CROSS-REFFERENCE TO RELATED APPLICATIONS

This application claims priority benefits under 35 U.S.C. Â§120 to co-pending U.S. patent application Ser. No. 10/348,136 filed on Jan. 21, 2003. This related patent application is herein incorporated by reference in It entirety.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present Invention generally-relates to a packaging structure. More particularly, the present invention relates to a collapsible box.

2. Description of the Related Art

Cardboard boxes are commonly utilized as containers and are generally available in many sizes and shapes. Many cardboard boxes are fully constructed by box manufacturers and delivered to customers as non-foldable boxes in ready-to-use forms. However, there are several disadvantages of a non-foldable cardboard box because the three-dimensional structure requires a large amount of space for transportation and storage, resulting in various economic inefficiencies. At the same time, an empty cardboard box may be easily damaged during transportation from the box manufacturer to its customers.

Foldable cardboard boxes, especially when designed as flat sheets, improve the storage and transportation Inefficiencies. However, foldable cardboard boxes generally require several steps of manually folding and tucking various parts of the cardboard box to construct the box for use. Additionally, an adhesive (e.g., glue and/or tape) may be required to hold the foldable box after being constructed. However, these manual steps of constructing a foldable box generally require tremendous time and labor costs. For example, additional time spent to make a box by a store clerk who is completing a purchasing transaction results in generally unacceptable delays and inefficiencies at the check-out register. Such delays and inefficiencies may be reduced if the foldable boxes are made ahead of time so that the boxes are ready for use. However, the storage space requirements of fully constructed boxes again may present problems.

U.S. Pat. No. 1,311,047 discloses a folding box which is formed by folding a single paper sheet. Since foldability of the paper sheet can decrease when the thickness of the paper sheet is increased, it is difficult to make a folding box having sufficient robustness from such a single paper sheet. U.S. Pat. No. 549,064 discloses a paper box made from a blank of two-layer structure which consists of an inner layer of strawboard or wood-pulp board and an outer layer of fancy or figured paper. The inner layer is excavated to form fold lines for the blank.

SUMMARY OF THE INVENTION

An object of the invention is to provide a collapsible box which is robust and which is formed of a foldable panel body of three-layer structure.

According to the invention, a collapsible box comprises a foldable panel body foldable to form a container which includes at least a front panel, a bottom panel, a back panel, a left side panel, and a right side panel. The panel body includes the front, bottom, back, left side and right side panels, wherein the front, bottom and back panels are foldably connected to each other in sequence, and the left and right side panels are connected foldably and respectively to left and right sides of the bottom panel. The panel body further includes a plurality of connectors to connect foldably the left and right side panels to the front and back panels so as to form corners of the container. One pair of the connectors are connected foldably and respectively to left and right sides of the front panel, and the other pair of the connectors are connected foldably and respectively to left and right sides of the back panel. Each of the connectors has two connector panels which are interconnected foldably. The panel body further includes a plurality of foldable connections to provide foldable connections among the front, bottom, back, left side, right side and connector panels so that the panel body is foldable along the foldable connections. Each of the front, bottom, back, left side, right side, and connector panels has a panel plate, and at least first and second sheet layers which sandwich the panel plate. The first and second sheet layers of the front, bottom, back, left side, right side, and connector panels are connected to each other, while the panel plates thereof are separated and spaced apart from each other to form gaps therebetween. Portions of the first and second sheet layers corresponding to the gaps form the foldable connections.

BRIEF DESCRIPTION OF THE DRAWINGS

Other features and advantages of the present invention will become apparent in the following detailed description of the preferred embodiment(s) of the invention, with reference to the accompanying drawings, in which;

FIG. 1 is a plan view of a foldable panel body according to a preferred embodiment of the invention;

FIG. 1A is a sectional view taken along line 1A-1A of FIG. 1;

FIG. 2 is a perspective view showing the panel body in transition to a box configuration;

FIG. 3 is a perspective view showing the box configuration of the panel body of FIG. 1;

FIG. 4 is a perspective view showing a two-layer flat configuration of the panel body;

FIG. 5 is an exploded view illustrating the fabrication of the panel body;

FIG. 6 is a perspective view of a collapsible box according to another preferred embodiment of the invention;

FIG. 7 is a plan view of a panel body for forming the collapsible box of FIG. 6;

FIG. 8 is a sectional view taken along line 8-8 of FIG. 7;

FIG. 9 is a perspective view showing a two-layer flat configuration of the panel body of FIG. 7;

FIG. 10 illustrates the assembling of the panel body of FIG. 7;

FIG. 11 is a perspective view showing the panel body of FIG. 7 in transition to a box configuration;

FIG. 12 is an elevation view showing the panel body of FIG. 7 in a compact storage position;

FIG. 13 is a perspective view showing the panel body stored in a lid:

