US20100006632A1

US20100006632A1 - Re-foldable one piece box and lid

Info

Publication number: US20100006632A1
Application number: US12/212,668
Authority: US
Inventors: Timothy Conroy
Original assignee: Individual
Current assignee: Individual
Priority date: 2008-07-14
Filing date: 2008-09-18
Publication date: 2010-01-14
Also published as: CN102171105A; US20110204129A1; EP2323910A1; WO2010007410A1; GB0813412D0; GB0812777D0

Abstract

A re-foldable, multifunctional, flat packing, quick fold erect, one piece box & lid incorporating an integral internal panel (B) or panels, in which the fold erect feature allows the base of the box to be held erected in a set up position by the folded incorporated integral internal panels whether or not the attached lid is open or closed, without the use of additional glue, adhesives, tape, clip, or other fastener.

Description

BACKGROUND OF THE INVENTION

This invention relates to a multi-functional, flat packing, quick fold erect, re-foldable one piece box and lid incorporating an integral internal panel or panels.
Retail staff are under pressure to serve as many customers as possible, in a short a time as possible, and to focus their attention on the client which they are serving.
Furthermore, there is limited storage space in business premises, retail spaces and in the logistics chain on the products journey from factory to consumer. It is rare to find products, the box and contents produced in the same location or even region, and rarer still for the end use to be in the same location as the production of the box, thus all boxes, lids and fitments require some form of transportation or storage.
In addition, freight is charge by volumetric weight (volume and weight used in cost calculation), so shipping set-up boxes means paying for shipping the contents (be it air or products) also.
Brands and business are under continual pressure to offer high quality products, in a well-designed presentation or packaging that is fit for purpose.

BRIEF SUMMARY OF THE INVENTION

To overcome this, this invention proposes a re-foldable, multi-functional, flat packing, quick fold erect, one piece box and lid incorporating an integral internal panel or panels. This invention is such that the lid, base and incorporated integral internal flap mechanism are joined together as one piece, the box can be assembled and disassembled very quickly and easily without the need to use glue or other fasteners or adhesives as the base of the box is held in an erect set-up position by folded panels incorporated into the body of the box and lid. This allows the box and lid to be re-used and re-folded, it frees the hands of the end-user, the quick assembly without glue or other adhesives means minimal time or effort is required for set up or disassembly by the end user.
The folded erect set-up feature of the box allows the base of the box to be erected into a set-up position, whether or not the lid is closed or open, whilst at the same time hiding the internal mechanism of the base of the box. This offers a very presentable and practical solution, and the box is designed to minimise the amount of raw edges showing on the main faces as the folding panels cover the internal mechanism.
The invention can also be flat packed, saving valuable space in retail, home, business and logistics environments. The flat packed feature also requires less packaging for transportation (fewer export cartons) and is more secure for transportation - as set-up boxes are more likely to be damaged.
The one piece format of the box, which includes the box, lid & incorporated integral flap and also the possibility of an integrated internal fitment (which will be described in more detail later) means that the processes of setting up the box and lid is simplified for the end user and it also removes the need for a separate lid and base. The internal flap can also be modified to act as an integrated fitment to the contents or product(s), again removing the need for a separate fitment.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING

The invention will now be described solely by way of example and with reference to the accompanying drawings:

FIG. 1: shows the exploded perspective view of the box, neither flat packed or set-up but in a state of flux between the two states.

FIG. 2: shows the exploded top view of the major and minor panels that make up the box.

FIG. 3: shows the exploded top view of the panels that make up the box.

FIG. 4: shows the perspective view of the box, neither flat packed or set-up but in the early stages of setting up the box from a flat packed position.

FIG. 5: shows the perspective view of the box and how part C1 is folded in the setting up the box from a flat packed position.

FIG. 6: shows the perspective view of the box and how part B, in particular B1, is folded in the setting up the box from a flat packed position.

FIG. 7: shows the perspective view of the box and how part B, in particular B2, is folded in the setting up the box.

FIG. 8: shows the perspective view of the box and how part B the integral attached flap, in particular B2, holds the base in an erected position.

FIG. 9: shows the box in a set up position with the lid closed.

FIG. 10: shows an alternative version of the box with a panel or window in the lid.

FIG. 11: shows an alternative version of the box with a panel or window in the lid.

FIG. 12: shows an alternative version of the box in different proportions & size.

FIG. 13: shows an alternative version of the box in different proportions & size.

FIG. 14: shows an alternative version of the box in different proportions & size.

