BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention is directed to collapsible rigid containers.

2. Description of Related Art

Rigid containers are every day articles. It is well known to mass manufacture boxes or other containers which, at some point in their manufacture, are comprised of flat members which are then assembled such as that disclosed by Oxley in U.S. Pat. No. 2,544,191. Such containers come in all shapes and sizes.

Boxes or similar containers which may be constructed of a rigid material, such as cardboard, plastic, or the like, are well known. When manufacturing a rigid container that may be shipped flat and then easily assembled by the user, a compromise must be made in the appearance of the container. Details of the assembly, such as the engaging or interlocking portions of the container walls are usually visible, thereby detracting from the overall appearance from the typical preassembled rigid container, such as, a hat box or the like.

Most folding boxes or containers are tubular structures with closures at both ends. A smaller proportion of existing folding containers form a box from a tray. These usually consist of a base and a lid or cover. On occasion, the lid may be attached to the tray.

In a typical rigid box, a sheet of paper board is cut and scored to a specific box size. Depending on the size needed, one or more boxes may be die cut from one sheet of paper board. For example, in manufacture, a sheet of paper board might be sufficiently dimensioned to permit the arrangement therein of a total of six trays, either six bases or lids or, potentially, three basses and three lids. The scored sheet is then broken into individual pieces. A tray may be assembled from one of the blanks and defined by four wings or side panels extending from a rectangle. The four side panels are bent along score lines to right angles with respect to the tray base and stay tape is applied to each of the four corners to form the tray. Cover paper (or wrap) is cut to size from sheets or rolls to the approximate desired size. The cover paper is then miter-cut to be so dimensioned as to permit a smooth fit about the assembled tray. The wrap paper is coated with an adhesive. The erected tray is disposed on the wrap at the desired location. The paper is then wrapped around the paper board tray. The portions of the wrap intended to fold over the edge of the tray the â€˜turn-in wrapâ€™â€”enclose all four edges of the tray, the rigid box is complete.

It is well known for the walls of a container to be held releasably held in place by mating connectors, including magnets as in U.S. Pat. No. 6,688,516 by Ussen. One deficiency of the prior art is that it uses complex means of assembling containers, making it difficult to provide efficient means of assembly and disassembly.

It is also believed that the prior art fails to teach a box or other container of relatively rigid material which may be readily assembled and, upon such assembly, give the appearance of being a completely rigid container and which may be easily collapsed, if desired.

BRIEF DESCRIPTION OF THE INVENTION

It is an object of this invention to provide a container which may be provided in a collapsed state and assembled to form a rigid appearing container.

It is another object of this invention to provide a container in which the base is formed of interlocking panels and there is provided hingedly secured covers for pivoting so as to cover the base to provide the appearance of a rigid container.

It is yet another object of this invention to provide a container which may be shipped flat and erected to present a rigid box.

It is still another object of this invention to provide a lid to a container having top and side panels and which may be provided flat and so connected at its corners as to form a lid with mating sides.

It is yet another object of this invention to use magnets to releasably join sides so that a rigid container may be easily assembled and disassembled.

It is a yet a further object of this invention to provide mating panels of a container which are held in position against the shearing force set up by objects within the container by not adhesive engaging tape with a high coefficient of friction therebetween relative to the coefficient of friction of the materials making up the panels.

In accordance with one embodiment of this invention there is provided a rigid collapsible container which comprises container means. The container means includes flexible base means and container side panel means. The base means and the container side panel means define therebetween a predetermined configuration open at at least one side and closed at one end by the base means so as to define the interior volume of the container. The base means comprises at least a pair of interlocking panels. The exterior base panel means is hingedly connected to the container means so as to fold over and enclose the base means within the container.

In yet another embodiment there is provided a lid for a container which comprises a cover panel and side panels. There is also provided wrap cover paper secured to the cover and side panels to thereby join the panels together to form a lid with extending sides. There is also provided gusset means for connecting one of the side panels to another of the side panels. The gusset means comprises closure means for making the connection.