FIG. 14 is a plan view of a panel body according to still another preferred embodiment of the invention; and

FIG. 15 is a plan view of the panel body of FIG. 14 in a two-layer flat configuration: and

FIG. 16 is a perspective view of a container portion formed from the panel body of FIG. 14.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring to FIGS. 1 to 4, there is shown a foldable panel body 100 for a collapsible box (A) according to a preferred embodiment of the invention. Although a rectangular collapsible box (A) is illustrated, collapsible boxes having other shapes are also contemplated. Generally, the collapsible box (A) comprises a top panel 110, a back panel 120, a bottom panel 130, a front panel 140, a left side panel 150 and a right side panel 160. The top panel 110, the back panel 120, the bottom panel 130, and the front panel 140 are connected foldably to each other in sequence through foldable connections 170 in the panel body 100 . The left and right side panels 150 and 160 are connected foldably and respectively to the left and right sides of the bottom panel 130 through foldable connections 170. Four connectors 180 are provided to connect the left and right side panels 150 and 160 to the front and back panels 140 and 120 to thereby form four corners of the box (A). Each connector 180 includes a pair of connector panels, i.e. first and second connector panels 182, 184 which are interconnected through a foldable connection 186.

Referring to FIG. 1A in combination with FIG. 1, each of the front panel 140, bottom panel 130, back panel 120, top panel 110, left side panel 150, right side panel 160, and connector panel 182, or 184 includes a panel plate 101 and at least first and second sheet layers 102, 102â€² which sandwich the panel plate 101 therebetween. The panel plate 101 may be made of a medium or heavy weight cardboard. Each first or second sheet layer 102, 102â€² may include one or more sheets of paper (relatively much material. Each panel plate 101 is fixed or glued to the first and second sheet layers 102, 102â€². The first and second sheet layers 102, 102â€² of the front panel 140, bottom panel 130, back panel 120, top panel 110, left side panel 150, right side panel 160, and connector panels 182 and 184 are connected to each other, while the panel plates 101 thereof are separated or spaced apart from each other to form gaps 105 therebetween. Parts of the first and second sheet layers 102, 102â€² corresponding to the gaps 105 serve to provide the foldable connections 170, 186.

Alternatively, the front, bottom, back, top, left side and right side panels 140, 130, 120, 110 and the connector panels 182, 184 may be taped together by strips of plastic or paper tapes to provide the foldable connections between the panels. The foldable connections 170 exist between the front panel 140 and the bottom panel 130, between the back panel 120 and the bottom panel 130, between the top panel 110 and the back panel 120, between each of the left and right side panels 150, 160 and the bottom panel 130, and between one of the connector panels 182 or 184 and one of the front panel, back panel, left side panel, and right side panel, 140, 120, 150 and 160, respectively. Foldable connections 186 are provided between the connector panels 182 and 184.

In this embodiment, both of the first and second connector panels 182, 184 of each connector 180 are triangular and are interconnected through the foldable connection 186 which extends along a diagonal line that extends from one of four corners of the bottom panel 130. The first connector panel 182 is fixedly attached (e.g., glued) to the interior surface of the front panel 140 (or back panel 120), and the second connector panel 184 is foldably connected to a side edge of the left side panel 150 (or right side panel 160). The thickness of the panel plates 101 of the first and second connector panels 182, 184 are smaller than the thickness of the panel plates 101 of the front panel 140, bottom panel 130, back panel 120, left side panel 150, and right side panel 160.

The panel body 100 further includes an enclosure flap 200 which is foldably connected to the top panel 110 through a foldable connection 170. A releasable fastener 210 may be attached to the enclosure flap 200 and the front panel 140 to facilitate closure of the collapsible box (A). In one embodiment, the releasable fastener 210 comprises a magnetic fastener set (e.g. a set of two magnets or a set of a magnet and a metal piece). Other releasable fasteners are contemplated for releasably holding the enclosure flap 200 (or the top panel 110) against the front panel 140.

FIG. 5 is a schematic diagram illustrating components for assembling the foldable panel body 100 according to one embodiment of a method according to the invention. The panel plates 101 of the enclosure flap 200, the top panel 110, the back panel 120, the bottom panel 130 and the front panel 140 are attached (glued) in sequence to one side of a first intermediate sheet member 510. The panel plates 101 are spaced apart to form the gaps 105 for the foldable connections 170. A second intermediate sheet member 511 is laid and fixed (e.g. by gluing) on the panel plates 101 and the first intermediate sheet member 510 to form an intermediate sub-panel body 51. The panel plates 101 of the left side panel 150 and the associated connectors 180 (each connector 180 having first and second triangular panels 182 and 184) are attached to one side of a first left sheet member 520 in a spaced-apart relationship to form the gaps 105.

