COLLAPSIBLE V-BOX CONTAINER

BACKGROUND OF THE INVENTION

TECHNICAL FIELD

The invention relates to storage and shipping boxes. More particularly, the invention relates to collapsible boxes formed of polymeric material and that can be reused.

DESCRIPTION OF THE PRIOR ART

Businesses, both nationally and internationally, require an increasing number of boxes in which to ship and store goods. Currently, the market is dominated by corrugated paperboard boxes: around 40 billion such boxes annually are made in the U.S. alone. These boxes are shipped to customers as unfolded or partially assembled flat layouts, and assembled into three-dimensional crates wherever the packaging takes place. The assembly is performed by folding sides of the box over the flaps of other sides of the box, and then locking the foldups into their places.

Smaller packers usually use foldable corrugated paperboard boxes that have special locking elements, or tabs, which mate with corresponding slots in the surfaces of the box. Larger-scale packing operations assemble their crates on special assembling machines, sometimes called erection or set-up machines, which fasten crates by more permanent means, such as glue, staples, special brackets, or some combination of the above. Once these paperboard boxes are used, they are discarded and destined either for a landfill or for recycling.

A number of problems, however, are inherent to use of corrugated paperboard boxes. The actual strength and environmental resistance of paperboard is determined by the ties between its fibers. The ties are formed by drying a layer of colander-squeezed pulp and are weak even under the most favorable of circumstances. The ties deteriorate completely when the moisture content in this absorbent material rises above a saturation value. Furthermore, the porous

structure of paperboard lowers its hygienic qualities, as bacteria or other contaminants can easily be absorbed.

Corrugated paperboard boxes also present environmental and recycling problems. Over 5.5 million tons of used paperboard boxes are discarded each year in the U.S. alone, presenting society with a considerable disposal problem. In addition, some paperboard crates have to be waxed or otherwise treated to help withstand moisture, thereby adding to the difficulties of recycling.

The process of making paperboard uses a great amount of toxic chemicals that need to be either recaptured from the technological waste stream or neutralized. This adds to the cost of the fabrication process. An additional factor in the rising cost of paperboard is the availability of wood pulp. In 1995, the U.S. price of pulp rose over 30%, from $600 to $900/ton.

While the use of plastic boxes solves many of the problems cited above, injection-molded plastic boxes are too expensive for general use. Each size box requires its own costly molds. The process itself is slow and wasteful of energy, as the massive molds have to be heated up and cooled down once per cycle.

Vacuum molding of thermoplastic sheet is not inexpensive, either, and is even less suited for mass production of collapsible boxes. Extrusion, on the other hand, is one of the cheapest, fastest and most versatile mass production methods known. Unfortunately, the extruded plastic boxes of the prior art do not capitalize on all of the known advantages of the material and technology.

The Advanced Container Corporation of Tracy, California markets a collapsible box for asparagus made of an extruded hollow sheet of corrugated polyethylene. These boxes are assembled by inserting a number of tabs into corresponding slots, just As one assembles a paperboard box. This process requires either tedious manual labor to insert all of the tabs, or special, complicated machinery. It is also difficult and time-consuming to remove all of the tabs from the slots to collapse the boxes for future use. Furthermore, bacteria from a previous use can collect within the corrugations, thus requiring a difficult and expensive cleaning process before reuse.

The U.S. Post Office uses lidless thermoplastic crates that are made of extruded plastic sheet material, cut into foldable shapes and welded, stapled, or riveted together to form permanent lidless crates. True, when empty these permanent boxes can be easily stored and transported because they are narrower at the bottom and can be stuck one into another. But that ability prevents stacking of full crates.

The CR&S Company in Roletto, Northern Italy, developed a light-weight, lidless fruit crate, about 20 inches long, 12 inches wide and 5 inches high. The crate was designed as a layer cut from an extruded plastic sheet, and was made more rigid by the addition of vacuum-molded rigidity ribs and four small, injection-molded corner pieces. These crates are produced by another Italian company, the KARTO, in Bressanno.

The crates are assembled in the field from a flat, ribbed layout and the four injection-molded corner pieces. After being filled, the crates are stacked one upon another for delivery to the marketplace. The crates must be handled carefully and are not suitable for normal shipping or long-term storage. Further, whatever advantages were gained by extrusion were lost by combining it with much less efficient technologies such as the cyclic, slow, and size-specific injection and vacuum molding technologies required to form the ribs and corner pieces. The four molded comer pieces along comprise a third of the overall fruit crate's cost.

