AU2006203494A1 - Stackable box - Google Patents

Description

S&FRef: 776120

AUSTRALIA

PATENTS ACT 1990 COMPLETE SPECIFICATION FOR A STANDARD PATENT Name and Address of Applicant: Actual Inventor(s): Address for Service: Norbury Pty. Ltd., an Australian Company, ACN 008 655 892, of c/o Ian Oliver Co., 76 Crawford Street, Queanbeyan, New South Wales, 2620, Australia lan Oliver Spruson Ferguson St Martins Tower Level 31 Market Street Sydney NSW 2000 (CCN 3710000177) Invention Title: Stackable box Associated Provisional Application Details: [33] Country:

AU

[31] Appl'n No(s): 2005904325 [32] Application Date: 11 Aug 2005 The following statement is a full description of this invention, including the best method of performing it known to me/us:- 5845c STACKABLE BOX Field of the Invention The present invention relates to a stackable box which has either an open front portion or a front portion closable by a hinged panel.

Background of the Invention Stackable storage boxes are known. These boxes include top and bottom walls, left and right side walls, a rear wall, and a front portion which is either open or closable by a hinged front panel. A number of the boxes can be stacked one on top of the other with the storage space inside the boxes accessible through the front wall.

A known disadvantage of the stackable boxes is that only a limited number of the boxes can be stacked, as the vertical walls of each box must be of sufficient strength in order to maintain the shape of the box and support the weight of the boxes stacked thereon and the contents of the upper boxes. In some prior art boxes, the vertical walls are reinforced by metal stiffening members or the boxes include an additional vertical panel in the mid-portion of the box to increase the vertical strength of the box. The metal stiffening members however increase the cost of the box and the vertical mid-portion panel prevents wide objects from being stored in the box.

It is the object of the present invention to substantially overcome or at least ameliorate the prior art disadvantages or at least provide a useful alternative.

Summary of the Invention In one aspect, the present invention provides a box formed from a blank, the blank including a plurality of panels, with adjacent panels being connected by hinge portions of the blank, and wherein: the box is a rectangular prism including a top wall, two side walls, a bottom wall and a rear wall, with the two side walls each being formed from at least three of said panels superposed.

The rear wall preferably includes at least two of said panels superposed. In another embodiment, the top and/or bottom walls each include at least two of said panels superposed. The left and right side walls preferably abut the rear wall.

In one embodiment, the front portion of the box is open. In another embodiment, the front portion of the box is closable by a hinged front panel. The hinged front panel can be hingably attached to the top wall or the bottom wall.

[R:\LIBLL] 17235.doc:hxa The blank preferably includes a bottom panel, a rear panel hingedly attached to a rear edge of the bottom panel, a top panel hingedly attached to a rear edge of the rear panel, first and second side panels respectively hingedly attached to side edges of the bottom panel, third and fourth side panels respectively hingedly attached to front edges of the first and second side panels and fifth and sixth side panels respectively hingedly attached to side edges of the top panel.

The blank preferably includes a front panel hingedly attached to a front edge of the bottom panel. The blank also preferably incudes first and second additional rear panels respectively hingedly attached to the rear edges of the first and second side panels.

The blank preferably includes a closing flap hingedly attached to a rear edge of the top panel, the closing flap having an elongated slot. The front panel preferably includes a closing tab hingedly attached to a front edge thereof. Preferably attached to the closing tab is a pull tab which extends into the front panel and separated therefrom around a cutline.

The fifth and sixth side panels preferably each include a locking tab which extends into the top panel and separated therefrom around a cutline. The bottom panel preferably includes slots therein for receiving the locking tabs of another said box. Each of the side panels preferably include an elongated aperture which respectively align when the box is formed.

In another embodiment, the blank preferably includes an additional bottom panel hingedly attached to a front edge of the bottom panel and an additional top panel hingedly attached to a rear edge of the top panel. The blank also preferably incudes seventh and eighth side panels respectively hingedly attached to the side edges of the rear panel.