A second left sheet member 521 is laid and fixed on the panel plates 101 and the first left sheet member 520 to form a left sub-panel body 52. The panel plates 101 of the right side panel 160 and the associated connectors 180 ( each connector 180 having first and second triangular panels 182 and 184) are attached to one side of a first right sheet member 530 in a spaced-apart relationship to form gaps 105. A second right sheet member 531 is laid and fixed on the panel plates 101 and the first right sheet member 530 to form a right sub-panel body 53. The panel body 100 is formed after the left and right sub-panel bodies 52, 53 are connected to the intermediate sub-panel body 51.

The panel body 100 is then folded so that the left and right side panels 150, 160 lie over the bottom panel 130 and so that the connectors 180 lie over the front and back panels 140, 120, as shown in FIG. 4. Afterward, the first triangular panels 182 of four connectors 180 are glued to the front panel 140 and the back panel 120. The panel body 100 is therefore placed in a two-layer flat configuration, as shown in FIG. 4. To facilitate storage and transportation, the panel body 100 may be folded further as shown by arrows D1 and D2 in FIG. 4.

Preferably, each of the intermediate, left and right sheet members 510, 520, 530 may include excess edge portions 512, 522, 532 that may be wrapped around and glued to the edges of the panel plates 101 to enhance the overall attractiveness of the box (A). Furthermore, the sheet members 510, 520, 530 may include logos and/or designs for particular occasions (e.g., holidays, birthdays, etc.) to further enhance the attractiveness of the box (A). It is contemplated that the sheet members 610, 520 and 530 may comprise a single sheet or a plurality of sheets to achieve the desire attractiveness or finished look of the box (A).

To form the panel body 100 into the box (A), a user may lift the side panels 150 and 160 laid on the bottom panel 130 (as shown in FIG. 4) to an upright position. As the left and right side panels 150, 160 are lifted, the front panel 140 and the back panel 120 are concurrently lifted, as shown in FIG. 2, because the first triangular panels 182 of the connectors 180 are glued to the interior surfaces of the front and back panels 140, 120.

With the left and right side panels 150 and 160 held in the upright position, the box (A) may be filled with one or more objects to be stored in the box. For example, the collapsible box (A) may be utilized in a gift shop, and a store clerk may place one or more purchased gift items into the collapsible box (A). The collapsible box (A) may include a decorated exterior, and additional gift wrapping would not be necessary, saving time and money for both the merchant and the customer. The collapsible box (A) may also be decorated with a store's emblem, logo or a trademark.

Referring to FIGS. 6 to 9, there is shown another embodiment of the present invention. In this embodiment, the collapsible box (B) generally comprises a lid 602 and a container 604. The lid 602 includes a top panel 610 and side portions 612 which confine a receiving space (not shown) with the top panel 610. The container 604 includes a back panel 620, a bottom panel 630, a front panel 640, a left side panel 650 and a right side panel 660.

The container 604 is formed from a foldable panel body 600 which includes the back panel 620, the bottom panel 630, the front panel 640, and the left and right side panels 650, 660. The front, bottom and back panels 640, 630, 620 are foldably connected to each other in sequence. The left and right side panels 650, 660 are connected foldably and respectively to left and right sides of the bottom panel 630. Foldable connections 670 exist between the front panel 640 and the bottom panel 630, between the back panel 620 and the bottom panel 630, and between each of the left and right side panels 650, 660 and the bottom panel 630, respectively. Four connectors 680 are provided to connect the left and right side panels 650 and 660 to the front and back panels 640 and 620 so as to form corners for the container 604. Each connector 680 comprises first and second triangular connector panels 682 and 684 which are foldably connected to each other through a foldable connection 686.

Each of the back panel 620, the bottom panel 630, the front panel 640, the left and right side panels 650, 660 and the connector panels 682, 684 has a sandwich structure which includes a panel plate 101 and at least first and second sheet layers 102, 102â€². The panel plate 101 may be made of a medium or heavy weight cardboard. Each first or second sheet layer 102, 102â€² may include one or more sheets of paper (relatively much lighter weight compared to the cardboard) or other similar sheeting material. Each panel plate 101 is fixed or glued to the sheets of the first and sheet layers 102, 102â€². The first and second sheet layers 102, 102â€² of the front panel 640, bottom panel 630, back panel 620, left side panel 650, right side panel 660, and connector panels 682 and 684 are connected to each other, while the panel plates 101 thereof are separated or spaced apart from each other to form gaps 105 therebetween (e.g., 1/32 to Â¼ inch gaps for 1/16 inch thick panels). Portions of the first and second sheet layers 102, 102â€²corresponding to the gaps 105 serve to provide the foldable connections 670, 686. Alternatively, the panels may be taped together by strips of plastic or paper tapes to provide the foldable connections between the panels.