FIG. 15: shows an alternative version of the box in different proportions & size.

FIG. 16: shows an alternative version of the box in different proportions & size.

FIG. 17: shows an alternative version of the box in different proportions & size with a carrying handle.

FIG. 18: shows an alternative version of the box in different proportions & size with a carrying handle.

FIG. 19: shows an alternative version of the box in different proportions & size with a carrying handle.

FIG. 20: shows an alternative version of the box in different proportions & size with a carrying handle.

FIG. 21: shows an alternative version of the one-piece box with an integral fitment attached to panel B.

FIG. 22: shows an alternative version of the one-piece box with an integral fitment attached to panel B.

FIG. 23: shows an alternative version of the one-piece box with an integral fitment attached to panel B.

FIG. 24: shows an alternative version of the one-piece box with an integral fitment attached to panel B.

FIG. 25: shows an alternative version of the one-piece box with an integral fitment attached to panel B.

FIG. 26: shows an alternative version of the one-piece box with an integral compartment attached to panel B.

FIG. 27: shows an alternative version of the one-piece box with an integral compartment attached to panel B.

FIG. 28: shows an alternative version of the one-piece box with an integral compartment attached to panel B.

FIG. 29: shows an alternative version of the one-piece box with an integral compartment attached to panel B.

FIG. 30: shows an alternative version of the one-piece box closed with a stud holding the lid shut.

FIG. 31: shows an alternative version of the one-piece box closed with a lock holding the lid shut.

FIG. 32: shows an alternative version of the one-piece box closed with a tag closure.

FIG. 33: shows an alternative version of the one-piece box closed with a tag holding the lid.

FIG. 34: shows an alternative version of the one-piece box closed with ribbon closure.

FIG. 35: shows an alternative version of the one-piece box closed with ribbon holding the lid shut.

FIG. 36: shows an alternative version of the one-piece box closed with Velcro holding the lid shut.

FIG. 37: shows an alternative version of the one-piece box closed with elastic holding the lid shut.

FIG. 38: shows an alternative version of the one-piece box closed with a magnet holding the lid shut.

FIG. 39: shows an example of the box in a flat packed position, in the first stage of further folding the panels whilst flat packed to minimise the area the box takes up, in this case C1 is folded inwards.

FIG. 40: shows an example of the box in a flat pack position, with panel C1 folded inwards.

FIG. 41: shows an example of the box in a flat pack position, with an arrow illustration how panels B1 and B2 are folded inwards.

FIG. 42: shows an example of the box in a flat pack position, with panels A4 and A5 being folded to reduce the amount of area the flat pack box takes up.

FIG. 43: shows an example of the box in a flat pack position, with the panels folded.

