Note: Descriptions are shown in the official language in which they were submitted.
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CORRUGATED CONTAINER BOX AND BLANK
FIELD OF THE INVENTION
[0001] The invention relates to box containers for storage and transportation
of documents and
other articles.
BACKGROUND OF THE INVENTION
100021 Individuals and businesses across many industries use containers to
store
documents, materials, personal items, memorabilia, and the like. A common
container for such
use is a box, typically having a lid, typically made of a corrugated
paperboard or cardboard, or
corrugated plastic. Such file boxes are used in the hundreds of millions to
hold and store any and
all sorts of items that can fit within them. Typically, these boxes carry up
to forty pounds or
more of materials within them.
[00031 In such previously known boxes the standard, slit handles or grips
found in the
container portion are well known. Conventional corrugated paperboard boxes
having a handle
opening and a lid have seen few changes since the introduction of that style
of box over seventy
years ago.
[00041 There are numerous circumstances where the user of a container box
may want to
prevent or deter other persons from accessing the contents of the box, after
documents or other
articles are placed inside the container box and a lid is placed over the top
opening of the
container. The contents placed into the box may include documents, articles,
devices, or other
things, related to a business, medical, personal or legal matter, that are
used in businesses,
offices, homes, home offices, and file storage facilities, and which may be of
a confidential,
secret, sensitive, personal, or private nature. In some circumstances, the
user might want to have
such documents, articles, etc. in a container with a lid that is securely
closed and locked so that
access by unauthorized persons is prevented, unless the lock or integrity of
the box or lid is
breached using a tool. However, in many situations, the user may want to deter
access by an
unauthorized person, or to provide some means of securing the lid in a closed
position on the box
that indicates tampering or breach of the securing means.
[00051 When a human user lifts and holds a commonly used and known
corrugated box
with handle or grip openings in the opposed sides, a number of changes
immediately occur to
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that user's body. When the user holds that known box (or other containers
similar to it) with her
arms extended, the top of the box and/or lid of the box will lie at an angle
(from horizontal)
against the legs or lower torso of the holder. Because the box is weighted,
the human user's
center of gravity is shifted from her natural position within her body, to a
point outside of her
body to compensate for the box's weight. This shift of the user's center of
gravity shifts the
user's naturally weighted stance from her heels to the front of her feet and
along her toes. Such
orientation can be painful and is not sustainable over time. This is true
because lifting and/or
holding a container or box engages muscles in the back, arms, shoulders,
torso, core, hips and
legs. It also puts the holder in an unbalanced position that can cause slips
or falls as a holder
holds the box and moves with it. When the holder's center of gravity is
shifted, her body
operates instantly to counteract such shift and to support the weight pulling
upon the front of her
body. Such weight pull is compensated by most of the user's major muscle
groups and in
particular those about her lower back and torso.
[0006] Corrugated paperboard is the primary material used in the
manufacture of document
boxes. Corrugated material, like many construction materials, continually
increases in price, and
there remains a need to reduce the amount of material used in a container box,
to reduce the
amount of wasted material during the manufacture of the box, to reduce the
amount of material
used in the box, and to reduce the cost for making reduced-material container
boxes.
[0007] Another widely-used container is a corrugated plastic tote bin
having tapered
sidewalls. These containers can be stacked or nested one inside the next to
save vertical storage
space, compared to a rectangular box These containers are not assembled from a
flat blank by
the user; rather, once they are manufactured, they are shipped and stored in
their three-dimension
form until used.
SUMMARY OF THE INVENTION
[0008] The present invention provides a container, including a box or a
tote. The container
comprising a bottom panel having a front edge, a rear edge, a right edge and a
left edge; a first
pair of opposed walls extending from the front edge and rear edge of the
bottom panel; and a
second pair of opposed walls extending from the right edge and left edge of
the bottom panel;
wherein either the first pair or the second pair of opposed walls each have an
inner surface and
comprise a first sidewall member having a first securement means and a second
sidewall member
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having a second securement means that cooperates with the first securement
means to secure the
first sidewall member to the second sidewall member.
[0009] The present invention also provides a container comprising a bottom
panel having a
front edge, a rear edge, a right edge and a left edge; a first pair of opposed
walls comprising a
front composite wall disposed along the front edge and a rear composite wall
disposed along the
rear edge of the bottom panel; a second pair of opposed walls comprising a
right wall and a left
wall disposed along the right edge and left edge, respectively, of the bottom
panel; wherein each
of the front composite wall and the rear composite wall comprise a first
sidewall member
including a first securement and a second sidewall member comprising a second
securement that
is secured to the first securement of the first sidewall member.
[00101 In a further aspect of the invention, the first and second sidewall
members along the
front edge are attached along a front side edge of the respective right wall
and left wall, and the
first and second sidewall members along the rear edge are attached along a
rear side edge of the
respective right wall and left wall.
[00111 In a further aspect of the invention, the container further includes
a front sidewall
extending from the front edge of the bottom panel, and a rear sidewall
extending from the rear
edge of the bottom panel, each of the front sidewall and rear sidewall lie
adjacent an inside
surface of the respective composite wall and rear composite wall.
[00121 The first securement can include a slot through the first sidewall
member, and the
second securement can include a tab extending from the second sidewall member,
wherein the
tab of the second sidewall member extends through slot of the first sidewall
member.
[0013] The present invention further provides a container comprising a box.
The box
comprising a bottom panel having a front edge, a rear edge, a right edge and a
left edge; a first
pair of opposed walls extending from the front edge and rear edge of the
bottom panel; and a
second pair of opposed walls extending from the right edge and left edge of
the bottom panel;
wherein the first pair of opposed walls each have an inner surface and
comprise a first sidewall
member having a slot and a second sidewall member comprising an extending tab,
wherein a
portion of the extending tab of the second sidewall member extends through the
slot of the first
sidewall member to secure the first sidewall member to the second sidewall
member.
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[0014] The container can be a box and the box can include four parallel
walls arranged
rectilinearly. The container can also be a tote with a bottom and four
outwardly tapered walls
arranged rectalinearly.
[0015] The first pair of opposed walls can each further comprise a second
sidewall
consisting of a rectangular panel that forms at least a portion of the inner
surface of each of the
first pair of opposed walls. Optionally both the first sidewall member and the
second sidewall
member have a grip opening in registry to form a through-wall grip opening for
lifting and
handling the box.