Boeckmann, et al, Carrier Tape, U.S. Pat. No. 4,708,245 (24.11.87) discloses a "carrier tape" (or "transfer tape") for storage, transportation and automatic feeding of small and/or measured items, such as electronic components, pharmaceuticals and similar products. The carrier tape is formed of extruded plastic, and has interlocking joints extruded into the profiles of its stripe-like elements. Sprockets are provided for driving the tape. The components of the carrier tape are significantly different in shape, and thus have different manufacturing requirements. Further, the base-and-cover-strip construction of the carrier tape cannot be collapsed to minimize storage space.

Continuously extruded thermoplastic webs having interlocking profiles have previously been used to make enclosures with up to four sides. In Oltmanns, et al., Box Formed Building Panel of Extruded Plastic, U.S. Pat. No. 4,299,070 (10.11.81), a building panel is formed of multiple extruded plastic components

joined together by a wedge-shaped projection fitting into a sealant-containing groove. This design is certainly not applicable to general purpose shipping boxes, as the multiple components of this panel must be separately fabricated, and precisely inserted. Additionally, the box is not easy to disassemble into panels.

Clarey, et al. Plastic Enclosure Box for Electrical Apparatus, U.S. Pat. No. 5,066,832 (19.11.91 ), discloses an extruded plastic box formed of multiple, differently-shaped sections adapted to receive metal and plastic inserts. This box is not designed for disassembly, and is difficult and expensive to fabricate. As a general purpose, rectangular shipping boxes require at least five-, if not six-, sided enclosures. The Clarey box does not fully utilize the advantages of thermoplastic extrusion to mass produce general purpose, collapsible boxes.

Terpstra, Box Construction With Interlocking Tab Fastening Means, U.S. Pat. No. 5,145,110 (8.9.92) describes a collapsible box formed of a single sheet having four identical panels. The sheet is folded and the flaps or tabs are inserted into cooperating slots to form a box. The tab-and-slot interconnection is common in paperboard industry. There are over a hundred different designs of boxes with such fastening devices collected and published in paperboard box designers manuals. When used with a plastic sheet, such boxes transfer the shortcomings of paperboard technology into plastic boxes without taking advantage of particularities of plastics and their production technologies. Besides, four identical size panels limit the shape of all boxes to a cube.

A thermoformed plastic package is disclosed in Rognsvoog, Jr., One-Piece Thermoformed Dispensing Packaging, U.S. Pat. No. 4,700,835 (20.10.87). A single sheet is folded along a hinge and interlocked to form a tape dispenser. This invention cannot be disassembled to a flat sheet for easy storage.

Hudson, Demountable and Reusable Shipping Carton, U.S. Pat. No. 3,540,613 (17.11.70) describes a shipping carton formed of a plurality of wall panels having mating tongues and grooves. The top and bottom of the carton are separately formed from, and differently-shaped than the side panels. This carton cannot be disassembled to flat components. Handles cannot be formed in the side panels, as carrying the box in such a manner would cause the components to come apart.

While the box described in Schifferle, Collapsible Crate or Box, U.S. Pat. No. 3,613,931 (19.10.71) can be disassembled to flat components, the Schifferle box is formed of separate side, bottom and top panels joined by connecting strips. The fabrication of all of these differing elements adds to the cost of manufacture of this box. These differing elements must be stored and then coordinated for reassembly of the box. Use of connecting strips also reduces the strength of the box, which is not adapted to carry heavier loads.

Rader, Collapsible Box, U.S. Pat. No. 4,798,304 (17.1.89) discloses a box designed to support hanging files, and formed of differently-shaped elements, pivotally connected with plastic pivot pins. While this box can be easily disassembled, the plastic pins limit its strength. Besides, this box is not adapted for stacked storage and transportation.

It would therefore be a significant advance in the art to provide a collapsible box adapted for shipping and storage of a wide variety of products. It would be a further advantage if this box were formed of components that can be fabricated on the same machinery with minimal adjustments. It would be yet a further advantage if the collapsible box were made from a wateφroof, easily cleansible material, economical, and formed in an environmentally-sound manner. It would be still more advantageous if such a collapsible shipping box can be reusable.