In yet another aspect of this invention there is provided a rigid container of the type of having a collapsed and an erect state. The container comprises housing means including flexible bottom means, and container side panel means. The bottom means and the container side panel means define therebetween a predetermined configuration open at at least one side and closed at one end by the bottom means so as to define therebetween the interior volume of the container when the container is erect. The bottom means comprises at least a pair of bottom panels. There is also provided joining means secured to at least one of said bottom panels and insert panel means for being removably disposable within the housing and against said bottom. The insert panel comprises engaging means for being connected with the joining means to thereby releasably hold the bottom panel together with the container in the erect state.

In still another aspect, there is provided a rigid container of the type of being collapsed and an erect state. The container comprises housing means which includes container side panel means. There is also bottom means. The container side panel means together with the bottom means define a predetermined configuration open at at least one side and closed at one end by the bottom means so as to define the interior volume of the container when the container is erect. The bottom means comprises at least one bottom panel. The bottom joining means are secured to the bottom panel. The side joining means are secured to at least one of the side panels for engaging the bottom joining means such that, upon engagement of the bottom and side joining means, the container is substantially locked in the erect state.

In another embodiment there is provided a container which comprises a housing. The housing has an interior volume and side panels. The side panel interior surfaces define therebetween at least a part of said interior volume. At least one closing panel has surfaces for removably engaging at least a part of the interior surfaces of the side panels. The side panel interior surfaces relative to the engaging surfaces of the closing panel having a first coefficient of friction first means are provided secured to the interior surfaces of the side panels. Second means are secured to the engaging surfaces of the closing panel. Upon the closing panel engaging the side panels, the first and second secured means nonadhesively contact one another and have a second coefficient of friction greater than the first coefficient of friction so as to hold the closing panel to the side panels fixedly in position.

There is further a method of making a rigid collapsible container which comprises the steps of providing a container with flexible bottom means and container side panel means open at at least one side and closed at one end by said bottom means to define therebetween the interior volume of the container; providing at least a pair of interlocking panels to form the bottom means; providing an exterior bottom panel means; and hingedly connecting the bottom panel means to the container means so as to fold over and enclose the bottom means within the container.

In another aspect there is provided a method of providing a container having a collapsed and an erect state, the method comprises providing housing means including bottom means, and container side panel means which together define a predetermined configuration open at least one side; closing one end with the bottom means to define therebetween the interior volume of the container when the container is erect; providing joining means to be secured to the bottom means; providing closure panel means that is removably positionable within the housing and against the bottom means; and providing insert panel means which includes engaging means for releasably connecting with the joining means so that the insert panel means releasably and rigidly holds the bottom means and the container side panel means such that container is in the erect state.

In yet another embodiment there is provided the method of making a container comprising providing a housing with an interior volume and side panels, the side panel interior surfaces defining therebetween at least a part of the interior volume; providing at least one closing panel having surfaces for removably engaging at least a part of the interior surfaces of the side panels; providing the side panel interior surfaces relative to the engaging surfaces of said closing panel with a first coefficient of friction; providing first means secured to the interior surfaces of the side panels; providing second means secured to the engaging surfaces of the closing panel; and bringing the first and second secured means into contact upon the closing panel engaging the side panels, and providing the contacting first and second secured means with a second coefficient of friction greater than the first coefficient of friction so as to hold the closing panel to the side panels fixedly in position.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1A and B are plan view of the bottom panels, including a Hymes bottom constructed in accordance with the teachings of the invention;

FIG. 2 is a perspective of an exterior sleeve constructed in accordance with the teachings of the invention; and

FIG. 3 is a perspective view of an interior tray; and

FIG. 4 is a perspective view of an assembled container; and

FIG. 5 is a perspective view of a cover for the container; and

FIG. 6 is a top perspective view of another embodiment of the container of this invention; and

FIGS. 7A-73 are side views of the panels of the container of FIG. 6; and

FIG. 8 is a bottom perspective view of the embodiment of FIG. 6; and

FIG. 9 is a side view of the box of FIG. 6 in a collapsed or folded state; and

FIG. 10 is a bottom perspective view of another embodiment of the side walls of the device of this invention; and

FIG. 11 is a top perspective view of the bottom section of the container of FIG. 10; and

FIG. 12 is a side view of the device of FIG. 10 in a collapsed state.