[0016] The present invention also relates to a blank formed on a single
board for folding
into a container. The blank comprising: a bottom panel having front, rear,
right side and left side
edges defined by corresponding fold lines on the blank; a front wall attached
to the front edge of
the bottom panel along the front fold line of the bottom panel; a rear wall
attached to the rear
edge of the bottom panel along the rear fold line of the bottom panel; a right
sidewall attached to
the bottom panel along the right side fold line of the bottom panel, the right
sidewall having a
front side edge defined by a corresponding front side edge fold line, and a
rear side edge defined
by a corresponding rear side edge fold line; a left sidewall attached to the
bottom panel along the
left side fold line of the bottom panel, the left sidewall having a front side
edge defined by a
corresponding front side edge fold line, and a rear side edge defined by a
corresponding rear side
edge fold line; a first front sidewall member attached to the front side edge
fold line of one of the
right sidewall and the left sidewall, the first front sidewall member being
one of a slotted
sidewall member having a slot or a tabbed sidewall member including an
extending tab; a second
front sidewall member attached to the front side edge fold line of the other
of the right sidewall
and the left sidewall, the second front sidewall member being the other of the
slotted sidewall
member or the tabbed sidewall member, wherein at least a portion of the
extending tab of the
front tabbed sidewall member is configured to extend through the slot of the
front slotted
sidewall member in an assembled position; a first rear sidewall member
attached to the rear side
edge fold line of one of the right sidewall and the left sidewall, the first
rear sidewall member
being one of a slotted sidewall member having a slot or a tabbed sidewall
member including an
extending tab; and a second rear sidewall member attached to the rear side
edge fold line of the
other of the right sidewall and the left sidewall, the second rear sidewall
member being the other
of the slotted sidewall member or the tabbed sidewall member, wherein at least
a portion of the
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extending tab of the rear tabbed sidewall member is configured to extend
through the slot of the
rear slotted sidewall member in an assembled position.
[0017] The present invention also relates to a blank formed on a single
board for folding
into a container. The blank comprising: a bottom panel having front, rear,
right side and left side
edges defined by corresponding fold lines on the blank; a front wall attached
to the front edge of
the bottom panel along the front fold line of the bottom panel; a rear wall
attached to the rear
edge of the bottom panel along the rear fold line of the bottom panel; a right
sidewall attached to
the bottom panel along the right side fold line of the bottom panel, the right
sidewall having a
front side edge defined by a corresponding front side edge fold line, and a
rear side edge defined
by a corresponding rear side edge fold line; a left sidewall attached to the
bottom panel along the
left side fold line of the bottom panel, the left sidewall having a front side
edge defined by a
corresponding front side edge fold line, and a rear side edge defined by a
corresponding rear side
edge fold line; a front slotted sidewall member attached to the front side
edge fold line of one of
the right sidewall and the left sidewall, the front slotted sidewall member
having a slot; a front
tabbed sidewall member including an extending tab attached to the front side
edge fold line of
the other of the right sidewall and the left sidewall, wherein at least a
portion of the extending tab
of the front tabbed sidewall member is configured to extend through the slot
of the front slotted
sidewall member in an assembled position; a rear slotted sidewall member
attached to the rear
side edge fold line of one of the right sidewall and the left sidewall, the
rear slotted sidewall
member having a slot; and a rear tabbed sidewall member including an extending
tab attached to
the rear side edge fold line of the other of the right sidewall and the left
sidewall, wherein at least
a portion of the extending tab of the rear tabbed sidewall member is
configured to extend through
the slot of the rear slotted sidewall member in an assembled position.
[0018] The blank can optionally include a portion having a grip opening in
both of the right
sidewall and the left sidewall, typically in the top portion of the right and
left sidewall.
Alternatively, the front wall and the rear wall can optionally include a top
portion have a grip
opening, wherein the front composite wall, comprising the front slotted
sidewall member and the
front tabbed sidewall member, has a grip opening that registers with the grip
opening of the front
wall when the front wall is assembled, and wherein the rear composite wall,
comprising the rear
slotted sidewall member and the rear tabbed sidewall member, has a grip
opening that registers
with the grip opening of the rear wall when the rear wall is assembled.
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[0019] The blank can optionally include a portion having a grip opening in
both of the right
sidewall and the left sidewall. Alternatively, the front wall and the rear
wall can optionally
include a top portion have a grip opening, wherein the front slotted sidewall
member and the
front tabbed sidewall member have a grip opening that each register with the
grip opening of the
front wall when the front wall is assembled, and wherein the rear slotted
sidewall member and
the rear tabbed sidewall member have a grip opening that each register with
the grip opening of
the rear wall when the rear wall is assembled.
[0020] An aspect of the present invention is a container box or tote that
is folded from a
blank that is made from a single corrugated sheet of material, without the use
of glue or
adhesive, or fusion, or other means for attaching together two pieces of
material, and that uses at
least 10% less material, and up to 25% (or more) less material, compared to
conventional
container boxes.
[0021] Another aspect of the present invention is a container box that is
folded from a
blank that is made from a single corrugated sheet of material, which is
produced with
significantly reduced waste, typically less than 5% waste material, including
less than 1% waste
material.
[0022] A further aspect of the present invention is a container box having
a double-
thickness wall that includes a continuous, smooth-surface inner sidewall and a
two-piece
compound outer sidewall.
[0023] Yet another aspect of the present invention is a container box
having a continuous,
smooth-surface bottom or floor that provides strength and integrity to the
container box around
the bottom.
[0024] Another aspect of the present invention is a container box that is
folded from a
blank that is intuitive to assemble, and includes a locking mechanism that
prevents easy or
spontaneous disassembly.
[0025] Another aspect of the invention is a container box with an integral
lid, including at
least one pair of opposed composite walls, and having means for locking the
hinged lid to the
container box that includes one or more openings in the lid opposite the
hinge, and an opening
through an upper portion of the front wall of the folded container box that
registers with at least
one of the lid openings.
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[0026] Another aspect of the invention is a container box that includes a
second
securement means for holding together and securing at least one pair of
opposed composite
sidewalls of a box sidewall, having at least one opening, and typically a pair
of adjacent
openings, formed through an upper portion of the box sidewall. The openings
penetrate through
the respective composite sidewall members. A cable tie or other fastener laced
through and
secured can assist holding together the composite sidewall members, and can be
used alone or in
combination with a pair of slotted and tabbed sidewall members.
[0027] Yet another aspect of the present invention is a container box that
can use up to
20% to 25% less material, while providing equivalent stacking strength to that
of convention file
boxes.
[00281 The containers can be made from a variety of conventional container
materials,
including cardboard, corrugated paper and plastic, cardboard, and plastic and
paperboard sheets.
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] While the specification concludes with claims particularly pointing
out and
distinctly claiming the invention, it is believed that the embodiments set
forth herein will be
better understood from the following description in conjunction with the
accompanying figures,
in which like reference numerals identify like elements and in which:
[0030] FIG. 1 is an exploded, perspective view of a container box and lid,
the container
box having opposed composite side walls, showing the lid removed from the top
opening of the
container box.
[0031] FIG. 2 is a perspective view of FIG. 1 showing the lid covering the
container box.
[0032] FIG. 3 is a side elevation view of the container box and lid of FIG.
1.
[0033] FIG. 4 is a plan view of the blank for folding into the container
box and lid of FIG.
1.
[00341 FIG. 5 is an exploded, perspective view of another embodiment of a
container box
and lid, the container box having opposed composite side walls.
[0035] FIG. 6 is a side view of the container box and lid of FIG. 5, with
the lid covering
the top opening of the container box.
[0036] FIG. 7 is a side view of the container box and lid of FIG. 5,
showing the lid
removed from the top opening of the container box.
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[00371 FIG. 8 is a perspective view of the container box of FIG. 5, with
the container walls
partially assembled.
[00381 FIG. 9 is a plan view of the blank for folding into the container
box and lid of FIG.
5.
100391 FIG. 10 is a side view of an alternative embodiment of a container
box and lid,
showing the lid removed from the top opening of the container box.
[00401 FIG. 11 is a plan view of a pair of blanks shown in FIG. 9, arranged
for production
together in a single die.