SUMMARY OF THE INVENTION

The invention relates to reusable, collapsible, general purpose shipping and storage boxes, and to the method of their production. In the preferred embodiment of the invention, two layers formed of polymeric material are extruded from raw material and folded at creases. The two folded layers are joined to form a box by snapping together male and female locking elements adapted for complementary, releasable interengagement.

In alternate embodiments of the invention, the inner and outer layers are joined to each other, or to themselves and then interconnected to assemble the box. In yet another embodiment of the invention, two identical side layers are attached to the outer layer to form a box. Another embodiment of the invention comprises a single layer, having complementary, interengageable locking elements extruded as a part thereof.

The box of the invention is produced with attached one or two-part lids, or with a separate lid. The box of the invention is easily disassembled by unlocking the male and female elements.

BRIEF DESCRIPTION OF THE DRAWINGS

Fig. 1 is an isometric view of the V-Box according to a first preferred embodiment;

Fig. 2A is a top view of the outer layer, according to the first embodiment of the invention;

Fig. 2B is a side view of the outer layer, according to the first embodiment of the invention;

Fig. 2C is a front view of the outer layer, according to the first embodiment of the invention;

Fig. 2D is an enlarged, detailed view of a selected area in Fig. 2B;

Fig. 2E is an enlarged, detailed view of a selected area inn Fig. 2C;

Fig. 3A is a top view of the inner layer according to the first embodiment of the invention;

Fig. 3B is a side view of the inner layer according to the first embodiment of the invention;

Fig. 3C is a front view of the inner layer according to the first embodiment of the invention;

Fig. 3D is an enlarged, detailed view of a selected area in Fig. 3B;

Fig. 3E is an enlarged, detailed view of a selected area in Fig. 3C;

Fig. 4 is an isometric view of a V-box, according to a second, equally preferred embodiment of the invention;

Fig. 5A is a top view of the outer layer according to the second, equally preferred embodiment of the invention;

Fig. 5B is a side view of the outer layer, according to the second, equally preferred embodiment of the invention;

Fig. 5C is a front view of the outer layer, according to the second, equally preferred embodiment of the invention;

Fig. 5D is an enlarged, detailed view of a selected area in Fig. 5B;

Fig. 5E is an enlarged, detailed view of a selected area in Fig. 5C;

Fig. 6A is a top view of the inner layer according to the second, equally preferred embodiment of the invention;

Fig. 6B is a side view of the inner layer, according to the second, equally preferred embodiment of the invention;

Fig. 6C is a front view of the inner layer, according to the second, equally preferred embodiment of the invention;

Fig. 6D is an enlarged, detailed view of a selected area in Fig. 6B;

Fig. 6E is an enlarged, detailed view of a selected area in Fig. 6C;

Fig. 6G is an enlarged, detailed view of a selected area in Fig. 6C;

Fig. 7A is the first step in a flow chart illustrating the steps of one method of assembling the two-layered embodiments of the V-Box of the invention in which the layers are to be interlocked with one another at assembly;

Fig. 7B is the second step in the flow chart of Fig. 7A;

Fig. 8A is the third step in the flow chart of Fig. 7A;

Fig. 8B is the fourth step in the flow chart of Fig. 7A;

Fig. 8C is a section in Fig. 8B;

Fig. 8D is a section in Fig. 8B;

Fig. 8E is a section in Fig. 8B;

Fig. 9 is an isometric view of a V-Box according to a third, equally preferred embodiment of the invention;

Fig. 10A is a top view of a side piece according to the third, equally preferred embodiment of the invention;

Fig. 10B is a side view of a side piece according to the third, equally preferred embodiment of the invention;

Fig. 10C is a front view of a side piece according to the third, equally preferred embodiment of the invention;

Fig. 10D is an enlarged, detailed view of a selected area in Fig. 10B;

Fig. 10E is an enlarged, detailed view of a selected area in Fig. 10C;

Fig. 11 is an isometric view of a V-Box, according to the fourth equally preferred embodiment of the invention;

Fig. 12 is an isometric view of a V-Box, according to the fifth equally preferred embodiment of the invention;

Fig. 13 is an isometric view of the partitioned V-Box, according to the sixth embodiment of the invention;

