel. The left and right end panels can be rotated
(i.e., folded) approximately 180.degree. relative to the left and
right side panels, so as to hold the foldable connectors flat
between the left and right side panels and the left and right end
panels, respectively. As such, the foldable box can be at least
partially secured in an open, three-dimensional configuration.
Next, the top panel can then be rotated relative to the back panel
such that the top panel covers the opening formed by the front
panel, back panel, left side panel, left end panel, right side
panel and right end panel. As such, the foldable box can be
transformed into a closed, three-dimensional configuration. The top
end panel can be rotated relative to the top panel to form a
releasable connection. For example, when one or more magnets are
provided in the top end panel and/or front panel and are caused to
approach one or more connectors (e.g., magnet, hook and loop
fastener, etc.) provided on or in the other panel of the foldable
box, the magnetic force between the one or more magnets on the top
end panel and/or the front panel is sufficient to releasably and
securely close the foldable box in a three-dimensional
configuration.
[0075] Referring now to FIG. 12-16, another embodiment of a
foldable box is illustrated. Two of the panels include an adhesive
connector that is used to assemble the box. The adhesive connector
can include a release liner that is designed to be removed from the
adhesive surface prior to the adhesive surface bine connected to
another panel during the assembly of the box. The adhesive material
can be positioned on or closely adjacent to one or more edges of
the connectable region and can cover a majority of the connectable
region; however, this is not required. When the connection
arrangement is not reconnected, and an adhesive material is used, a
removable top protective release liner can be used with the
adhesive; however, this is not required. The release liner (when
used) exposes a top adhesive surface of the adhesive material when
removed. One non-limiting advantage to providing a preapplied
adhesive material is that the end user does not need to apply any
additional materials to the foldable box prior to its use. When
exposed, the top adhesive surface of the adhesive material is
designed to bond with a portion of the left and/or right side
panels positioned at or near the second connectable section. In
such a configuration, when the foldable box is converted into its
second, three-dimensional structure, the adhesive material on the
outside surface of the second connectable section can facilitate in
holding the foldable box in a three-dimensional configuration;
however, this is not required. As can be appreciated, other or
alternative releasable connection arrangements can optionally be
used to connect the second connectable region of each foldable
connector to the front and/or back panels; however, this is not
required. As can be appreciated, when the connection arrangement is
preconnected, the connection arrangement is typically not a
releaseable connection without damage to the foldable box.
[0076] It will be appreciated that variants of the above-disclosed
and other features and functions, or alternatives thereof, may be
combined into many other different systems or applications. Various
presently unforeseen or unanticipated alternatives, modifications,
variations or improvements therein may be subsequently made by
those skilled in the art which are also intended to be encompassed
by the following claims.
* * * * *