The box in this embodiment preferably includes a number of spaced vertical dividers, wherein each divider is a panel having tabs at top and bottom edges thereof, each tab being inserted into respective slots of the additional top and bottom panels.

Alternatively, the box in this embodiment preferably includes a number of horizontal shelves, wherein each shelf is a panel having tabs at side edges thereof, each tab being inserted into respective slots of the side panels.

Alternatively, the box in this embodiment preferably includes wine bottle holder panels, wherein each panel has tabs at edges thereof and a number of wine bottle holder holes therein, each tab being inserted into respective slots of the top, bottom and side panels.

[R:\LIBLL] 17235.doc:hxa Brief Description of the Drawings Preferred forms of the present invention will now be described by way of examples only, with reference to the accompanying drawings, wherein: Fig. 1 shows a blank having connected panels for forming a box according to a preferred embodiment of the present invention; Figs. 2 to 7 sequentially show the steps for forming the box from the blank of Fig. 1; Fig. 8 shows the formed box; Fig. 9 show stacking of three of the boxes; Fig. 10 shows three of the boxes stacked one on top of the other; Fig. 11 shows front view and side view of stacking of the three boxes; Fig. 12(a) shows a front view of the box and 12(b) shows the box lying on its rear panel; Fig. 13 shows a perspective view of the box lying on its rear panel; Fig. 14 shows a blank having connected panels for forming a box according to a second preferred embodiment of the present invention; Fig. 15 shows abox formed from the blank of Fig. 14; Fig. 16 shows the box of Fig. 14 with vertical dividers; Fig. 17 shows the box of Fig. 14 with horizontal shelves; and Fig. 18 shows a modified box of Fig. 14 having wine bottle holders.

Detailed Description of the Preferred Embodiment Fig. 1 shows a blank 30 formed from a single sheet so as to be of a unitary construction and having hingably connected panels for forming a box according to a preferred embodiment of the present invention. The blank 30 includes a front panel 31, a bottom panel 32 hingedly attached to a rear edge of the front panel 31, a rear panel 33 hingedly attached to a rear edge of the bottom panel 32, and top panel 34 hingedly attached to a rear edge of the rear panel 33. Front panel 31 and rear panel 33 are substantially similar in dimensions, and bottom panel 32 and top panel 34 are also substantially similar in dimensions.

The front panel 31 includes a closing tab 35 hingedly attached to a front edge thereof Attached to the tab 35 is a smaller pull tab 36 which extends into the front panel 31 and separated therefrom around cutline 37.

The bottom panel 32 includes first and second elongated cutout slots 40 at side edges thereof. Respectively hingedly attached to the bottom panel side edges are [R:\LIBLL] 17235.doc:hxa rectangular first and second side panels 44. The first and second side panels 44 each include an elongated aperture 45 therein.

Respectively hingedly attached to the front edges of the first and second side panels 44 are rectangular third and fourth side panels 46. The third and fourth side panels 46 each include an elongated aperture 45 therein, an elongated cutout portion 47 at an inside edge thereof and a tab 56 at a front edge thereof.

Respectively hingedly attached to the rear edges of the first and second side panels 44 are rectangular first and second rear half-panels 48, each having a slot 57 therein and a rear edge 49.

Respectively hingedly attached to side edges of the top panel 34 are fifth and sixth side panels 50. Each of the side panels 50 include a locking tab 51 which extends into the top panel 34 and separated therefrom around cutline 52. Each of the side panels also include an elongated aperture 45 and an elongated cutout portion 47 at an outside edge thereof.

Hingedly attached to the rear edge of the top panel 34 is a closing flap 54 which includes an elongated slot 55 therein.

Figs. 2 to 7 sequentially show the steps for forming the box from the blank of Fig. 1. In Fig. 2, the side panels 44, 46 and half-panels 48 are pivoted upwardly relative to the bottom panel 32 toward an upright position, with the half-panels 48 being pivoted toward the side panels 44. In Fig. 3, the panels 44, 46 and 48 are in a more upright orientation, with the half-panels 48 substantially perpendicular to the side panels 44. The rear panel 33 is pivoted toward an upright position.