DESCRIPTION OF THE PREFERRED EMBODIMENT

Turning to FIGS. 1A and B there is shown two interlocking planar members which may be made out of any suitable material such as relatively flexible cardboard blanks 10 and 12 to form a bottom 8 (FIG. 3) of the box 11 (FIG. 4). The blanks 10 and 12 are identical mirror images of one another other and comprise a substantial rectangular portion 14 and 16, respectively. A marginal longer dimensioned edge 18, 20 of each blank 10, 12, respectively, may define the interlocking parts 18, 20 of a Hymes bottom. A crease or score line 22, 24, defines the longer dimensioned side of each rectangular portion 14, 16, respectively, which is opposed to the Hymes bottom lock 18, 20, respectively. To one side of each rectangular portion 14, 16 may be provided a triangularly shaped section 26, 28, respectively. The base 30, 32 of each triangle 26, 28 is an extension of the crease or score line 22, 24. Each triangle 26, 28 may be joined to the rectangular portion 14, 16 by means of an integrally formed substantially rectangular panel 34, 36. A crease line 38, 40 in each panel 34, 36, where an apex 42, 44 of the triangular portion 26, 28 contacts a corner 42, 44 of each respective rectangular portion 14, 16, divides each respective rectangular panel 34, 36 into two rectangular parts, 34a, 34b, and 36a, 36b. Each rectangular panel 34, 36 has an extending flap 46, 48. (Any other type of known interlocking bottom may be used, such as, a Houghland bottom.) While cardboard, paper board, and chip or white board are referred to throughout, it will be understood that any material, such as plastic or wood, may be used.

Four chipboard panels 52-58, may be joined together to thereby define a rectangular sleeve 50 (FIG. 2) open at the top 60 and bottom 62. The panels 52-58 may be joined or held together by any convenient means, such as by forming from a continuous panel which may be folded or scored. Here, the four rectangularly shaped panels 52-58, which may be made of chip or white board, may be held together by tape, other joining means, including a strong wrap or cover paper which is turned over as, for example at 64, 66 along the top and bottom defining edges 60, 62.

One extending panel 68 (shown in phantom) of the cover paper is, however, not folded over its respective side 52. An exterior bottom rigid panel 70, which may be made of the same material as the side panels 52-58 of the sleeve 50 may be wrapped in the same covering wrap. The bottom panel 70 is so dimensioned as to fit snugly within the sleeve 50. The panel 68 of the wrap paper may be connected to the exterior bottom panel 70 by adhesive or similar means (in the same way that the wrap paper is adhered to the side panels 52-58) so as to hingedly connect the exterior panel 70 to the sleeve 50 so as to present a rigid appearing bottom integral with the remainder of the container.

One panel 16 of the Hymes bottom lock has an aperture 72 therethrough. An inside panel 74 (FIG. 3) which may be made of cardboard or the like, may be secured to the other part 14 of the Hymes lock as by, for example, clear tape 76 so that when the Hymes lock is assembled, the inside panel 74 moves hingedly to cover and thereby hide from view the Hymes bottom. Matching connectors 78 (FIG. 3) and 80 (FIG. 2), which may for example be VelcroÂ®, are secured respectively to the interior panel 74 and exterior panel 70 by well known means and so positioned as to mate with one another through the aperture 72 on opposed sides of the Hymes lock bottom panels 16 and 18.