Referring to FIG. 10, to fabricate the foldable panel body 600 for the container 640, all of the panel plates 101 of the front panel 640, bottom panel 630, back panel 620, left side panel 650, right side panel 660, and connector panels 682 and 684 are first glued to a first sheet member 730 in a spaced apart relationship to form the gaps 105. A second sheet member 731 is laid and fixed on the aforesaid panel plates 101 and the first sheet member 730. The gaps 105 between the panel plates 101 may be provided with an appropriate dimension so that the foldable connections 670 are sufficient for the panel body 600 to be folded to a compact position.

After the panel plates 101 are assembled, the panel body 600 is in a single layer flat configuration as shown in FIG. 7. The panel body 600 is then folded to a two-layer flat configuration, as shown in FIG. 9, in which the left and right side panels 650, 660 lie over the bottom panel 630 and the connectors 680 lie over the front and back panels 640, 620. Furthermore, the first connector panels 682 are fixed (e.g. glued to) to the interior surfaces of the front and back panels 640, 620.

To form the panel body 600 from the two-layer flat configuration (FIG. 9) into a three-dimensional box configuration (FIG. 6), a user may lift the left and right side panels 650 and 660 to an upright position. As the left and right side panels 650, 660 are lifted, the front panel 640 and the back panel 620 are concurrently lifted because the first connector panel 682 are fixed to the interior surfaces of the front and back panels 640, 620. FIG. 11 shows the panel body 600 in transition to the three-dimensional box configuration when the left and right side panels 650 and 660 are lifted. In this state, the second connector panels 684 are folded over the first connector panels 682, respectively. Strips of double-sided tape 688 may be disposed on the first or second connector panels 862 or 864 in order to keep the panel body 600 in a three-dimensional box configuration.

The panel body 600 may be folded further from the two-layer flat configuration (FIG. 9) to a compact storage position, as shown in FIG. 12, in which the front and back panels 640, 620 are laid over the bottom panel 630 opposite to left and right side panels 650, 660. To achieve this compact storage position, the gaps 105 or foldable connections 670 between each of the front and back panels 640, 620 and the bottom panel 630 and between each connector 680 and one of the left and right side panels 650, 660 may be provided with a sufficient width depending on the thickness of the panel plates 101 so that the folded layers of the panel body 600 can be in a substantially parallel relationship.

Preferably, the panel plates 101 of the connector panels 682, 684 which function to provide connection rather than robustness for the container 604 may be provided with a thickness smaller than that of the panel plates 101 of the front, bottom, back, left and right side panels, 640, 630, 620, 650, 660 to reduce the size or thickness of the connectors 680. As such, the appearance of the container 604 may be enhanced, and the panel body 600 may be folded easily and neatly to the compact storage position.

With the panel body 600 folded into the compact position, the container 604 may be stored into the lid 602 as shown in FIG. 13. In one embodiment, the height of the side portions 612 and the thickness of the panel body 600 in the compact storage position is substantially the same. In the compact position, a plurality of collapsible boxes (B) can be stored and/or transported easily, increasing efficiencies in storage space requirements and transportation costs.

Referring to FIGS. 14 to 16, there is shown still another embodiment of the present invention which is substantially similar to the embodiment shown in FIGS. 6 to 13. However, the height of the front, bottom, and back panels 840, 830, 820 and the left and right side panels 850, 860 of the panel body 800 for the container 804 (i.e. the height of the container 804) is increased compared to the height of the container 604 of the previous embodiment. Particularly, the height of the container 804 is larger than half of the width of the bottom panel 830 measured between the left and right side panels 850, 860 so that the left and right side panels 850. 860 overlap each other (FIG. 15) when being folded and placed over the bottom panel 830 to form the two-layer flat configuration.

Furthermore, each foldable connection 886 which extends between the first and second connector panels 882, 884 along the diagonal line does not extend to the top edge 841 or 821 of the front or back panel 840 or 820. Rather, the foldable connection 886 terminates at a point below the top edge 841 or 821 of the front or back panel 840 or 820. As such, the first connector panels 882 are trapezoidal, and the top edges 8841 of the triangular second connector panels 884 do not extend to the top edges 841, 821 of the front and back panels 840, 820.

Compared to the triangular first connector panel 682 of the previous embodiment, the trapezoidal shape of the first connector panel 882 provides an increased contact and adhesion area between the first connector panel 882 and the front or back panel 840 or 820, especially at the region adjacent to the top edge 841 or 821 of the front or back panel 840 or 820 where the first connector panel 882 becomes tapered. The triangular first connector panel 682 in the previous embodiment is liable to peel off from the front or back panel 640 or 620 at its tip adjacent to the top edge of the front or back panel 640 or 620 due to its small contact area with the front or back panel 840, 820 (see FIG. 11). Compared to the container 604 of the previous embodiment, the container 804 has a neater top edge as the edge 8841 of the second connector panel 884 is not exposed at the top edge.

While the foregoing is directed to embodiments of the present invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow.