One-piece box with integrally connected lid

• US 8,733,625 B2
• Filed: 03/14/2012
• Issued: 05/27/2014
• Est. Priority Date: 03/14/2011
• Status: Active Grant

• Current Assignee: THATBox Design, LLC
• Original Assignee: THATBox Design, LLC
• Inventors: Costanzo, Donn J. Jr.
• Primary Examiner(s): ELKINS, GARY E
• Application Number:
  US13/420,411
• Publication Number:
  US 20120234903A1
• Time in Patent Office: 804 Days
• Field of Search: 229/141, 229/142, 229/143, 229/144, 229/147, 229/149, 229/150, 229/154
• US Class Current: 229/144
• CPC Class Codes: B31B 2100/00 Rigid or semi-rigid containers made by folding single-piece sheets, blanks or webs
• CPC Class Codes: B31B 2100/0024 having all side walls attached to the bottom
• CPC Class Codes: B31B 2105/0027 Making boxes from blanks consisting of side wall panels integral with a bottom panel and additional side wall panels
• CPC Class Codes: B31B 2120/30 collapsible; temporarily collapsed during manufacturing
• CPC Class Codes: B31B 2120/302 collapsible into a flat condition
• CPC Class Codes: B31B 50/26 Folding sheets, blanks or webs
• CPC Class Codes: B31B 50/44 by plungers moving through folding dies
• CPC Class Codes: B31B 50/98 in stacks or bundles
• CPC Class Codes: B65D 25/205 Means for the attachment of labels, cards, coupons or the like; cards or coupons for the other types of rigid or semi-rigid containers B65D25/36 takes precedence
• CPC Class Codes: B65D 5/20 by folding-up portions connected to a central panel from all sides to form a container body, e.g. of tray-like form B65D5/36 takes precedence
• CPC Class Codes: B65D 5/2047 trapezoidal, e.g. to form a body with diverging side walls B65D5/2033 takes precedence
• CPC Class Codes: B65D 5/241 and the gussets folds connected to the inside of the container body B65D5/247 and B65D5/248 take precedence
• CPC Class Codes: B65D 5/4266 Folding lines, score lines, crease lines
• CPC Class Codes: B65D 5/46112 either the handle elements being formed with lugs which engage with the other side walls or closure flaps, or the other closure flaps folding over a part of the handle to maintain the handle in position
• CPC Class Codes: B65D 5/563 Laminated linings; Coatings
• CPC Class Codes: B65D 81/386 formed of corrugated material

Abstract

A one-piece container includes a single sheet of corrugated material, including: four walls, a bottom, and a lid, the lid being hingedly and integrally connected to one of the four walls. The bottom and the four walls define a storage area for housing articles therein. The lid is configured to transition between an open position, an intermediate position, and a closed position. The one-piece container includes a mechanism for maintaining the lid in a closed position. In some embodiments, the mechanism biases the lid toward a closed position when in the closed position, an open position when in the open position, and an intermediate position when in the intermediate position. In other embodiments, the mechanism includes tabs and slots for retaining the lid in the closed position. Other embodiments include a combination of these features. The container may be a cardboard box.

Claims

1. A one-piece container, comprising:

(a) a single, folded sheet of material comprising;

(i) a bottom section,

(ii) four wall sections, including

(A) a first wall section integrally and hingedly attached directly to the bottom section and having a first slotted opening located closer to the bottom section than to a top edge of the first wall section,

(B) a second wall section on an opposite side of the bottom section relative to the first wall section, integrally and hingedly attached directly to the bottom section, and having a second slotted opening located closer to the bottom section than to a top edge of the second wall section,

(C) a third wall section integrally and hingedly attached directly to the bottom section, and

(D) a fourth wall section on an opposite side of the bottom section relative to the third wall section, and integrally and hingedly attached directly to the bottom section,

(iii) side wall attachment portions, including

(A) a first side wall attachment portion integrally and hingedly attached directly to the fourth wall section but not hingedly attached directly to the first wall section, and

(B) a second side wall attachment portion on an opposite side of the fourth wall section relative to the first side wall attachment portion, and integrally and hingedly attached directly to the fourth wall section but not hingedly attached directly to the second wall section,

(iv) a first lid portion integrally and hingedly attached directly to the third wall section,