In assembly (FIGS. 1A, B, 3, and 4), the rectangular panels 34, 36 are each folded upwardly along the crease lines 22-30, 32-24 and then along vertical crease lines 38 and 46 and 40 and 48. Placed in Hymes bottom engagement, the upstanding panels 34, 36 form the sidewalls of a shallow tray 82 (FIG. 3). The extending flaps 46, 48 may be secured, as by glue or the like, to the respective mating walls 34a and 36a to thereby form the shallow tray 82. Upon engaging the Hymes bottom lock 16, 18, the triangular part 26, 28 of each blank fold to complete the bottom 90 (FIG. 4). The shallow tray 82 is so dimensioned as to fit snugly within the bottom 62 of the sleeve 50 (FIG. 4). The shallow tray 82 may be attached to the sleeve 50 by any known means as by glue or the like.

In operation, with the Hymes bottom engaged and the bottom 90 formed, the inside panel 74 and the exterior panel 70 are each hingedly connected along the same edge defmed by the bottom edge 84 of one side 52 of the sleeve 50 and the crease line 24 of the shallow tray 80. As indicated, the Velcro connectors 78, 80 mate through opposing sides of the aperture 72 in the Hymes bottom. When fully assembled, the rigid exterior panel 78 combines with the sleeve 50 to form a rigid box. Opening the exterior panel exposes the aperture 72 in the Hymes bottom. By pushing through the aperture 78, the inside panel 74 is pivoted upwardly (FIG. 4). The Hymes bottom lock 16, 18 may then be disengaged in a well known manner and the box 86 collapsed by folding sides 56, 58 upon sides 52, 54 or sides 56, 54 upon sides 52, 58, forming a flat but easily assembled rigid appearing box.

A lid 100 (FIG. 5) may be constructed to also be collapsed. Such a cover may comprise a top rectangular panel 102 and four side panels 104-110. The side panels 104-110 may be joined to the top panel 102 as by a wrap paper 112 adhered by an adhesive to the exterior side of the panels 102-110. A rectangular gusset 114 may be formed at each end 116 of the sides 104-110 of the lid 100. Each gusset may be folded upon itself to define hinged triangular sections 118, 120. One of the triangular sections 120 may have adhered thereto double-sided tape with a piece of release paper covering it as is well known. The lid may be disposed flat by folding the sides 110-114 flat with the top panel 102. To assemble, the release paper (not visible) is removed and the triangular sections 118, 120 of each gusset 114 adhered to one another to form the lid 100. If it is desired to permit the lid 100 to be erected and collapsed, the corners 116 may be connected by such closure means as Velcro or the like.

While the rigid box herein has been described as comprised of a tray insertable within a sleeve, it is to be understood that the same device can be constructed in other ways, as by, for example, the locking bottom being integrally formed with the sleeve sides and made from one or more appropriately scored blanks.

In another aspect of this invention there may be provided a container 200 (FIGS. 6, 8) which may comprise four sides 202, 204, 206, 208. This is but one example. However, other shapes are contemplated, such as containers with a square cross section and other symmetrical or asymmetrical configurations. Containers of different dimensions or having a different number of sides are contemplated. In the example shown, the container 200 is rectangularly shaped with two sides 206, 208 being longer than the other two sides 202, 204. Each pair of sides 202, 204 (see also FIG. 7c) and 206, 208 (see also FIG. 7B) may have identical dimensions for ease of assembly. The bottom 210 of the container 200 may be comprised of triangularly shaped pieces 212, 214 (see also FIG. 7D) and two identically dimensioned isosceles trapezoids 216, 218 (see also FIG. 7A). In the shorter dimensioned side 224, 226 of the trapezoids 216, 218, may be an opening. In the example shown, this opening may be a notch 220, 222. The shape if the opening 220, 222 is one of choice and, in the drawing, is shown as a rectangular cross section.