In Fig. 4, the panels 46, 44 and 48 are perpendicular to the bottom panel 32, the rear half-panels 48 are perpendicular to the side panels 44 and the rear half-panel edges 49 meet at a mid-portion of the box, which creates a space 60 in the box. The rear panel 33 is pivoted toward an upright position to be perpendicular to the bottom panel 32 and to be superposed with rear half-panels 48. The fifth and sixth side panels 50 are pivoted to be perpendicular to the top panel 34. This moves the tabs 51 to project from the top panel 34.

In Fig. 5, the rear panel 33 is perpendicular to the bottom panel 32 and superposed with the rear half-panels 48. The top panel 34 is pivoted toward the rear panel 33 such that the side panels 50 are inserted into the space 60. In Fig. 6, the top panel 34 is parallel to the bottom panel 32, the fifth and sixth side panels 50 rest on the bottom panel 32 and are superposed with the first and second side panels 44. In this position, the cutout portions 47 in the side panels 50 (as best shown in Fig. 5) respectively align with the slots [R:\LIBLL] I 7235.doc:hxa of the bottom panel 32. The elongated apertures 45 of the side panels 50 also align with the elongated apertures 45 of the panels 44. The third and fourth side panels 46 are then pivoted inwardly into the space 60 until the panels 46 are superposed with the side panels In Fig. 7, the third and fourth side panels 46 are superposed with the side panels The cutout portions 47 of the side panels 46 respectively align with the cutout portions 47 of the side panels 50 and the slots 40 in the bottom panel 32, which features are best shown in Fig. 5 and 6. Also, the tabs 56 of the side panels 46 are inserted into the slots 57 of the rear half-panels 48, which features are best shown in Fig. 5. Referring back to Fig. 7, the flap 54 is pivoted downwardly and the front panel 31 can be pivoted upwardly such that the flap 35 is inserted into the slot 55 of the flap 54.

Fig. 8 shows the formed box 70. The storage space 60 is accessible by pivoting the front panel 31 via the pull tab 36.

Figs. 9 to 1l(b) show stacking of three of the boxes 70. When a box 70 is stacked onto another box 70, the locking tabs 51 of the lower box 70 are respectively inserted into the slots 40 of the bottom panel 32 of the upper box 70, with the locking tabs 51 being received by the cutout portions 47 of the side panels 46 and 50. The locking tabs substantially ensure that the side walls of the stacked boxes align with each other to provide strength to the stack. The tabs also assists in "locking" the stacked boxes, to substantially retain the boxes together when a pulling action is applied to any box in the rear to front direction. This also assists in substantially retaining the boxes together in the side to side direction.

Fig. 12(a) shows a front view of the box 70 and Figs. 12(b) and 13 shows the box lying on its rear panel 33. As mentioned, the elongated apertures 45 of the side panels 44, 46 and 50 are aligned with each other. The aligned apertures 45 can thus be used as a carry handle for the box Fig. 14 shows a blank 80 having connected panels for forming a box according to a second preferred embodiment of the present invention. The blank 80 includes a first bottom panel 81, which is hingedly attached to a second bottom panel 82, which is hingedly attached to a rear panel 83, which is hingedly attached to a first top panel 84, which is hingedly attached to a second top panel 85. The panels 81, 82, 84 and 85 are substantially similar in dimensions.

The first bottom panel 81 includes first and second sets of laterally spaced slots 86 and 87 therein, wherein each slot is aligned with a corresponding slot from the other set.

[R:\LIBLL] 17235.doc:hxa The second bottom panel 82 includes three spaced slots 88 along each side edge thereof. Respectively hingedly attached to the second bottom panel side edges are first and second side panels 94. The first and second side panels 94 each include a tab 95 at its rear edge.

Respectively hingedly attached to the front edges of the first and second side panels 94 are part-side panels 96. The part-side panels 96 each include a cutout 97 and tab 98 at an inside edge thereof, tabs 99 at an outside edges thereof, and two spaced slots 100.

The rear panel 83 includes a slot 101 at respective side edges thereof.