[0041] FIG. 12 shows an alternative embodiment of the container box of FIG.
5
[0042] FIG. 13 shows an embodiment a container box of the invention with an
integral lid.
[0043] FIG. 14 is a plan view of a blank for folding into the container box
and lid of FIG.
13.
[0044] FIG. 15 shows an embodiment a container box of the invention with
sidewalls that
outwardly taper.
[0045] FIG. 16 shows a plan view of a blank for folding into the container
box and lid of
FIG. 15.
[00461 FIG. 17 shows a container box having a second slot in the inner
sidewall to accept
insertion therethrough of the tab of the tabbed sidewall member.
[0047] FIG. 18 shows a plan view of a blank for folding into the container
box and lid of
FIG. 17.
100481 FIG. 19 shows another container box having a second securement means
for
holding together and securing the first and second sidewall members after
assembly.
100491 FIG. 20 shows a plan view of a blank for folding into the container
box and lid of
FIG. 19.
[00501 FIG. 21 shows another container box with the second securement means
for holding
together and securing the first and second sidewall members after assembly.
[0051] FIG. 22 shows a plan view of a blank for folding into the container
box and lid of
FIG. 21.
[0052] FIG. 23 shows an alternative embodiment of the container box shown
in Figure 13.
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DETAILED DESCRIPTION OF THE INVENTION
[0053] The term "grip" or "ergonomic grip" is defined herein as a fixed or
moveable,
permanent or temporary handle or grip, observation hole or opening, grip or
any other opening or
impression that could accommodate one or more figures of a human hand.
[0054] The term "height" is a distance or dimension determined in a
direction
perpendicular to a surface on which sets the bottom panel of the container, or
bottom edge if the
container does not have a bottom panel.
[0055] The term "width" is a distance or dimension determined in a lateral
direction,
perpendicular to the height.
[0056] The terms "front", "rear", "right" and "left" are relational terms
for the orientation
of the side surfaces of the container, wherein any one side surface of the
container is denoted as
"front", and the remaining side surfaces are accordingly denoted as "rear",
"right" and left",
when facing the front surface.
[0057] The term "registration" with respect to openings, port openings, or
grip openings,
means that a first opening in one panel member with a second opening in
another confronting or
adjacent panel member have substantial overlap, and can include: wherein
substantially all of the
second opening is overlapped by the first opening, and their respective
peripheries do not
substantially overlap or coincide; or wherein the first and second grip
openings are substantially
the same size and shape, their peripheries substantially overlap or coincide.
The first opening
can be the same size as or larger than the second opening.
[0058] FIGs. 1 through 4 show a first embodiment of a container 5 that
including an open-
topped box 6, and an optional lid 7. The box 6 includes four rectangularly-
arranged walls,
including a front wall 16 and a rear wall 17, and left wall 18 and a right
wall 19 disposed
respectively between and attached to both the front wall and the rear wall. A
bottom 20 has a
front edge joined to the bottom edge of the front wall 16, a rear edge joined
to the bottom edge of
the rear wall 17, a left edge joined to the bottom edge of the left wall 18,
and a right edge joined
to the bottom edge of the right wall 19. The upper edges of the four walls 16,
17, 18 and 19
define the top opening into the box.
[0059] The front wall 16 and the rear wall 17 form a first pair of opposed
walls having
substantially the same size and shape. The left wall 18 and the right wall 19
form a second pair
of opposed walls, typically of the same size and shape. Left wall 18 consists
of left sidewall 23
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formed of a continuous, smooth rectangular material integral with and hinged
to bottom 20 along
its left side edge. Right wall 19 consists of right sidewall 24 formed of a
continuous, smooth
rectangular material integral with and hinged to bottom 20 along its right
side edge.
[00601 Each of the walls of the first pair of opposed walls, front wall 16
and rear wall 17,
have an inner surface and an outer surface, and can include one, two, or more
layers of board
material. A layer of material can be a continuous, smooth, single piece of
board material, or can
be formed of a composite of two (or more) pieces of material. Wall 16 has an
inner surface (not
shown) and an outer surface 26o, and wall 17 has an inner surface 27i and an
outer surface (not
shown).
[0061] Each of front wall 16 and rear wall 17 includes a composite wall
that comprises a
first sidewall member having a first securement means, illustrated as a
slotted sidewall member
31 having a slot 32, and a second sidewall member having a second securement
means,
illustrated as a tabbed sidewall member 35 comprising an extending tab 36. The
slotted sidewall
member 31 is joined integrally with, and extends laterally from, the left
sidewall 23 or right
sidewall 24 along a side edge 23a or 24b. The tabbed sidewall member 35 is
also joined
integrally with, and extends laterally from, the left sidewall 23 or right
sidewall 24 along a side
edge 23b or 24a. A portion of the extending tab 36 of the tabbed sidewall
member 35 extends
through the slot 32 of the slotted sidewall member 31, thereby cooperating
with the slot to form a
securement of the first or slotted sidewall member to the second or tabbed
sidewall member. In
the illustrated embodiment, the tabbed sidewall member 35 overlaps the outer
surface of the
slotted sidewall member 31, with the tab portion 36 extending through the slot
32 and to the
inner surface of the slotted sidewall member 31, which contains the edge of
the tab 36.
[0062] As shown in Figure 3, the slot 32 extends through a portion of the
height of the
slotted sidewall member 31. The slot 32 can be oriented in a horizontal
direction or a vertical
direction, or therebetween, and can be straight, angular, curved or
curvilinear. In the illustrated
embodiment, the slot 32 is a curve formed substantially vertically in the
sidewall 31, from an
upper slot end to a lower slot end. The slot 32 is illustrated having a width
sufficient to insert the
tab 36 therethrough. The width of slot can range from just slightly wider than
the thickness of
the material of the tab, to a substantially greater width to ease insertion of
the tab therethrough.
The slot 32 continues from a distance "x 1" from the top edge 30 to a distance
"x2" from the
bottom 20. A tab 36 of the tabbed sidewall member 35 extends horizontally
(laterally) through
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the slot 32, and includes a portion or portions that also extend vertically
above the top edge and
below the bottom edge of the slot 32, toward the top end or bottom end of the
container box,
respectively. The tab 36 extends laterally from a neck 37 on the tabbed
sidewall member 35, and
includes at least one, or both, of an upper lobe 38 and a lower lobe 39. The
upper lobe 38 can
extend upward to a distance "y1" from the top edge 30. The lower lobe 39 can
extend downward
to a distance "y2" from the bottom 20.
[0063] The lower lobe 39 through the slot 32 extends a distance below the
lower end of the
slot 32 (the difference between the distances x2 and y2) that can be nil, or
nominal (for example,
a small distance, typically 0%-5% of the height of the wall 16,17), or up to a
distance that is
substantial (typically 15%-25% or more of the height of the wall 16,17), to
provide easy
assembly while also inhibiting or preventing the tab 36 from being pulled
laterally away or
pivoting out from the slot 32. Similarly, the upper lobe 38 extends through
the slot 32 and
extends a distance above the upper end of the slot 32 (the difference between
the distances x 1
and y 1 ) that can be can be nil, or nominal (for example, a small distance,
typically 0%-5% of the
height of the wall 16,17), or up to a distance that is substantial (typically
15%-25% or more of
the height of the wall 16,17), to provide easy assembly while also inhibiting
or preventing the tab
36 from being pulled laterally away or pivoting out from the slot 32.