The bottom 210 (FIGS. 6, 8) may comprise the abutting and mating edges of the triangular 212, 214 and the isosceles trapezoids 216, 218.

The notches 220, 222 in the short side 224, 226, respectively, will, upon assembly mate to form an opening or aperture in the bottom where the two isosceles trapezoids meet (224, 226). The opening or aperture defmed between abutting sides may have any desired symmetrical or asymmetrical configuration.

Joined to the bottom side 228 of one of the isosceles trapezoids 216 may be a magnet receptor 230 which may be of any well known material, such as a ferrous medallion (as shown). The receptor 230 may have any desired shape, such as circular, as shown. The magnet 230 may be secured to the exterior bottom wall 228 of the container 200 by any means, such as glue or the like. The receptor 230 may be so positioned such that, when the two edges 224, 226 of the shorter dimensioned sides 224, 226 of the isosceles trapezoids mate, the receptor 230 covers the meeting notches 220, 222.

A closing panel 234 (FIG. 7E), may be so dimensioned as to fit in the interior of the box and abut the bottom wall 210. In the example shown, the closing wall 234 may be a rectangularly shaped planar member which is dimensioned to conform to the interior dimensions of the container 200 and abut the interior bottom wall 210. A magnet 238 may be secured to the side 236 of the bottom wall 210 that abuts or contacts the interior surface 232 of the bottom wall 210. The magnet 238 may be affixed by any well known means, as by glue or tape. The magnet 238 may be attached to the closing panel 234 so as to be in registry with the aperture 220, 222 when the closing panel 234 positioned against the bottom wall 210 of the container 200.

In assembly, the abutting sides 240 of two of the sidewalls 206 and 204 (FIG. 9) may be joined or attached to one another. In like manner, the abutting sides or edges 242 of the adjacent two sidewalls 204, 208 may be secured or joined to one another. The remaining side 202 may be joined at its abutting edge 244 with the sidewall 208 and abutting edge 246 with the wall 206. The isosceles trapezoids 216, 218 may be secured at their longer-dimensioned parallel abutting edges 248, 250 to the respective bottom edges 248, 250 of the side walls 206, 208. The triangular sections 212, 214 of the bottom wall 210 may have one side 252, 254 joined to the respective side walls 204, 206. In this way, the completed blank may be collapsed flat (FIG. 9). When opened, the bottom wall 210 forms easily. The individual sides 202, 204, 206, 208 may be joined along abutting edges 240, 242, 244, 246, 248, 250, 252, 254 as by tape or wrapping paper (not shown). The wrapping paper, when covering all surfaces of the container, gives the appearance of a unitary rigid container.

As indicated above, the shape of the container may be geometrically symmetrical or asymmetrical. In general, the geometry of the sections making up the bottom wall of the container will change with the shape of the container. If, for example, the container were to have a square cross section, the bottom walls may comprise four mating frusto-triangles (not shown). The apices of the mating triangles may be defined by the frusto ends thereby defining an aperture. A magnetic receptor, such as a ferrous medallion of any desired shape may be secured to one of the triangles and engages the aperture in the same way as the above embodiment. As before, a removable bottom planar member is insertable within the housing of the container and may have a magnet in registry with the aperture and the base magnet.

In operation, the attached and folded blank is erected into the shape of the container 200. The receptor 230 mates with the magnet 238 on opposed sides of the aperture 220, 222 to hold the container 200 rigidly in position. To collapse the container, all that need be done is to remove the closing panel 234 to return the container to its folded blank condition. As in the first embodiment, cardboard, paper board, and chip or white board may be used construct the container. However, it will be understood that any material, such as plastic or wood, may be used.

Wherever a magnet or receptor is described above (and below) it will be understood that the position of the receptor and magnet are interchangeable or that oppositely poled magnets may be used in place thereof.