DETAILED DESCRIPTION OF THE INVENTION

The basic structure of the box is made up of a number of panels, including the main body (A1, A2, A3, A4, and A5), end flap (C1), incorporated integral internal panel (B1, B2) and side walls (D1, D2, D3, D4, D5 and E1, E2, E3, E4, E5) as shown on FIG. 1, FIG. 2, FIG. 3. These panels are made flexible and foldable through the use of materials between the panels that have been pre-cut, pre-creased, pre-folded, or by connecting the panels with a flexible material, which may be a thicker or thinner substrate, or may connect the panels totally to each other or in part, as referred to in claim 4.
Panel A, which comprises the main body of the box, including the base part and the lid, is made up of 5 smaller panels (A1, A2, A3, A4 and A5). In a folded position, A1, A2, A3 together make up the base of the box, with parts A4 and A5 making up the lid as shown in FIG. 6, FIG. 7 and FIG. 8.
Panel B, which is the incorporated internal flap and/or integrated fitment, is connected to the join between panels A3 and A4 with a flexible material. Panel B is made up of parts B1 and B2.
Panel C1 is connected to the end of Panel A to part A1 using a flexible material. Panel C in this example is constructed of 1 panel piece only, however, this can be altered in size or structure and additional panels or parts may be added as per claim 5.
Panel D and Panel E are the side flaps for the box, each made up of 5 panels joined to each other by a flexible material, as illustrated in FIG. 1, FIG. 2 and FIG. 3.
The edge of D1, D3 and D5 and correspondingly the edge of E1, E3, and E5 are joined respectively to each side of the panels A1, A2 and A3, and lie flat against the surface of A1, A2 and A3 when the box is in a flat position, FIG. 4 shows the location of panels D and E. D1 and correspondingly E1 are affixed to panel A1, this attachment eases the assembly of the box for the end user, although this construction still works if D1 and E1 are not permanently affixed. D5 and respectively E5 are affixed to panel A3, as illustrated in FIG. 4.
The join between D3 and A2, and correspondingly the join between E3 and A2, are flexible so that D3 and E3 can lie flat against the surface of A2 or fold upwards to a position at 90 degrees to the surface of A2, as illustrated in FIG. 4, FIG. 5, FIG. 6 and FIG. 7.
The positions of the panels, the flexible joins between the individual panels making up the main parts of the box, are such that the box can be assembled into a setup position and easily disassembled into a flat pack position. The process of folding into a set-up position is illustrated step by step in FIG. 4 through to FIG. 9 inclusively. This process can easily be reversed to unfold the boxes back to a flat pack position. Ribbons, or an alternative method, can be added to the edge of panel B2 and also C to make unfolding even simpler as they provide an area that can easily be gripped by the user to unfold the panels; this ribbon is illustrated in FIG. 4 through to FIG. 7 attached to B2. Alternative solutions for gripping the edge of the panels could also be used, an example of which is small cuts or finger holes.
To assemble from a flat position, A1 and A3 are pushed towards each other by the end user (either by holding onto the Lid (A4 and A5) and end flap C, or some other location) such that A1 and A3 lie at 90 degrees against the surface of the inner face of panel A2, as illustrated by FIG. 4, FIG. 5 and FIG. 6. This motion will automatically fold D3 and E3 into a vertical (90 degree) position against the inner surface of A2, if the parts D1, D5, E1 and E5 have been affixed to A1 and A3 respectively as described above, otherwise the user will need to push these parts in. The position of the flaps is now such that A1, A3, D3 and E3 all lie at 90 degrees to the inner surface of A2, thus forming the beginnings of the base structure of the box. Due to the folding up of Panels D3 and D4 the panels D1 and D2, D4 and D5, E1 and E2, E4 and E5 will all fold together such that their surface lie flat against each other, this processes is illustrated in FIG. 6, where D4 and D5, E4 and E5 are pushed towards each other as the box is set up.
Panel C1 is then folded over such that its inner surface lies flat against the inner surface of panel A1, as illustrated in FIG. 5. The panel C1, in its folded position, will cover the panels D1 and D2, E1 and E2, so that they lie underneath panel C1, between C1 and A1.
An integral feature of this flat packing, quick fold erect, re-foldable one piece box & lid, the incorporated Panel B, is then folded over such that the inner surface of part B1 lies flat against A3, as shown in FIG. 6 and FIG. 7. The panel B1, in its folded position, will cover the panels D4 and D5, E4 and E5, so that they lie underneath panel B1 between B1 and A3.
The Panel B2, is then be pushed down so that it lies flat against the panel A2 as illustrated in FIG. 7 and FIG. 8. The pushing down of panel B2, or an incorporated panel added for this purpose, has the effect of holding panel C1 and B1 in place in their folded positions, hence holding the base of the box in a set up position, as illustrated in FIG. 7, FIG. 8. Thus the bottom part of the box is now erected with A1, A3, D3 and E3 all at 90 degrees to the inner surface of A2 and held in place by the folding of the inner panels B and also C1 as described above, as illustrated by FIG. 8. With the flaps in this position, the bottom part of the box will remain erected whether or not the lid, comprised of A4 and A5 is opened or closed.
The panel A4 can be folded over the top of the erected bottom part of the box to act as a lid or cover, with the panel A5 folding over the outer surface of A1, as illustrated by FIG. 9. To keep the lid closed on the box when in an erected position, A5 can be attached to the outer surface of panel A1 through the use of magnets, clips, cuts, additional parts, ribbons, ties or other method as per claim 8.