(v) a second lid portion integrally and hingedly attached directly to the fourth wall section,

(vi) a first side portion integrally and hingedly attached directly to the first side wall attachment portion and integrally and hingedly attached directly to the second lid portion, the first side portion further comprising a diagonal fold line dividing the first side portion,

(vii) a first tab integrally and hingedly attached directly to the first side portion only on one side of the diagonal fold line dividing the first side portion,

(viii) a second side portion on an opposite side of the second lid portion relative to the first side portion, integrally and hingedly attached directly to the second side wall attachment portion, and integrally and hingedly attached directly to the second lid portion, the second side portion further comprising a diagonal fold line dividing the second side portion, and

(ix) a second tab integrally and hingedly attached directly to the second side portion only on one side of the diagonal fold line dividing the second side portion;

(b) wherein the bottom section and the four wall sections define a storage area adapted to house articles therein;

(c) wherein the first lid portion and second lid portion together define a cover for the storage area; and

(d) wherein the second lid portion is secured in a covering orientation by inserting the first tab into the first slotted opening and the second tab into the second slotted opening, with the first side portion being folded along the diagonal line that divides the first side portion and with the first side portion extending downwardly along an outer surface of the first wall section from the second lid portion to the first slotted opening, and with the second side portion being folded along the diagonal line that divides the second side portion and with the second side portion extending downwardly along an outer surface of the second side wall section from the second lid portion to the second slotted opening, and wherein the first lip portion is secured in a covering orientation by the second lip portion.

2. The container of claim 1, wherein the first lid portion is secured in a covering orientation by the second lid portion by a portion of the second lid portion extending over and abutting the first lid portion.

3. The container of claim 1, wherein the single sheet of material comprises a generally planar sheet of corrugated material that is folded.

4. The one-piece container of claim 1, wherein the single sheet of material comprises cardboard.

5. The one-piece container of claim 1, further comprising a decorative element on a surface of the single sheet of material.

6. The one-piece container of claim 5, wherein the decorative element is adhered to the surface of the single sheet of material using adhesives.

7. The one-piece container of claim 5, wherein the decorative element is printed directly on the surface of the single sheet of material.

8. A blank for forming a one-piece container when folded, comprising:

(a) a single sheet of material comprising;

(i) a bottom section,

(ii) four wall sections, including first, second, third and fourth wall sections, the first wall section being integrally and hingedly attached directly to the bottom section and having a first slotted opening located closer to the bottom section than to a top edge of the first wall section;

the second wall section being on an opposite side of the bottom section relative to the first wall section, being integrally and hingedly attached directly to the bottom section, and having a second slotted opening located closer to the bottom section than to a top edge of the second wall section;

the third wall section being integrally and hingedly attached directly to the bottom section; and

the fourth wall section being on an opposite side of the bottom section relative to the third wall section, and being integrally and hingedly attached directly to the bottom section,

(iii) side wall attachment portions, including

(A) a first side wall attachment portion integrally and hingedly attached directly to the fourth wall section but not directly to the first wall section, and

(B) a second side wall attachment portion on an opposite side of the fourth wall section relative to the first side wall attachment portion, and integrally and hingedly attached directly to the fourth wall section but not directly to the second wall section,

(iv) a first lid portion integrally and hingedly attached directly to the third wall section,

(v) a second lid portion integrally and hingedly attached directly to the fourth wall section,

(vi) a first side portion integrally and hingedly attached directly to the first side wall attachment portion and integrally and hingedly attached directly to the second lid portion, the first side portion further comprising a diagonal fold line dividing the first side portion,

(vii) a first tab integrally and hingedly attached directly to the first side portion only on one side of the diagonal fold line dividing the first side portion,

(viii) a second side portion on an opposite side of the second lid portion relative to the first side portion, integrally and hingedly attached directly to the second side wall attachment portion, and integrally and hingedly attached directly to the second lid portion, the second side portion further comprising a diagonal fold line dividing the second side portion, and

(ix) a second tab integrally and hingedly attached directly to the second side portion only on one side of the diagonal fold line dividing the second side portion;

(b) wherein the bottom section and the four wall sections define a storage area adapted to house articles therein when the blank is folded;

(c) wherein the first lid portion and second lid portion together define a cover for the storage area when the blank is folded; and

(d) wherein the second lid portion is secured in a covering orientation by inserting the first tab of the first side portion into the first slotted opening and the second tab of the second side portion into the second slotted opening, and the first lid portion is secured in a covering orientation by the second lid portion when the blank is folded, with the first side portion being folded along the diagonal line that divides the first side portion and with the first side portion extending downwardly along an outer surface of the first wall section from the second lid portion to the first slotted opening, and with the second side portion being folded long the diagonal line that divides the second side portion and with the second side portion extend downwardly along an outer surface of the second side wall section from the second lid portion to the second slotted opening.

