This invention generally relates to flat pack storage boxes, more specifically to flat pack storage boxes that are expandable to a larger size.
The phrase “flat pack” within the meaning of the present application references products assembled from a one or more planar components that are assembled to the desired product. The phrase “flat pack” is often used in referencing furniture. In the field of the present invention, namely boxes and trays, this phrase “flat pack” can be equated with the phrase “knock down.” See, for example, the “Corrugated Plastic Knockdown Tray” sold by Minnesota Diversified or the “Knock Down Storage Box” sold by Bigso Box of Sweden. The terms “Collapsible” and “Foldable”, and similar terms, have also been used in this industry to convey the same concept and can also accurately describe the present invention.
The terms “boxes” and “trays” do not have consistent and precise definition in the art and can be interchangeably used together with the terms container, bin, receptacle, crate, chest, trunk, carton, and a host of other similar terms. Within the meaning of the present application the phrase “storage box” defines a container with substantially vertical sides (+/−7 degrees), and the phrase “nesting tote box” defines a container with non-vertical sides that extend upward at an angle of more than 7 degrees from vertical and less than 75 degrees from vertical, also called “flared sided” herein, wherein the containers may be nested together. The nesting of the tote boxes generally aids in storage and shipment of the containers. The flared sides of a nesting tote box yield numerous other advantages, such as ease of access to contained articles that are lower in a stack of article within the nesting tote box. The outward angle yield a greater containment volume within the box than if the sides extended vertically from the base, thus yielding greater containment volume. Further the nesting tote box design offers an improved display of products within the nesting tote box then a storage box would in some commercial establishments. For example, there are some supermarkets that minimize shelving labor and display products within shipping containers, and a nesting tote box allows for a better display of products on the shelf, although the storage box is preferable for product shipping.
The U.S. patent system has long illustrated the ingenuity of flat pack containers, such as the 1894 U.S. Pat. No. 529,053 for a “Paper Pail”, which was later emblazoned with the graphical image of a pagoda, and has become well known as the now ubiquitous “Chinese food” take out container.
As noted above the present invention is directed to flat pack storage boxes that are expandable to a larger size. The U.S. patent system also shows innovations in this specific flat pack container field as well, with U.S. Pat. Nos. 2,793,802; 3,373,923; 3,520,409; and 4,111,306 being representative examples of these boxes. These patents are incorporated herein by reference.
There remains a need in the art to design cost effective, efficient and effective flat pack storage boxes that are expandable.
The various embodiments and examples of the present invention as presented herein are understood to be illustrative of the present invention and not restrictive thereof and are non-limiting with respect to the scope of the invention.
The present invention provides a flat pack convertible stackable four sided storage box and eight sided nesting tote box. Specifically one embodiment of the present invention provides a flat pack convertible stackable four sided storage box and eight sided nesting tote box which comprises a base including two parallel base longitudinal score lines and two parallel base end score lines, two opposed longitudinal sides each longitudinal side adjacent one of the longitudinal score lines and having opposed longitudinal side end score lines, two end sides with each end side adjacent one of the base end score lines and having at least one cutline defining at least one end side opening, four triangular expansion sides each triangular expansion side located adjacent one of the side end score lines and having an expansion side score line, four moving conversion panels with each panel adjacent one of the expansion side score line, each panel includes at least one panel opening configured to selectively align with one opening formed by at least one cutline and configured to receive a locking element there-through to be locked into one position, wherein in one position a stackable four sided storage box is formed and in another position an eight sided nesting tote box is formed and the box may be moved back and forth between the two configurations.
One embodiment of the present invention provides a flat pack convertible stackable four sided storage box and eight sided nesting tote box comprising: a rectangular base; two opposed longitudinal sides; two end sides, each end side having at least one cutline defining at least one end side opening; four triangular expansion sides; four moving conversion panels, each panel including at least one panel opening configured to selectively align with one opening formed by at least one cutline and configured to receive a locking element there-through to be locked into one position, wherein in one position a stackable four sided storage box is formed as one configuration and in another position an eight sided nesting tote box is formed as a second configuration and wherein the box may be moved back and forth between the two configurations; and a lid configured to be secured on top of the box when in the storage box configuration.
These and other advantages of the present invention will be clarified in the description of the preferred embodiments taken together with the attached figures.
The present invention provides a flat pack box 100 and 300, specifically a stackable four sided storage box 100 or 300 that can expand to a larger containment size by converting to an eight sided nesting tote box 100 or 300, and vice-versa as shown in
The flat pack box 100, aside from the lid 200, is formed from a die cut planar substrate or member such as cardboard, plastic, corrugated plastic cardboard or possibly other similar materials. The flat pack layout for the box 100 is shown in
A base 110 forms the plan view outline of the storage box 100 and is shown as a rectangle. The rectangular base includes two parallel base longitudinal score lines 112 for the longitudinal sides 120 and two parallel base end score lines 114 for the outer end sides 130. Score lines are known in the art and can also be described or referenced as hinges, living hinges or fold lines. The base 110 includes two openings 116 along each base end score line 114 for receiving locking tabs 166 which help secure or maintain the box 100 in both deployed positions shown in
The two opposed rectangular longitudinal sides 120 each have opposed end score lines 122 along the ends between the sides 120 and triangular sides 140 and top edges 124 defining a top surface for the box 100 upon which the lid 200 sits when attached to the storage box 100.
The two rectangular outer end sides 130 each have opposed cut lines 132 and a top score line 134 associated with the top surface for the box 100 upon which the lid 200 rests when attached to the storage box 100. Cut lines, as opposed to score lines, extend through the substrate, and cut lines 132 separate the end sides 130 from the material forming the moving conversion panels 150. Each rectangular outer end side 130 includes a cutline 136 around three sides of an oval handle opening and forming a locking tab 138.