Fig. 14 is an isometric view of the multiply-partitioned V-Box of the sixth embodiment of the invention;

Fig. 15A is an isometric view of a V-Box, according to a seventh, equally preferred embodiment of the invention;

Fig. 15B is an enlarged, detailed view of a selected area in Fig. 15A;

Fig. 16A is a top view of the outer layer, according to the seventh, equally preferred embodiment of the invention;

Fig. 16B is a front view of the outer layer, according to the seventh, equally preferred embodiment of the invention;

Fig. 16C is an enlarged, detailed view of a selected area in Fig. 16B;

Fig. 16D is an enlarged, detailed view of a selected area in Fig. 16B;

Fig. 16E is an enlarged, detailed view of a selected area in Fig. 16B;

Fig. 16F is a side view of the prying tool, according to the seventh, equally preferred embodiment of the invention;

Fig. 18A is an isometric view of a V-Box, according to the eighth, equally preferred embodiment of the invention;

Fig. 18B is a detailed view of a selected area in Fig. 18A;

Fig. 19A is an isometric view of a V-Box, according to the ninth embodiment of the invention;

Fig. 19B is an isometric view of a V-Box, according to the ninth embodiment of the invention;

Fig. 20A is a top view of a single-layer V-Box, according to the tenth embodiment of the invention;

Fig. 20B is a front view of a single-layer V-Box, according to the tenth embodiment of the invention;

Fig. 20C is an enlarged, detailed view of a selected area in Fig. 20B;

Fig. 20D is an enlarged, detailed view of a selected area in Fig. 20B; and

Fig. 20E is an enlarged, detailed view of a selected area in Fig. 20B.

DETAILED DESCRIPTION OF THE INVENTION

The invention provides a reusable, collapsible, general purpose box formed of polymeric material that can be easily assembled just before being filled up with products, and as easily disassembled for easy storage after being emptied of the product at its destination. The collapsible box of the invention, known as the V-Box, can enclose the same volume as a comparable paperboard box using less square inches of sheet (board). For example, in comparison with the rectangular slotted box ("RSC"), the most popular design of corrugated paperboard box, the third, equally preferred embodiment of the invention requires at least 30% less sheet.

Fig. 1 is an isometric view of the V-Box, according to a first preferred embodiment of the invention 10. The V-Box is foπned of an outer layer 11 and an inner layer 12. The inner layer is placed onto the outer layer at a 90° angle. The layers are then joined together to form the first preferred embodiment of the V-Box.

The outer and inner layers are formed of any semi-flexible material, including polymeric materials such as plastics. Polymeric material boxes are superior to the currently used corrugated paperboard boxes, as they are more hygienic, more resistant to bacteria, insects and rodents, and resistant to moisture. The invention may also be formed of a class of highly-filled polymer compositions, such as those discussed in U.S. Patent Application No. 08/531 ,458, entitled HIGHLY-FILLED POLYMER COMPOSITIONS, filed September 20, 1995 by Applicants. These polymer compositions, filled with materials such as fly ash and recaptured (recycled) plastics, are less expensive than paperboard of equal strength.

The layers are preferably formed by extrusion or coextrusion, but may also be formed by other means, including molding. Extrusion and coextrusion technology offer two major advantages - the ease by which the locking joints are extruded out of polymeric materials, and the low cost of mass production.

In altemate embodiments of the invention, the inner and outer layers are solid or are hollow. Hollow layers offer the advantage of having Iower weight, but the same strength and stability as solid layers. Hollow layers of the same weight as solid layers exhibit higher levels of strength and stability.

Different types of hollow layers are used in alternate embodiments of the invention, including corrugated plastic sheeting and closed air cells. Corrugated layers are advantageous as they are extruded at relatively high speeds using special extrusion dies. Closed air cells offer the advantage of being easily cleansed.

All layers, for all embodiments of the invention, are readily produced on the same production line. When switching from producing one layer, or one size V- Box, to another, the required readjustments of the production line are minimal: the extrusion die has to be changed, and some cutting and creasing units readjusted.

A top view of the outer layer according to the first embodiment of the invention is shown in Fig. 2A. Creases 120 are formed in the layer to enhance bending. The creases are formed on the borderlines between the areas of the outer layer that will become the bottom 104 and the two side walls 105, as well as on the border regions between the side walls and the larger 106 and smaller 107 parts of the lid. (Naturally, in some embodiments, a V-Box can have both parts of the lid being the same size, or it can have only one lid, the other part of it being of zero length.)