Respectively hingedly attached to the side edges of the rear panel 83 are first part-side panels 102, each having a tab 103 at front and rear edges thereof and two spaced slots 104.

The first top panel 84 includes three spaced slots 88 along each side edge thereof, similar to the second bottom panel 82. Respectively hingedly attached to side edges of the first top panel 84 are side panels 105, each having a cutout portion 106 at a front edge and a tab 107 at a rear edge.

The second top panel 85 includes first and second sets of laterally spaced slots 86 and 87 therein, similar to the first bottom panel 81.

Forming of a box using the blank 80 is similar to the sequential steps for forming the box 70 shown in Figs. 2 to 7. The side panels 94 and 96 are pivoted to be perpendicular to the bottom panels 81 and 82, forming a space 110 inside the box. The side panels 102 are also pivoted to be perpendicular to the rear panel 83. The rear panel 83 is then pivoted to be perpendicular to the bottom panels 81 and 82, with the side panels 102 inserted into the space 110. The side panels 105 are pivoted to be perpendicular to the first top panel 84 and the first top panel 84 is pivoted to be perpendicular to the rear panel 83 such that each side panel 105 is inserted into the space 1,10 between the respective side panels 94 and 102. The tabs 103 in side panels 102 are then inserted into slots 88 of the bottom panel 82 and top panel 84. The side panels 94 are thus superposed with the side panels 105.

The side panels 96 are pivoted inwardly, such that the side panels 96 and 102 together are superposed with the side panels 105. The tabs 98 and 99 in each side panel 96 are inserted into slots 88 of the bottom panel 82 and top panel 84. The first bottom panel 81 is then pivoted inwardly to be superposed with the second bottom panel 82 and the second top panel 85 is pivoted inwardly to be superposed with the first top panel 84.

This completes assembly of the box 120 as shown in Fig. [R:\LIBLL] 17235.doc:hxa The box 120 does not includes a front panel, in contrast to the box 70. A number of the boxes 120 can be used as display or for general storage as desired. The box 120 includes a bottom wall having two panels 81, 82, a top wall having two panels 84, 85 and a side wall having three panels 94, 96 and 102, and 105. These layers provide strength to the box 120.

Fig. 16 shows a modified box 120a which includes vertical dividers 121. Each divider 121 is a panel which includes tabs 122 at top and bottom edges thereof. Each divider 121 is inserted into the space 110 with the tabs 122 being inserted into the slots 86, 87 of the top and bottom panels 81 and 85. The box 120a is useful for holding folders of documents.

Fig. 17 shows a modified box 120b which includes horizontal shelves 123. Each shelf 123 is a panel which includes tabs 124 at side edges thereof. Each shelf 123 is inserted into the space 110 with the tabs 124 being inserted into the slots 100, 104 of the side panels 96 and 102. The box 120b is useful for storing items such as shoes.

Fig. 18 shows a modified box 120c which includes wine bottle holder panels 125. Each panel 125 is a panel which includes tabs 126 at all edges thereof and a number of holes 127 therein. Each panel 125 is inserted into the space 110 with the tabs 126 being inserted into slots of the top and bottom panels 81 and 85 and side panels 96 and 102, which slots are not shown in Fig 14 but can readily be formed by persons skilled in the art. The box 120c is useful for storing wine bottles.

The blanks 30 and 80 can be formed from cardboard, plastics or any other suitable material which will provide the sufficient strength desired for the box 70 or 120.

Such box strength is assisted by providing three panels for each side wall of the box 70 or 120.