[0064] In the embodiment illustrated in Figure 3, the lower lobe 39 extends
below the
lower end of the slot 32 (the difference between the distances x2 and y2) a
substantial distance,
typically 15%-25% of the height of the wall 16,17, and the upper lobe 38
through the slot 32
extends above the upper end of the slot 32 (the difference between the
distances xl and y 1) a nil
or nominal distance.
[0065] In other embodiments of the container, the upper lobe can be
substantially the same
size and shape as the lower lobe, or can be a different size and shape.
[0066] In an alternative embodiment illustrated in Figure 10, lower lobe 39
through the slot
32 extends below the lower end of the slot a nil or nominal distance, while
the upper lobe 38
through the slot 32 extends above the upper end of the slot a substantial
distance. It can be
understood that both the upper lobe and lower lobe can have vertical extension
that are
substantial distances beyond the edges of the slot toward the top edges 30 and
bottom 20. As can
be envisioned from the illustration in Figure 8, to aid the insertion of the
upper lobe 38 of the tab
36 through the slot 32 in the slotted sidewall member 131L, a portion 89 of
the upper lobe 38 can
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be folded over along a line, preferable a pre-formed score or impression line
88, that extends
from near the extension of the lobe 38 from the neck 37. Once the tab 36 with
the folded-over
portion 89 has been inserted through the slot 32, the folded-over portion 89
of the upper lobe 38
can be unfolded at line 88, back to its original form, to inhibit or prevent
the tab 36 from being
pulled laterally away or pivoting out from the slot 32 after assembly of the
container.
[0067] The width and height of the sidewalls of the container are selected
to ensure an
overlap of the slotted sidewall member 31 with the tabbed sidewall member 35.
The amount of
overlap of the compound wall, formed by the slotted sidewall member 31 and the
tabbed
sidewall member 35, expressed as a percentage of the combined widths of the
slotted sidewall
member 31 and of the tabbed sidewall member 35, is typically at least 10%,
including at least
15%, at least 20%, at least 25%, at least 30%, and at least 35%, and up to
100%, including up to
90%, up to 80%, up to 70%, up to 60%, up to 50%, up to 40%, up to 30% and up
to 20%, and
therebetween by units of 1%. In the illustrated embodiment wherein the
compound wall is
disposed over the wider end (wall 16) of the container box, the overlap
percentage is about 22%.
The percentage overlap of the compound wall when disposed on the narrower end
of the
container box is typically greater than when disposed on wider end. For
example, in another
embodiment of the invention wherein the compound wall is disposed over the
narrower end of
the container (wall 118 is Figure 5), the overlap percentage is about 40%.
[0068j Figures 1 and 3 show that first slotted sidewall member 31 is
integral with and
hinged to right sidewall 24 (right wall 19) along pivot line PA, and right
sidewall 24 is integral
with and hinged to bottom 20 along its right side edge that defines a pivot
line PB, while second
tabbed sidewall member 35 is integral with and hinged to left sidewall 23
(left wall 18) along
pivot line Pc, and left sidewall 23 is integral with and hinged to bottom 20
along its left side edge
that defines a pivot line PD. Consequently, in the assembled configuration
shown in Figure 3,
first slotted sidewall member 31 and second tabbed sidewall member 35 are
fixed at and pivot
away from one another at respective pivot points PB and PD, as shown by arrows
P1 and P2.
Correspondingly, upper lobe 38 of second tabbed sidewall member 35 pivots into
engagement
with material of first slotted sidewall member 31 above slot 32, and visa
versa, which inhibits the
first and second sidewall members 31,35 from separating.
[0069] Each of front wall 16 and rear wall 17 also includes a second
sidewall that is a
continuous, smooth rectangular material. Second front sidewall 21 is integral
with and hinged to
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bottom 20 along its front edge, and second rear sidewall 22 is integral with
and hinged to bottom
20 along its rear edge. Second front sidewall 21 defines the inner surface 261
of the front wall
16, while second rear sidewall 22 defines the inner surface 27i of the rear
wall 17, each
presenting a smooth continuous surface to objects contained within the
container box 6. All fold
and attachment lines along the four sides of the bottom are continuous and
uninterrupted with
openings or gaps, presenting a clean interior bottom. The front wall 16 and
rear wall 17,
attached to and extending from and along the edges of the bottom 20, provide
structural support
and integrity for the container. While the height of the front wall 16 and
rear wall 17 are
illustrated as a full height, equal to the height of the left wall 23 and
right wall 24, such height
can be shorter, and substantially shorter.
[0070] In an alternative embodiment, the compound wall can be disposed on
the inner
surface of the front wall 16 and rear wall 17.
[0071] An optional lid 7 is configured to fit over and cover the top
opening and top edges
30 of the box 6. Lid 7 includes a top panel 41 that has a front edge joined to
the top edge of a
front panel 46, a rear edge joined to the top edge of a rear panel 47, a left
edge joined to the top
edge of a left panel 48, and a right edge joined to the top edge of a right
panel 49. The opposed
front panel 46 and rear panel 47 are disposed between and joined along common
side edges to
the left panel 48 and right panel 49 to form an inverted box lid, dimensioned
so that the panels
46,47,48,49 of the lid 7 cover the top portions of the corresponding walls
16,17,18,19 of the
container box 5, as shown in Figure 2.
[0072] The container of the present invention can optionally include a grip
or handle
opening in the container box, and locking ports for securing the lid to the
container box. The
grip or handle opening can have a shape that can include rectangular,
elliptical and oval. The
grip or handle opening can have major access that is horizontal, or angled
from horizontal to
improve handling. An example of a grip opening and through-lid grip opening is
an
ergonomically-shaped grip openings, including a grip opening described in
International Patent
Publication WO/2012/154763, the disclosure of which is incorporated by
reference in its
entirety. The illustrated container 5 has a through-lid grip opening 50 and a
through-lid locking
port 60, as shown in Figure 2. The through-lid grip opening 50 is formed by
the registry of a
container grip opening 52 in the top portion of left wall 18 of the container
box 6, and a lid grip
opening 55 in the left panel 48 of the lid 7. The through-lid locking port 60
is formed by the
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registry of a container locking port 62 in the top portion of left wall 18 of
the container box 6,
and a lid locking port 65 in the left panel 48 of the lid 7. An opposed
through-lid grip opening
and through-lid locking port can be formed on the right side of the container
5 in the same
manner. A center point of the through-lid grip opening can be positioned at or
near the lateral
center point of the respective left and right walls, and preferably is
positioned closer to the front
wall 16 than to the rear wall 17 to provide better ergonomics during lifting
and carrying the
container.
[0073] The through-lid locking port is disposed proximate the through-lid
grip opening,
and provides therewith a pair of openings through the attached lid of the
container 5 through
which a locking means can be inserted and locked, for securing the lid 7 to
the container 6. The
locking means can include a strap seal or cable tie. As shown in Figure 2, a
cable tie 98 is
passed through the through-lid grip opening 50 and through-lid locking port
60, and the ends of
the cable tie 98 are fastened or secured together. The cable tie 98 can
include an elongated strap
member having a distal end and a proximal end with an integrated open case
having a ratchet.