One embodiment of a crease is shown in the front view of the outer layer of Fig. 2C. These creases help to make 90° bends in these regions without subjecting the outer surface 102 of the outer layer to undue elongation. Depending upon the thickness, thermoplastic composition and the wall design of the outer layer, the 90° bends can be assisted with one, two or even more creases. An enlarged view of a two-crease bending area is given in Fig. 2E.

Locking elements 140 are formed on, and perpendicular to, the inner surface 102 of the outer layer. Fig. 2B is a side view of the outer layer, according to the first preferred embodiment of the invention. In this preferred embodiment, the

locking elements are female elements; however, any appropriate locking element may be used.

In the first preferred embodiment of the invention, female locking elements are extruded into, and located at parallel edges 103 of, the outer layer. In this embodiment of the invention, the female locking elements are grooves 141 with locking lips 142 in the outer layer, shown in the enlarged view in Fig. 2D, and protruding above the inner surface of the outer layer.

Fig. 3A is a top view of the inner layer 12 according to the first embodiment of the invention. The inner layer is placed on the inner surface of the outer layer 101 for subsequent assembly into the box of the invention. A side view of the inner layer according to this embodiment of the invention is shown in Fig. 3B.

The locking elements 150 are extruded into, and perpendicular to, the outer surface 112 of the inner layer. The male locking elements shown in Fig. 3B have flexible, half-arrow like locking wedges 151. When a large number of such inner layers are stacked up one upon another for transportation, these locking wedges are flexed back under the weight of the load of packaging and do not protrude beyond the outer surfaces of the inner layers 112. In alternate embodiment of the invention, any locking element that is adapted for complementary, releasable engagement with the locking elements on the outer layer is used.

Creases 130 are provided in the inner side 111 of the inner layer 12 to enhance the bending of the inner layer to form the inner bottom 114 and inner side walls 115 of the box. An enlarged view of the crease area is show in Fig. 3E. In alternate embodiments of the invention, various cuts are made in the inner layer, such as the two side cuts 116 shown in Fig. 3A. These side cuts facilitate the interlocking of the male locking elements of the side walls of the inner layer and the respective female locking elements of the side walls of the outer layer.

All four corners of the inner layer are cut 117 to make space for the bending region(s) between the lid and the side wall(s) of the outer layer. Assembly of this embodiment of the invention requires the inner layer to be bent 90°. However, the inward-protruding locking elements of the outer layer in its bottom section interfere with this bending. Therefore the 90° bending is done in two

separate portions to bypass the protruding locking element. Two creases are shown for each 90° bend in the front view of the inner layer of Fig. 3C.

Fig. 4 is an isometric view of a V-Box according to a second, equally preferred embodiment 20 of the invention. As in the first preferred embodiment of the invention, the lid is an integral part of the outer layer 21. The second embodiment of the invention differs from the first embodiment in several respects. The female locking elements 240 do not protrude out of the thickness of the outer layer but are flush with the inner surface of the outer layer 202. Thus, the female locking elements are fully hidden in the thickness of the outer layer, as is shown in Figs. 5B and 5D. Therefore, there is no need to bend the inner layer in two stages, as it is done in the first embodiment.

The inner and outer layers 21 , 22 of this second embodiment are solid. In both the first and the second embodiments of the invention, the width of each of the layers for a given V-Box corresponds with either one or another of the two dimensions of the bottom.

Six holes 282, three in each side wall, are formed in the inner layer of this embodiment to facilitate its disassembly. Both the outer layer 21 and the inner layer 22 have holes for drainage in their bottoms 271 , 281. In this second preferred embodiment of the invention, elongated holes 273 are formed through the outer layer to provide handles for the box. It is apparent to one skilled in the art that different amounts of holes may be provided for various purposes in alternate embodiments of the invention.

A top view of the outer layer 21 according to the second embodiment of the invention is shown in Fig. 5A. Creases are formed in the layer to enhance bending. The creases are formed on the borderlines between the areas of the outer layer that will become the bottom 204 and the two side walls 205, as well as on the border regions between the side walls 205 and the larger 206 and smaller parts of the lid 207.