In yet another embodiment, a container 300 (FIG. 10) may be formed from individual planar members. As before, chip or white board is provided in this example, but any material, as indicated above may be used. In the example shown, the container (shown with the bottom upper most) may have a square cross section and be formed of four individual planar members 302, 304, 306, 308. (Any desired shapeâ€”to form a geometrically symmetrical or asymmetrical container may be used.) In this example, the four sides 302, 304, 306, 308 may, as with the other embodiments, present a unitary rigid appearance by the use of wrapping paper 310 placed over the outer surfaces of the members 302, 304, 306, 308 and secured thereto as by glue. The wrapping paper 310 may be folded over the marginal edges 312, 314 of the assembled sides 302, 304, 306, 308 with a relatively small skirt 316 to be folded over the marginal edges 312, 314 and attached by glue or similar means. Prior to gluing, magnets (or magnetic receptors) 318 may be attached to the interior walls 320, 322, 324, 326 of the sides 302, 304, 306, 308, respectively. As an example, the magnets 318 may be small disks. The small skirt 316 may be disposed over the magnets 318 to assist holding them in place. The magnets 318 may be held in place by the addition of tape, which may be, for example, clear cellophane tape 328. Any other suitable means of attachment may be used as well. Further, the size and shape of the magnet 318 is one of choice and will be, as will be more apparent from the discussion above and below, a function of the desired strength of the magnet.

A bottom closure lid 330 (FIG. 11) may be in the shape of a typical cover, with a bottom wall 332 and upstanding sides 334, 336, 338, 340. These may be, again, of ordinary chipboard or cardboard or other structural material, held together by a wrapping paper. Under the wrapping papers and attached to the outer surfaces of the sides 334, 336, 338, 340, may be magnets 342 (shown in phantom in FIG. 11). The bottom cover 330 is so dimension to be slidably into the container 300.

In assembly, the bottom cover 330 is oriented so that its bottom wall 332 will define the bottom wall of the completed container, with the marginal walls 334, 336, 338, 340 inside the container. The magnets 342 and 318, when aligned for a strong bond and define the rigid container. To assist in moving the bottom cover 330 from the top of the open container downward until the magnets 318, 342 mate, a strip of material, such as PVC tape (not visible) may be disposed about the outside of the marginal walls 334, 336, 338, 340. Similar tape may be secured to the interior walls of the container 300 (not visible).

The resulting container 300 is rigid or locked in position when erected from the collapsed state. The closure lid 330 may be slid into place from the top of the open container. The engaged magnets in the closure lid 330 and side walls 302, 304, 306, 309 serve to position the walls with respect to one another. However, magnetic fields may not be sufficiently strong to overcome the shearing forces set up when objects are placed in the container. When the closure lid 330 is in position in the base of the container 300, the PVC tape secured to the interior walls of the side walls of the container 300 may be in registry with the PVC secured to the outer surface of on the upstanding walls 334, 336, 338, 340 of the closure lid 330. The mating PVC tape like material exhibits a higher coefficient of friction than exists between the cardboard or other material making up the panels. (Of course, any other material exhibiting a mating higher coefficient of friction than the panels may also be used.) In such circumstances, the mating surfaces of the tape prevents the closure lid from separating from the container side walls under the shearing forces set up by objects placed in the container. The mating tape surface form a rigid container which may be easily disassembled since they are not adhesively joined. Thus, the mating surfaces are not permanently affixed as by glue or similar substantially permanent joining means.

A top cover or lid of typical construction and well known in the art may be so dimensioned as to fit over the top 344 of the container. With the top and bottom covers removed, the walls may be easily folded upon themselves (FIG. 12) for storage or shipment.

While certain novel features of this invention have been shown and described and are pointed out in the annexed claims, the invention is not intended to be limited to the details above, since it will be understood that various omissions, modifications, substitutions, and changes in the forms and details of the device illustrated and in its operation can be made by those skilled in the art without departing in any way from the spirit of the present invention.