The strap member has a rack of teeth along its length. Pulling the distal end
of the cable tie
through the case and past the ratchet prevents the strap member from being
pulled back out of
the case. Typically, the loop of the secured strap member has to be cut to
remove the cable tie
and unlock the lid from the box. Further details of a locking port for a
container box and lid are
described in US Provisional Patent Application 61/649,231, filed May 18, 2012,
the disclosure of
which is incorporated by reference in its entirety.
[0074] Figure 4 shows a blank 99 formed in a single board of material for
folding into the
container. The blank can also include a portion of board for folding into the
lid. The portion for
folding into the container is substantially square or rectangular, with very
little void space (or
board material cut away), including along the peripheral region of the blank.
The lid portion of
the blank is also substantially rectangular and attached to the container
portion along one edge
thereof. The lid portion is oriented to have a width dimension that is one
half of at least one of
the length or width of the container portion of the blank, to minimize board
waste.
[0075] The blank comprises a bottom panel 20 having front, rear, right side
and left side
edges defined by corresponding front fold line 20a, rear fold line 20b, left
side fold line 20c, and
right side fold line 20d on the blank. A front sidewall 21 is attached to the
bottom panel 20
along the front fold line 20a of the bottom panel, extending to a distal edge
that defines the
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height of the front sidewall 21, and a rear sidewall 22 is attached to the
bottom panel 20 along
the rear fold line 20b of the bottom panel, extending to a distal edge that
defines the height of the
rear sidewall 22, which is typically the height of the front sidewall 21.
[0076] The blank also includes rectangularly-shaped left sidewall 23
attached to the bottom
panel along the left side fold line 20c of the bottom panel 20, and extending
to a distal edge that
defines the height of the left sidewall 23, which is typically the height of
the front sidewall 21.
The left sidewall 23 has a front side edge, defined by a corresponding front
side edge fold line
23a, from which extends frontwardly a front tabbed sidewall member 35f. The
left sidewall 23
also has a rear side edge, defined by a corresponding rear side edge fold line
23b, from which
extends rearwardly a rear slotted sidewall member 31r. The front tabbed
sidewall 35f and the
rear slotted sidewall 31r each extend from their respective fold lines a
distance that is the same
height of the wall members, such as the height of the front sidewall 21.
[0077] The blank also includes rectangularly-shaped right sidewall 24
attached to the
bottom panel 20 along the right side fold line 20d of the bottom panel, and
extending to a distal
edge that defines the height of the right sidewall 24, which is typically the
height of the front
sidewall 21. The right sidewall 24 has a front side edge, defined by a
corresponding front side
edge fold line 24a, from which extends frontwardly a front slotted sidewall
member 31f. The
right sidewall 24 also has a rear side edge, defined by a corresponding rear
side edge fold line
24b, from which extends rearwardly a rear tabbed sidewall member 35r. The
front slotted
sidewall 31f and the rear tabbed sidewall 35r each extend from their
respective fold lines a
distance that is the same height of the wall members, such as the height of
the front sidewall 21.
[0078] In the illustrated embodiment, the container portion of the blank is
formed
asymmetrically, such that the tabbed sidewall members 35 are disposed on the
left side of the
compound walls (front wall 16 and rear wall 17 in Fig. 1) and the slotted
sidewall members 31
are disposed on the right side of the compound walls. In Figure 4, the blank
would appear
identically if rotated in its own plane 180 degrees. It can be understood that
the blank can be
formed conversely, with the tabbed sidewall members 35 disposed on the right
side and slotted
sidewall members 31 disposed on the left side, and that the blank, and
corresponding container
box, can be formed symmetrically about a center axis. For example, both of the
tabbed sidewall
members 35 could extend forwardly from the corresponding left sidewall 23 and
right sidewall
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24, and both of the slotted sidewall members 31 could extend rearwardly from
the corresponding
left sidewall 23 and right sidewall 24, or visa versa.
[0079] The front and rear slotted sidewall members 31 comprise a
substantially
rectangular-shaped base portion having a curved slot 32 penetrating through a
distal end of the
base portion. The slot can also be a linear slot. The length of the slot is
sized to accommodate a
tab, described hereinafter. As shown in Figures 2 and 4, the slotted sidewall
members can
include localized scoring, including scoring line or lines 77 and 78 extending
outward from the
upper end 32a and the lower end 32b, respectively, of the slot 32, to aid in
orienting or facing the
opening of the slot 32 toward the extending tab 36, and thus aiding assembly.
[0080] The front and rear tabbed sidewall members 35 comprise a
substantially
rectangular-shaped base portion that tapers abruptly to a narrowed neck
portion 37, and includes
a tab 36 extending from the neck portion 37. The tab 36 is configured to pass
through the slot
and to engage the material of the slotted sidewall members 31 to retain
engagement of the tab 36
within the slot 32. The tab 36 includes at least one lobe that extends
laterally along the
respective front or rear side edge fold line, and preferably includes a pair
of lobes 38,39. As
shown in Figures 4, the tabbed sidewall members can include localized scoring,
including
scoring line or lines 79 extending along the neck portion 37, to aid in
manipulating the tab 36
through the slot 32, and thus aiding assembly.
[0081] As shown in Figure 4, the blank can also include a portion of the
single board for
folding into the lid, which can be separated from the container portion of the
blank for folding
and assembly.
[0082] It can be understood that the embodiment shown in Figure 1-4 can be
described
wherein walls 16 and 17 are defined as right and left walls, and walls 18 and
19 are defined as
front and real walls.
[0083] FIGs. 5 through 9 show a second embodiment of a container 105 that
includes an
open-topped box 106 and a lid 7, wherein like reference numerals are used to
describe elements
described herein above for the first embodiment. The box 106 includes four
rectangularly-
arranged walls, including a front wall 116 and a rear wall 117, and left side
wall 118 and a right
side wall 119 disposed respectively between and attached to both the front
wall and the rear wall.
A bottom 20 has a front edge joined to the bottom edge of the front wall 116,
a rear edge joined
to the bottom edge of the rear wall 117, a left edge joined to the bottom edge
of the left side wall
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118, and a right edge joined to the bottom edge of the right side wall 119.
The upper edges of
the four walls 116, 117, 118 and 119 define the top opening into the box.
[0084] The front wall 116 and the rear wall 117 form a first pair of
opposed walls having
substantially the same size and shape. The left side wall 118 and the right
side wall 119 form a
second pair of opposed walls, typically of the same size and shape. Front wall
116 consists of
front sidewall 121 formed of a continuous, smooth substantially rectangular
material integral
with and hinged to bottom 20 along its front edge. Rear wall 117 consists of
rear sidewall 122
formed of a continuous, smooth substantially rectangular material integral
with and hinged to
bottom 20 along its rear edge. The front sidewall 116 and rear sidewall 117
are illustrated as
about the width of the side walls 118 and 119. Also within the scope of the
invention are front
sidewall 116 and rear sidewall 117 that are substantially wider than the side
walls 118 and 119,
including at least twice as wide, at least three times as wide, and at least
four times as wide. FIG.