9. The blank of claim 8, wherein the single sheet of material comprises a generally planar sheet of corrugated material.

10. The blank of claim 8, wherein the single sheet of material comprises cardboard.

11. The blank of claim 8, further comprising a decorative element on an exterior surface of the blank.

12. The blank of claim 11, wherein the decorative element is adhered to a surface of the single sheet of material using adhesives.

13. The blank of claim 11, wherein the decorative element is printed directly on a surface of the single sheet of material.

14. A method of forming a container comprising a single-piece box having an integrally connected lid by folding a blank comprising a single sheet of material, the method comprising the steps of:

(a) providing a single sheet of material comprising,

(i) a bottom section,

(ii) four wall sections, including first, second, third and fourth wall sections, the first wall section being integrally and hingedly attached directly to the bottom section and having a first slotted opening located closer to the bottom section than to a top edge of the first wall section;

the second wall section being on an opposite side of the bottom section relative to the first wall section, being integrally and hingedly attached directly to the bottom section, and having a second slotted opening located closer to the bottom section than to a top edge of the second wall section;

the third wall section being integrally and hingedly attached directly to the bottom section; and

the fourth wall section being on an opposite side of the bottom section relative to the third wall section, and being integrally and hingedly attached directly to the bottom section,

(iii) side wall attachment portions, including

(A) a first side wall attachment portion integrally and hingedly attached directly to the fourth wall section but not directly to the first wall section, and

(B) a second side wall attachment portion on an opposite side of the fourth wall section relative to the first side wall attachment portion, and integrally and hingedly attached directly to the fourth wall section but not directly to the second wall section,

(iv) a first lid portion integrally and hingedly attached directly to the third wall section,

(v) a second lid portion integrally and hingedly attached directly to the fourth wall section,

(vi) a first side portion integrally and hingedly attached directly to the first side wall attachment portion and integrally and hingedly attached directly to the second lid portion, the first side portion further comprising a diagonal fold line dividing the first side portion,

(vii) a first tab integrally and hingedly attached directly to the first side portion only on one side of the diagonal fold line dividing the first side portion,

(viii) a second side portion on an opposite side of the second lid portion relative to the first side portion, integrally and hingedly attached directly to the second side wall attachment portion, and integrally and hingedly attached directly to the second lid portion, the second side portion further comprising a diagonal fold line dividing the second side portion, and

(ix) a second tab integrally and hingedly attached directly to the second side portion only on one side of the diagonal fold line dividing the second side portion;

(b) folding each of the side wall sections perpendicular to the bottom section such that the bottom section and the four wall sections define a storage area adapted to house articles therein, with the side wall attachment portions folding into the interior of the container adjacent inner surfaces of the first and second wall sections, and with the first and second side portions extending outside of the interior of the container;

(c) folding the first lid portion and the second lid portion such that both lid portions together define a cover for the storage area with the second lid portion overlapping a side edge portion of the first lid portion; and

(d) securing the first lid portion and the second lid portion in a covering orientation by folding the first and second side portions along the respective diagonal fold lines, folding the first and second side portions to extend adjacent the outer surfaces of the first and second wall sections, and inserting the first tab into the first slotted opening and the second tab into the second slotted opening.

15. The method of claim 14, further comprising the step of adhering one or more of the side wall sections.

16. The method of claim 14, wherein the single sheet of material comprises a generally planar sheet of corrugated material.

17. The method of claim 14, wherein the single sheet of material comprises cardboard.

18. The method of claim 14, further comprising a decorative element on a surface of the single sheet of material.

19. The method of claim 18, wherein the decorative element is adhered to the surface of the single sheet of material using adhesives.

20. The method of claim 18, wherein the decorative element is printed directly on the surface of the single sheet of material.