Although preferred embodiments of the present invention have been described, it will be apparent to persons skilled in the art that modifications can be made to the described embodiments or that the present invention can be embodied in other forms. For example, if additional strength is required for the boxes, additional panels can be provided in the form of a separate panel which can be inserted between the side panels, for example between side panels 44 and 50 and/or panels 50 and 46 of the box 70. Similarly, additional top and bottom panels can be inserted between the top panels 84 and 85 and bottom panels 81 and 82 of the box 120. Also, the side panels 96 and 102 of the blank can be formed to extend the entire length of the side panel 94, such that the box 120 will include side walls with four layers of the panel material. Similarly, the rear half-panels 48 of the blank 30 can be formed to extend the entire length of the rear panel 33, such that [R:\LIBLL] 17235.doc:hxa the box 70 will include a rear wall with three layers of the panel material. In the present specification, reference to the panels being "superposed" includes the arrangement of the panels being substantially superposed, as the panel perimeters may not exactly coincide because of the hinge connections to other panels.

[R:\LIBLL] 17235.doc:hxa

Claims (22)

1. A box formed from a blank, the blank including a plurality of panels, with adjacent panels being connected by hinge portions of the blank, and wherein: the box is a rectangular prism including a top wall, two side walls, a bottom wall and a rear wall, with the two side walls each being formed from at least three of said panels superposed.

2. The box of claim 1, wherein the rear wall includes at least two of said panels superposed.

3. The box of claim 1 or 2, wherein the top and/or bottom walls each lo include at least two of said panels superposed.

4. The box of claim 1, 2 or 3, wherein the side walls preferably abut the rear wall.

The box of any one of claims 1 to 4, wherein the box has an open front.

6. The box of any one claims 1 to 4, wherein the box has a front hinged panel.

7. The box of claim 6, wherein the hinged front panel is hingably attached to the top wall or the bottom wall.

8. The box of any one of claims 1 to 7, wherein a bottom panel, a rear panel hingedly attached to a rear edge of the bottom panel, a top panel hingedly attached to a rear edge of the rear panel, first and second side panels respectively hingedly attached to side edges of the bottom panel, third and fourth side panels respectively hingedly attached to front edges of the first and second side panels and fifth and sixth side panels respectively hingedly attached to side edges of the top panel.

9. The box of any one of claims 1 to 7, having a front panel hingedly attached to a front edge of the bottom panel.

The box of any one of claims 1 to 9, further including first and second additional rear panels respectively hingedly attached to rear edges of the first and second side panels.

11. The box of claim 10, further including a closing flap hingedly attached to a rear edge of the top panel, the closing flap having an elongated slot.

12. The box of claim 11, wherein the front panel preferably includes a closing tab hingedly attached to a front edge thereof.

13. The box of claim 12, wherein the closing tab is a pull tab which extends into the front panel and separated therefrom around a cutline. [R:\LIBLL] I 7235.doc:hxa

14. The box of claim 8 or 9, wherein the fifth and sixth side panels each include a locking tab which extends into the top panel and separated therefrom around a cutline.

The box of claim 14, wherein the bottom panel includes slots therein for receiving the locking tabs of another said box, with each of the side panels including an elongated aperture which respectively align when the box is formed.

16. The box of any one of claims 1 to 15, wherein the box includes an additional bottom panel hingedly attached to a front edge of the bottom panel and an additional top panel hingedly attached to a rear edge of the top panel.

17. The box of claim 16, further including seventh and eighth side panels respectively hingedly attached to the side edges of the rear panel.

18. The box of any one of claims 1 to 17, further including a number of spaced vertical dividers, wherein each divider is a panel having tabs at top and bottom edges thereof, each tab being inserted into respective slots of the additional top and bottom panels.

19. The box of any one of claims 1 to 18, wherein the box includes a number of horizontal shelves, wherein each shelf is a panel having tabs at side edges thereof, each tab being inserted into respective slots of the side panels.

The box of any one of claims 1 to 19, wherein the box includes wine bottle holder panels, wherein each panel has tabs at edges thereof and a number of wine bottle holder holes therein, each tab being inserted into respective slots of the top, bottom and side panels.

21. The box of any one of claims 1 to 20, wherein said blank is formed from a single sheet so as to be of a unitary construction.

22. A box substantiates hereinbefore described with reference to the accompanying drawings. DATED this Eleventh Day of August, 2006 Norbury Pty. Ltd. Patent Attorneys for the Applicant SPRUSON FERGUSON [R:\LIBLL] 17235.doc:hxa