12 illustrates a container box 206 that is similar in design to the container
box 106 of FIG. 5,
with an elongated bottom 220, elongated front and rear sidewalls 221 and 222,
to provide an
elongated container box.
[00851 Each of the walls the second pair of opposed walls 118 and 119 have
an inner
surface and an outer surface, and can include one, two, or more layers of
board material. A layer
of material can be a continuous, smooth, single piece of board material, or
can be formed of a
composite of two (or more) pieces of material in FIG. 5. Left wall 118 has an
inner surface (not
shown) and an outer surface 126o, and right wall 119 has an inner surface 127i
and an outer
surface (not shown).
[0086] Each of walls 118 and 119 includes a composite wall that comprises a
first slotted
sidewall member 131 having a slot 32, and a second sidewall member 135
comprising an
extending tab 36. The slotted sidewall member 131 is joined integrally with,
and extends
laterally from, the rear sidewall 122 along opposite side edges 122L and 122R,
while the tabbed
sidewall member 135 is joined integrally with, and extends laterally from, the
front sidewall 121
along opposite side edges 121L or 121R. A portion of the extending tab 36 of
the second or
tabbed sidewall member 135 extends through the slot 32 of the first or slotted
sidewall member
131. In the illustrated embodiment, the tabbed sidewall member 135 overlaps
the outer surface
of the slotted sidewall member 131, with the tab portion 36 extending through
the slot 32 and to
the inner surface of the slotted sidewall member 131, which contains the edge
of the tab 36.
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[0087] As shown in Figures 6 and 7, the slot 32 extends through a portion
of the height of
the slotted sidewall member 131, from a distance "x 1" from the top edge 30 to
a distance "x2"
from the bottom 20. The tab 36 extends laterally from a neck 37 on the second
sidewall member
135, and includes upper lobe 38 that extends upward to a distance "y1" from
the top edge 30, and
a lower lobe 39 that extends downward to a distance "y2" from the bottom 20.
The lower lobe
39 through the slot 32 extends a distance below the lower end of the slot 32
(the difference
between the distances x2 and y2) that is a substantial distance (typically 15%-
25%, or more of
the height of the wall 118,119), while upper lobe 38 through the slot 32
extends a distance above
the upper end of the slot 32 (the difference between the distances xl and y 1)
that is nil or only a
small distance, typically 0%-5% of the height of the wall 118,119, to provide
easy assembly
while inhibiting the second tabbed sidewall member 135 from being pulled
laterally away from
the first slotted sidewall member 131. As described herein earlier and shown
in Figure 10, the
upper lobe 38 can be configured to extend higher above the upper end of the
slot, to improve the
securement for the tabbed sidewall member to the slotted sidewall member.
[0088] Figures 5 - 7 show that first sidewall member 131 is integral with
and hinged to rear
sidewall 122 (rear wall 117) along pivot line PA, and rear wall 117 is
integral with and hinged to
bottom 20 along its rear edge that defines a pivot line PB, while second
sidewall member 135 is
integral with and hinged to front sidewall 121 (front wall 116) along pivot
line Pc, and front
sidewall 121 (front wall 116) is integral with and hinged to bottom 20 along
its front edge that
defines a pivot line PD. Consequently, in the assembled configuration shown in
Figure 7, first,
slotted sidewall member 131 and second, tabbed sidewall member 135 are fixed
at and pivot
away from one another at and around respective pivot points PB and PD, as
shown by arrows P1
and P2. Correspondingly, upper lobe 38 of tabbed panel member 135 pivots into
engagement
with material 133 of first slotted sidewall member 131 above slot 32, and visa
versa, which
inhibits the first and second sidewall members 131,135 from separating.
[0089] Each of left wall 118 and right wall 119 also includes a second
sidewall that is a
continuous, smooth rectangular material. Second left sidewall 123 is integral
with and hinged to
bottom 20 along its left side edge, and second right sidewall 124 is integral
with and hinged to
bottom 20 along its right side edge. Second left sidewall 123 defines the
inner surface of the left
wall 118, while second right sidewall 124 defines the inner surface 127i of
the right wall 119,
each presenting a smooth continuous surface to objects contained within the
container box 106.
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[0090] In an alternative embodiment, the compound wall can be disposed on
the inner
surface of the left wall 118 and right wall 119.
[0091] An optional lid 7 is configured to fit over and cover the top
opening and top edges
30 of the box 106. Lid 7 includes a top panel 41 that has a front edge joined
to the top edge of a
front panel 46, a rear edge joined to the top edge of a rear panel 47, a left
edge joined to the top
edge of a left panel 48, and a right edge joined to the top edge of a right
panel 49. The opposed
front panel 46 and rear panel 47 are disposed between and joined along common
side edges to
the left panel 48 and right panel 49 to form an inverted box lid, dimensioned
so that the panels
46,47,48,49 of the lid 7 cover the top portions of the corresponding walls
116,117,118,119 of the
container box 105.
[0092] The container 105 has a through-lid grip opening 150 and a through-
lid locking port
160, as shown in Figure 6. The through-lid grip opening 150 is formed by the
registry of a
container grip opening 152 in the top portion of left wall 118 of the
container box 106, and a lid
grip opening 55 in the left panel 48 of the lid 7. The container grip opening
152 in the left wall
118 is formed by the registry of grip opening 152a (not shown) in left
sidewall 123, and the grip
openings 152c and 152b in the slotted sidewall member 131 and the tabbed
sidewall member
135, respectively, as shown in Figure 8.
[0093] The through-lid locking port 160 is formed by the registry of a
container locking
port 162 in the left wall 118 of the container box 106, and a lid locking port
65 in the left panel
48 of the lid 7. The container locking port 162 in the left wall 118 is formed
by the registry of
locking port 162a (not shown) in left sidewall 123, and the locking ports 162c
and 162b in the
slotted sidewall member 131 and the tabbed sidewall member 135, respectively,
as shown in
Figure 8.
[0094] An opposed through-lid grip opening and through-lid locking port can
be formed on
the right side of the container 105 in the same manner. A center point of the
through-lid grip
opening is typically positioned at or near the lateral center point of the
respective left and right
walls. A cable tie 98 or other suitable locking fastener can be passed through
the through-lid
grip opening 150 and through-lid locking port 160, with the ends of the cable
tie 98 are fastened
or secured together to secure the lid 7 to the container box 106.
[0095] Figure 9 shows a blank 199 formed in a single board for folding into
the container.
The blank comprises a bottom panel 20 having front, rear, right side and left
side edges defined
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by corresponding front fold line 20a, rear fold line 20b, left side fold line
20c, and right side fold
line 20d on the blank. A front wall 121 is attached to the bottom panel 20
along the front fold
line 20a of the bottom panel, extending to a distal edge. The front wall 121
has a left side edge,
defined by a corresponding left side edge fold line 121L, from which extends
leftwardly a left
tabbed sidewall member 135L. The front wall 121 also has a right side edge,
defined by a
corresponding rear side edge fold line 121R, from which extends rightwardly a
right tabbed
sidewall member 135R.
[0096] A rear wall 122 is attached to the bottom panel 20 along the rear
fold line 20b of the
bottom panel, extending to a distal edge. The rear wall 122 has a left side
edge, defined by a
corresponding left side edge fold line 122L, from which extends ieftwardly a
left slotted sidewall
member 131L. The rear wall 122 also has a right side edge, defined by a
corresponding rear side
edge fold line 122R, from which extends rightwardly a right slotted sidewall
member 131R.