FIG. 10 and FIG. 11 illustrate an alternative version of this invention, with a panel or window in the lid panel A4. A panel, window or cut out can be included on any panel or side of the box or lid, to act as an adornment, decoration, feature or to allow visibility or access to the products.
FIG. 12, FIG. 13, FIG. 14, FIG. 15 and FIG. 16 illustrate an alternative version of this invention in various sizes and proportions.
FIG. 17, FIG. 18, FIG. 19 and FIG. 20 illustrate an alternative version of this invention with a handle (H1) attached to a panel in various sizes and proportions. The invention could be made with other methods for carrying it attached to any location on the outer or inner surface, or carrying method not attached directly to the product. Attachments could also be added for as a feature or for decorative or adornment purposes to the outside or inside of this invention. A handle, made from a ribbon, string or other material could be affixed to the outer surface of panel A1 such that it passes through a cut, whole or slot in A5, or on any other panels, to act as a handle or adornment, or decoration or other use, as per claim 7.
FIG. 21 illustrates an alternative version of this invention with an incorporated integrated fitment. The fitment in this example is the result of foldable panels (of which B5, B7 and B8 are visible in FIG. 21) incorporated and attached on to either side of panel B2, such that the panels fold and act as a fitment. Panels B3, B4, B5, B7 and B8, which in this example are additional panels connected to the main B (B1 and B2) panel, are visible (although not all these panels feature in each drawing) in FIGS. 21 through to FIG. 25 inclusive, they fold so as to form a fitment, that in this example is an extension of panel B2. These panels are made flexible and foldable through the use of materials between the panels that have been pre-cut, pre-creased, pre-folded, or by connecting the panels with a flexible material, which may be a thicker or thinner substrate, or may connect the panels totally to each other or in part, as referred to in claim 4. The panels may have a cut out or slits to hold the product when the fitment is folded in place in the set up position, as illustrated in FIG. 22, FIG. 23, FIG. 24 and FIG. 25.
There are a number of ways in which a fitment can be integrated into this invention, including altering the size, shape and number of panels, adding flaps, parts, cuts or interlocks to create an integrated fitment as per claim 10, claim 11 and claim 12. Some additional examples of alternatives for integrated fitment are illustrated in FIG. 22, FIG. 23, FIG. 24 and FIG. 25, which show fitments made using more incorporated integral panels, flaps, interlocks, cut outs, slots, holes and slits. In these examples, the fitment can also be flat packed, and is directly connected to the box.
More panels or parts can be incorporated to the existing panels and flaps. The existing panels which make up the box may also be changed in size, proportions and or structure, for example to act as a fitment or internal compartment.
This invention can also be made by altering the panel B2 or incorporating more panels, flaps, parts, cuts or interlocks so that the invention is held together in an erect set up position without the need for the panel B2 to touch or lie flat against the inner surface of the panel A2, as illustrated by the example FIG. 23 in which more panels have been incorporated onto the box to act as a fitment and also to hold the base of the box erect.
The box and lid could also be lined on the inside or the outside with material for decorative purposes or to protect the contents when in a set-up position. The box and lid could be lined with fabric material.
FIG. 26, FIG. 27, FIG. 28 and FIG. 29 illustrate an alternative version of this invention with an incorporated integral integrated compartment. The panels making up the compartment may be integrated with panel B2, as an extension of panel B2 or it may be incorporated to the other panels that make up the box and lid, or new panels or flaps incorporated to the box. FIG. 26 illustrates the use of additional incorporated panels (panel B3 is visible in FIG. 26) to act as an integrated compartment when folded in the set-up position. More panels can be integrated to form a combination of compartments and fitments. This is illustrated by the panels B3, B5, B6, B7, B8, B9 which are visible in figures 26 through to 29 inclusively (although not all panels feature in each drawing), and act as an integral integrated compartment, as they are attached to the main panel B (B1 and B2)
FIG. 30, FIG. 31, FIG. 32, FIG. 33, FIG. 34, FIG. 35, FIG. 36, FIG. 37 and FIG. 38 illustrate an alternative version of this invention with alternative methods for holding the lid (in this example parts A4 and A5) closed. The examples include the use of magnets (FIG. 38), ribbons (FIG. 34 and FIG. 35), studs clips, locks, Velcro and straps.
A key feature of the box is that the box, lid and incorporated integral internal panels can be folded into a flat packed position. FIG. 39 illustrates a top view of the box in a flat packed position. FIGS. 39 through to FIG. 43 inclusive show how the panels of the box can be further folded, to minimise the area the flat packed box takes up. FIG. 39 shows how panel C1 is folded over. FIG. 41 illustrates how panels B1 and B2 are folded over the inside face of panels A1, A2, A3 and the folded panel C1. FIG. 42 shows how panels A4 and A5 are folded around the back of the box. FIG. 43 shows another example of how the box can be flat packed, with panels A4 and A5 folded around the back, and panels B1, B2 and C1 folded over the inside of the box, all in a flat packed position. The folding of the panels reduces the amount of area the box takes up, making it easier to store and also more compact for shipping which reduces the risk of damage in transit, as well as saving space.