The box 100 includes four triangular expansion sides 140 located adjacent the ends of the sides 120, with the triangular expansion sides 140 having a score line 142 between the side 140 and the conversion panel 150. Each triangular expansion side 140 has a top edge 144.
The box 100 includes four the moving conversion panels 150, each adjacent an expansion side 140. Each panel 150 includes an opening 152, a top edge 154 and a second expansion opening 156. The openings 152 and 156 are configured to selectively align with the handle opening formed by cut 136 and be locked into position with the tab 138.
The box 100 includes a pair of inner end sides 160 generally adjacent the end sides 130 with a score line 162 offset from score line 134 by a thickness adapted to accommodate folding the end sides 160 such that the sides 160 and 130 are on opposite sides of intervening panels 150 and sides 140 as discussed below. The sides 160 include opening 164 that aligns with the handle opening formed by cutline 136. The openings 164 are essentially the handle openings for the box 100.
In the storage box position of
As noted above a key aspect to the invention is that the present invention provides a flat pack box 100 (and 300 discussed below), specifically a stackable four sided storage box 100 (or 300) that can convert to an eight sided nesting tote box 100 (or 300), and vice-versa as shown in
The box 100 of the present invention includes a lid 200 configured to be secured on top of the box 100 when in the storage box configuration as generally shown in
A top 210 forms the plan view outline of the lid 200 for the storage box 100 and is shown as a rectangle. The rectangular top 210 includes two parallel score lines 212 for the longitudinal sides 220 and two parallel score lines 214 for the outer end sides 230. The top 210 includes two openings 216 along each score line 214 for receiving locking tabs 266 which help secure the lid 200 of the box 100 in a deployed position shown in
The two opposed rectangular longitudinal sides 220 each have opposed end score lines 222 along the ends between the sides 220 and triangular sides 240 and bottom edges 124. The two rectangular outer end sides 230 each have opposed cut lines 232 and a top score line 234 associated with the bottom edge for the lid 200 of the box 100. Cut lines 232 separate the end sides 230 from the material forming the moving conversion panels 250. Each rectangular outer end side 230 includes a cut line 236 around three sides of a semi-circular opening and forming a locking tab 238.
The lid 200 includes four triangular expansion sides 240 located adjacent the ends of the sides 220, with the triangular expansion sides 240 having a score line 242 between the side 240 and the conversion panel 250. Each triangular expansion side 240 has a top edge 244. The lid 200 includes four the moving conversion panels 250, each adjacent an expansion side 240. Each panel 250 includes an opening 252, a top edge 254. The opening 252 is configured to selectively align with the opening formed by cut 236 and be locked into position with the tab 238 when used as a storage box lid.
The lid 200 includes a pair of inner end sides 260 generally adjacent the end sides 230 with a score line 262 offset from score line 234 by a thickness adapted to accommodate folding the end sides 260 such that the sides 260 and 230 are on opposite sides of intervening panels 250 and sides 240 as discussed below. The sides 260 include opening 264 that aligns with the opening formed by cutline 236.
With the lid 200 in position for use as a lid 200 for storage box 100 as shown in
The lid 200 can convert to an eight sided nesting tote box, and vice-versa as shown essentially in the same manner as the storage portion of the box discussed above. Beginning with the lid 200 locked in the position as a lid for the storage box 100 configuration, the locking tab 238 is pushed back through the then aligned openings 264 and 252 to allow the conversion. The sides 220 are pulled laterally outwardly to fully expose the expansion sides 240. The lid 200 as shown differs from the storage component of the box in that there is no method of locking the lid 200 in the eight sided nesting box configuration. Such a locking structure could be added if needed, but the primary purpose for conversion of the lid 200 is nesting as shown in
The base 310 does not include openings along each score line 314 (analogous to the opening 116) for receiving locking tabs (not present in this design) because the box 300 uses one piece double headed connecting studs 370, one of which is shown in detail in
The two opposed rectangular longitudinal sides 320 each have opposed end score lines 322 along the ends between the sides 320 and triangular sides 340 and top edges 324 defining a top surface for the box 300 upon which the lid 200 sits when attached to the storage box 300. The end sides 330 each have opposed cut lines 332 and a top cutline 234 associated with the top surface for the box 300 upon which the lid 200 rests when attached to the storage box 100. The top cut line 334 is opposed to score lines 134 in the embodiment of
The box 300 includes four triangular expansion sides 340 located adjacent the ends of the sides 320, with the triangular expansion sides 340 having a score line 342 between the side 340 and the conversion panel 350. Each triangular expansion side 340 has a top edge 344. The box 300 includes four the moving conversion panels 350, each adjacent an expansion side 340. Each panel 350 includes a slot opening 352 with two downward detent positions, a top edge 354.
In the assembly of the box 300 the longitudinal sides 320 are folded up along score lines 312 and the triangular expansion sides 340 and the conversion panels 350 are folded in along score lines 322. Then the end sides 330 are folded up along score line 314. The studs 370 are secured within openings 336 and the openings 352 to complete the box 300.
In the storage box position the studs 370 are in the detent of opening or slot 352 that is closest to the sides 320. The four exposed sides of the box 300 will be lateral sides 320 and end sides 330.
While this invention has been particularly shown and described with references to the preferred embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the scope of the invention.
The present application claims the benefit of U.S. Provisional Patent Application Ser. No. 62/920,465 filed May 2, 2019 titled “Opened Tray, or Opened Box, or Opened Container with Straight up Side Walls that can Flare Out and Retract Back” which is incorporated herein by reference.
Number | Date | Country | |
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62920465 | May 2019 | US |