[0097] The blank also includes rectangularly-shaped left sidewall 123
attached to the
bottom panel along the left side fold line 20c of the bottom panel 20, and
extending to a distal
edge, and rectangularly-shaped right sidewall 124 attached to the bottom panel
20 along the right
side fold line 20d of the bottom panel, and extending to a distal edge.
[0098] The left and right slotted sidewall members 131L and 131R comprise a
substantially rectangular-shaped base portion having a curved slot 32
penetrating through a distal
end of the base portion. The slot can also be a linear slot. The length of the
slot is sized to
accommodate a tab, described hereinafter.
[0099] The left and right tabbed sidewall members 135L and 135R comprise a
substantially rectangular-shaped base portion that tapers to a narrowed neck
portion 37, and
includes a tab 36 extending from the neck portion 37. The tab 36 is configured
to pass through
the slot and to engage the material of the slotted sidewall members 131 to
retain engagement of
the tab 36 within the slot 32. The tab 36 includes at least one lobe that
extends laterally along
the respective front or rear side edge fold line, and preferably includes a
pair of lobes 38,39.
[00100] As shown in Figure 9, the blank can also include a lid portion for
folding into the
lid. The lid portion of the blank is substantially rectangular and attached to
the container portion
along one edge thereof. The lid portion is oriented to have a width dimension
that is one half of
at least one of the length or width of the container portion of the blank, to
minimize board waste.
Figure 11 shows orientation of a pair of container-lid blanks, with the two
lid blank portions
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disposed side-by-side and separating the two container blank portions, for
producing two
container-lids together in a single die and using carton board material
efficiently in production.
[00101] An alternative embodiment of the container box of the present
invention is a
container box as described herein, with a hinged lid. The integral
construction can comprise a
permanent or semi-permanent attachment of a side panel of a lid to the top
portion of the
sidewall, such as by adhesive attachment, or can comprise forming both the lid
and the sidewall
from the same blank of corrugated material. An example of an integral lid
having an extending
side panel with an inner surface that is attached, typically adhesively, to
the outer surface of the
top portion of the sidewall is shown in International Patent Publication
W02012/154763, the
disclosure of which is incorporated herein by reference.
[00102] FIG. 13 illustrates an embodiment of a container box 306 with an
integral lid 307,
the integral lid 307 extending from rear sidewall 322 of the container body.
The integration of
the lid 307 with the container body provides a hinged connection 317 so that
the lid 307 can be
folded back from and over the opening 321 of the container body. Figure 14
illustrates a plan
view of a blank 399 for folding into the container box and lid of FIG. 13.
[00103] The embodiment shown in FIG. 13 illustrate the integral hinged lid
extending from
the second rear sidewall 322, which lies inward of the rear composite wall
(not shown), and is
similar to the embodiment shown in FIGs. 1-4. It would be understood by a
person of ordinary
skill that an integral lid can be included in the embodiments shown in FIGs. 5-
9, wherein the
integral hinged lid would extend from the distal edge of the rear wall 117.
[00104] An alternative means for locking the integral hinged lid over the
top opening of the
container is also shown in Figure 13, and includes an opening 63 through the
upper portion of the
front wall 16 of the folded container box 306, and openings in the hinged lid
307, opposite the
hinge 317. The opening 63 is formed by the registration of the openings in the
panels of the
blank after folding the blank into the container box. These openings include
opening 68 in an
upper portion of the second (inner) front sidewall 21, and an opening 67
through an upper
portion of the slotted first wall member 31 (panel 31f in Figure 14) that
register to form opening
63. The openings in the hinged lid 307 include an opening 64 in the front
panel 347 of the
integral lid 307, which registers with the opening 63 in the front wall 16
when the lid 307 is
covering the open top of the container box, and a second opening 66 in the top
portion 341 of the
lid near the front panel 347. After the lid 307 is closed over the top opening
of the box 306, a
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cable tie (not shown) can be laced through the top opening 66, and out through
the registered
openings 64 in the front panel of the lid, and opening 63 in the container
box, and connected to
secure the lid closed on the box.
[00105] Figure 14 shows the blank 399 with the openings 64 and 66 in the
lid, and openings
67 and 68 in the panels of the front sidewall 21 and the front slotted first
wall member 31f. The
openings 64, 66, 67 and 68 are illustrated a circles with a size of about the
diameter of a person's
index finger, but other shapes and sizes can be selected as convenient to
maintain or improve the
integrity of the box panels and materials, and to make easier the assembly of
the box or improve
the securement of the panels together into the container box unit. The
adjacent openings in the
lid and container box are spaced sufficiently close to allow a cable tie to be
laced into one
opening and out the adjacent opening, but not so close that the integrity of
the panel material
between is compromised. Another embodiment of a container box and lid combines
the
elongated container box 206 described herein and shown in FIG. 12, with an
integral lid as
described and shown in FIG. 13.
[00106] Figure 14 shows the blank 399 formed in a single board for folding
into the
container. The blank 399 is similar to the blank 99 of Figure 4, except that
the portion of board
for folding into a lid includes top panel 341 that extends hingedly from the
upper edge 317 of the
sidewall 322.
[00107] An alternative embodiment of the container can include two or more
through-lid
locking ports formed into adjacent corners of the lid along the common edge.
[00108] A further embodiment of the invention is a container box 206 having
outwardly
tapered sidewalls 216 and 217, and/or front and back walls 218 and 219,
providing a top opening
230 that has an open area and dimension larger than those of the bottom 220.
[00109] Another embodiment of the container box of the present invention
provides a
container tote having sidewalls and endwalls that taper outwardly from the
bottom. FIG. 15
shows a container that includes an open-topped box 406 and a lid 7, which is
based on the
embodiment of the container shown in FIGs. 5-9, wherein like reference
numerals are used to
describe elements described herein above for the second embodiment.
[00110] The tote 406 includes four trapazoidally-shaped, rectangularly-
arranged walls,
including a front wall 416 and a rear wall 417, and left side wall 418 and a
right side wall 419
disposed respectively between and attached to both the front wall and the rear
wall, and a floor
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20. The front wall 416 and the rear wall 417 form a first pair of opposed
walls having
substantially the same size and trapezoidal shape, each having opposed side
edges (421L/421R,
and 422L/422R) that taper outwardly from bottom to top. The left side wall 418
and the right
side wall 419 form a second pair of opposed walls, typically of the same size
and trapezoidal
shape, each also having opposed side edges that are shared with the front wall
416 and rear wall
417, and that taper outwardly from bottom to top. Front wall 416 consists of
front sidewall 421
formed of a continuous, smooth substantially rectangular material integral
with and hinged to
bottom 20 along its front edge. Rear wall 417 consists of rear sidewall 422
formed of a
continuous, smooth substantially rectangular material integral with and hinged
to bottom 20
along its rear edge.