Claims

1. A re-foldable, multifunctional, flat packing, quick fold erect, one piece box & lid incorporating an integral internal panel or panels, in which the fold erect feature allows the base of the box to be held erected in a set up position by the folded incorporated integral internal panels whether or not the attached lid is open or closed, without the use of additional glue, adhesives, tape, clip, or other fastener.

2. A re-foldable, multifunctional, flat packing, quick fold erect, one piece box & lid incorporating an integral internal panel or panels according to claim 1, with a folding lid, folding side walls and incorporated integral internal folding panels, in which the lid, integral internal panels and side walls are attached to the main body of the box, and all are foldable such that the structure folds to form a fully covered complete box with attached lid (and not a box comprised of a separate lid and base parts).

3. A re-foldable, multifunctional, flat packing, quick fold erect, one piece box & lid incorporating an integral internal panel or panels according to claim 1, in which the box can be assembled from the flat pack position to the set-up position and the box can be disassembled and returned to the flat pack position, without the use of adhesives, double sided tape, tape, or other fastener to hold it in the set-up position.

4. A re-foldable, multifunctional, flat packing, quick fold erect, one piece box & lid incorporating an integral internal panel or panels according to claim 1, in which the lid, side walls, base and internal flaps are made flexible and foldable through the use of materials that have been pre-cut, pre-creased, pre-folded, or through by connecting the panels making up the sides and parts of the box with a flexible material, which may be a thicker or thinner substrate, or may connect the panels totally to each other or in part.

5. A multifunctional, flat packing, quick fold erect, re-foldable one piece box & lid according to claim 1, in which the box, lid and integral panels can be of varying dimensions, proportions, and sizes.

6. A re-foldable, multifunctional, flat packing, quick fold erect, one piece box & lid incorporating an integral internal panel or panels according to claim 1, in which any part of the box, lid or integral panels may have a window, slot, cut out or panel or may have part of the material replaced by a different material which is clear, see-through or not see-through to act as a window, or adornment or decoration, or access to the product.

7. A re-foldable, multifunctional, flat packing, quick fold erect, one piece box & lid incorporating an integral internal panel or panels according to claim 1, on which a carry mechanism, handle or part by which the box can be carried is added to any of the internal or external panels, including but not limited to a ribbon, string, plastic, paper or metal handle affixed to the box.

8. A re-foldable, multifunctional, flat packing, quick fold erect, one piece box & lid incorporating an integral internal panel or panels according to claim 1, in which the lid in a closed arrangement can be held in position by magnets, a ribbon, a clip, a slotting method, or other such method for securing the position of the lid of the box when in a set-up arrangement, or the lid can be left open and unattached.

9. A re-foldable, multifunctional, flat packing, quick fold erect, one piece box & lid incorporating an integral internal panel or panels according to claim 1, in which the internal panel holds the box in an erect set up position by a fold erect mechanism of internal panels or by engaging frictionally, via slots or cuts in either flap, via a clip, or magnet, or by altering the shape of the panels or by interlocking between panels of the box, including more incorporated panels.

10. A re-foldable, multifunctional, flat packing, quick fold erect, one piece box & lid incorporating an integral internal panel or panels according to claim 1, in which the internal flaps or panels act as a fitment.

11. A re-foldable, multifunctional, flat packing, quick fold erect, one piece box & lid incorporating an integral internal panel or panels according to claim 1, in which the internal flaps have additional panels, flaps or material attached to them to support a product as a fitment, or to act as an adornment or decoration.

12. A re-foldable, multifunctional, flat packing, quick fold erect, one piece box & lid incorporating an integral internal panel or panels according to claim 1, in which the internal flaps have panels attached to them, or material cut out from them or the size or shape alerted in order to support a product as a fitment, or to act as an adornment or decoration.

13. A re-foldable, multifunctional, flat packing, quick fold erect, one piece box & lid incorporating an integral internal panel or panels according to claim 1, in which the internal flaps have additional panels, flaps or material attached to form a compartment or multiple compartments.

14. A re-foldable, multifunctional, flat packing, quick fold erect, one piece box & lid incorporating an integral internal panel or panels according to claim 1, where part or all the materials are lined or coated with fabric or other materials, or various materials are used to make up the parts of the box.

15. A re-foldable, multifunctional, flat packing, quick fold erect, one piece box & lid incorporating an integral internal panel or panels according to claim 1, which can be fixed permanently in a set up position the use of additional glue, adhesives, tape, clip, or other fastener, or interlocking, clips or other method for permanently holding the box in a set-up position.