[00111] Each of the walls the second pair of opposed walls 418 and 419 have
an inner
surface and an outer surface, and can include one, two, or more layers of
board material. A layer
of material can be a continuous, smooth, single piece of board material, or
can be formed of a
composite of two (or more) pieces of material. Each of walls 418 and 419
includes a composite
wall that comprises a first slotted sidewall member 431 having a slot 32, and
a second sidewall
member 435 comprising an extending tab 36. The slotted sidewall members 431
are joined
integrally with, and extend laterally from, the rear sidewall 422 along the
side edges 422L and
422R. The tabbed sidewall members 435 are also joined integrally with, and
extend laterally
from, the front sidewall 421 along the side edges 421L and 421R. A portion of
the extending tab
36 of the second or tabbed sidewall member 435 extends through the slot 32 of
the first or slotted
sidewall member 431. In the illustrated embodiment, the tabbed sidewall member
435 overlaps
the outer surface of the slotted sidewall member 431, with the tab portion 36
extending through
the slot 32 and to the inner surface of the slotted sidewall member 431, which
contains the edge
of the tab 36.
[00112] The opposed pairs of sidewalls provide a top opening that is large
than the bottom
20, resembling a tote. Once formed, the tote-shaped box 406 can be nested
within other similar
pre-formed tote-shaped boxes, for efficient temporary storage prior to use.
[00113] FIG. 16 shows a blank 499 for forming the container box and lid of
Figure 15.
[00114] It would also be understood that a tote container as described
above can be made
based upon the container embodiments shown in FIGs. 1-4.
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[00115]
Another embodiment of the container box of the present invention is shown in
Figure 17 as a container box 506 having a corresponding slot 132 formed into
both of the second
front sidewall 121 and the second rear sidewall 122, to accept insertion
therethrough of the tab
36 of the tabbed sidewall member 35. The corresponding slots 132 are formed
into the second
front sidewall 121 and second rear sidewall 122 substantially as described for
the slots 32 in the
slotted sidewall member 31. The positioning of the corresponding slots 132 in
the sidewalls
121,122 are disposed slightly out of registry with, and "downstream" of, the
slots 32 in the
slotted sidewall members 31 to accept entry of the tab 36 after it has exited
the slot 32 on the
inside surface of the slotted sidewall 31.
[00116]
FIG. 18 shows a blank 599 for forming the container box and optional lid of
Figure
17, illustrating the additional corresponding slots 132 formed into the second
sidewall panels
121,122.
[00117]
It can be understood that other first and second securement means, and other
types
or arrangements of slots and tabs, can be employed as are known, for securing
the first and
second sidewall members of a composite sidewall to inhibit or prevent their
separation from one
another. Examples of such other securement means include: snap fasteners; a
pair of adjacent
openings and a cable tie therethrough, as described hereinafter, and including
grommeted
openings; hooks and loops; latches and catches; mating hook and loop
mechanical fasteners,
buttons and eyelets, a pair of adjacently-positioned buttons, and yarn or
string; and a strap and
ratcheting means.
[00118]
Another embodiment of the container box of the present invention is shown in
Figure 19 as a container box 606 including the front wall 16 and rear wall 17,
with the front and
rear walls including the composite walls comprising the first sidewall member
31 and the second
sidewall member 35, and including a second securement means for holding
together and securing
the first sidewall member 31 and the second sidewall member 35 after assembly.
The second
securement means comprises a first pair, at least, of adjacent apertures 70
formed through a
upper portion of both the front wall 16 and rear wall 17, and an optional
second pair, at least, of
adjacent apertures 71 formed through a lower portion of both the front wall 16
and rear wall 17.
One of the first pair of upper apertures 70 passes through an upper portion of
the first sidewall
member 31, and the other of the first pair of upper apertures 70 passes
through an upper portion
of the second sidewall member 35. The first pair of upper apertures 70 also
pass through an
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upper portion of the second front sidewall 21. Similarly, one of the second
pair of lower
apertures 71 passes through a lower portion of the first sidewall member 31,
and the other of the
second pair of lower apertures 71 passes through a lower portion of the second
sidewall member
35, and the second pair of lower apertures 71 also pass through a lower
portion of the second
front sidewall 21. The upper apertures 70 and lower apertures 71 are formed in
the rear wall 17
is similar manner.
[00119] FIG. 20 shows a blank 699 for forming the container box and lid of
Figure 15. The
blank 699 includes front and rear slotted panels 731f and 731r that have upper
openings 72a and
lower openings 72b in their respective distal and proximal edges, and front
and rear tabbed
panels 735f and 735r that have upper openings 73a and lower openings 73b in
their respective
distal and proximal edges. The panels forming the second front sidewall 721
and the second rear
sidewall 722 each have a pair of upper openings 74a and 75a, and a pair of
lower openings 74b
and 75b. The openings are positioned in the blank 699 to form the through
apertures 70 and 71
when folded into the container box 606.
[00120] Once the container box has been manipulated into its form from the
blank 699, pairs
of cable ties 98 can be laced through the pairs of upper apertures 70 and
lower apertures 71 and
secured together. The cable ties improve the integrity and add a degree of
permanence to the
securement together of the first and second sidewall members. The cable tie
can be manipulated
to place the ratcheting housing on the inside of the box as shown in the
figure, or on the outside.
[00121] In an optional aspect of the embodiment, a complementary pair of
apertures can
also be formed in the sidewalls 46 and 47 of the lid, to register with the
upper apertures 70 when
the lid is placed in position over the open top of the container box. In this
aspect, the same cable
tie, or a second cable tie 98, can be laced through the complementary pair of
apertures in the lid
and the upper apertures 70 in the box container sidewall to secure the lid in
place.
[00122] The second securement means, comprising the pair of upper apertures
70 and the
pair of lower apertures 71 in the composite walls, can be employed in
combination with the tab-
and-slot first securement means, to improve the securement and integrity of
the formed
container. In another embodiment, shown in Figure 21, a container box 706 is
illustrated with
the second securement means alone is employed for holding together and
securing a first
sidewall member 731 and a second sidewall member 735 after assembly of the
container box
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706. As illustrated, the first sidewall member 731 and a second sidewall
member 735 are not
required to be tabbed and slotted, and can have angular or rounded corners and
edges.
[00123] FIG. 22 shows a blank 799 for forming the container box 706 and lid
of Figure 21.
[00124] Figure 23 shows an alternative embodiment of the container box 306
shown in
Figure 13, wherein the front wall 16 has a pair of adjacent openings 63a and
63b through an
upper portion, and the front panel 347 of the lid 307 has a pair of openings
64a and 64b
therethrough. In the illustrated container box 306, a first cable tie 98 is
laced through both of the
pair of container box openings 63a,63b and secured. The cable tie provides
added securement of
the tabbed sidewall member 35 with the slotted sidewall member 31, and
prevents the same from
being pulled apart (and the box disassembled) without first cutting the cable
tie. After the lid
307 is closed, a second cable tie (not shown) can be laced through the
openings of the lid (64a
and 64b) that are registered with the respective openings in the container box
(63a and 63b) to
secure the lid closed over the top opening of the container box.
[00125] This written description uses examples to disclose the invention,
including the best
mode, and also to enable any person skilled in the art to make and use the
invention. The
patentable scope of the invention is defined by the claims, and may include
other examples that
occur to those skilled in the art. Such other examples are intended to be
within the scope of the
claims if they have structural elements that do not differ from the literal
language of the claims,
or if they include equivalent structural elements with insubstantial
differences from the literal
language of the claims.
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