Fig. 5C is a front view of the outer layer, according to the second, equally preferred embodiment of the invention. The creases 220 help to make 90° bends without subjecting the outer surface 202 of the outer layer to undue elongation. An enlarged view of the creases is shown in Fig. 5G. Depending upon the thickness, thermoplastic composition and the wall design of the outer

layer, the 90° bends can be assisted with one crease, two creases (as shown in Figs 5C and 5G), or even more creases.

The side view of the outer layer is given in Fig. 5B. Enlarged side views of the locking elements 240 of the outer layer of this embodiment are shown in Fig. 5D. The locking elements of this embodiment are two mirror-image female locking elements situated along the outer edges 203 of the outside layer. Each of these locking elements consists of a nearly rectangular cavity 241 made into the inner surface 201 of the outer layer, and a locking lip 242.

A top view of the inner layer 22 according to the second embodiment of the invention is shown in Fig. 6A. Creases 230 are formed in the inside surface 212 of the inside layer to enhance bending. The creases for bending the layer at 90° are formed on the borderlines between the areas of the outer layer that will become the bottom 214 and the two side walls 215. An enlarged view of the creases is given in Fig. 6E.

Locking male elements 250 are formed into the outer edges 213 of the inner layer. Fig. 6B is a side view of the inner layer, according to the second, equally preferred embodiment of the invention. In this preferred embodiment, the locking elements are male elements of a certain shape wherein the retention of the interlocked layers is secured by a locking groove 251 along the outer edges 213 of the outer surface 212 of the inner layer. This locking groove is hooked by a corresponding locking lip 242 of the outer layer. In alternate embodiments of the invention, any appropriately matching pair of interlocking elements of inner and outer layers may be used.

Once any part of the lid is closed, the lip 242 of the lid is retained in the closed position by a lid retention groove 291 in the outer surface. The lip enters into this lid retention groove, which is located on the inner layer close, and parallel, to the edge 218. One of the embodiments of such lid retention groove is shown in the front view of the inner layer, according to the second, equally preferred embodiment of the invention, shown in Fig. 6C. An enlarged view of the retention groove is shown in Fig. 6G. The force needed to open the lid of a closed V-Box, according to this second, preferred embodiment, is controlled by factors including the depth and the slope of the retention groove for a given female locking element of the inner layer.

ln the second preferred embodiment of the invention, drainage holes 271 are formed through the outer layer, and positioned to coincide with drainage holes 281 formed in the inner layer. Similarly, elongated holes are formed through the outer layer to provide handles 273 for the box. In altemate embodiments of the invention, the V-Box is formed without drainage holes, or without handles.

In order that the inner layer can be placed inside the outer layer and then interlocked with it, cuts 216 are made in the sides of the inner layer, s shown in Fig. 6A. Additionally, all four outside comers are cut 217.

Figs. 7A, 7B, 8A and 8B illustrate the steps of one method of assembling the V- Box of the second preferred embodiment of the invention. both sides of the outer layer are first folded up to 70° (Fig. 7A). Both sides of the inner layer are then folded 90° (200). The folded inner layer is rotated 90° (see arrow A in Fig. 7B) and then placed inside the folded outer layer (Fig. 8A) so that the bottom portions of both layers coincide. Both layers must be positioned in such a way that the outside of the inner layer 212 is on top of the inside of the outer layer 201 in proper orientation, and both side walls 215 of the inner layer bent at 90° to its bottom 214. The corresponding male locking elements of the inner layer 250 are then forced into the corresponding female locking elements of the outer layer 240 and snapped into locked position (Fig. 8B). In the process, the interlocking elements of the inner and outer layers are snapped together (Figs. 8C and 8D) and the lid closed (Figs. 8B and 8G), if desired.

To disassemble an empty V-Box, the lid is opened, the two outer edges of the bottom of the outer layer are held in position, and the inner layer is slid out of the outer layer. The sideholes 282 on both sides of the inner layer are adapted to facilitate holding the inner layer to lift it upwards, thereby disengaging the locking elements.

Fig. 9 is an isometric view of a V-Box according to the third, equally preferred embodiment of the invention 30. This embodiment differs from the previous two embodiments in that its inner layer is no longer in one piece, but as two identical side pieces 33. The outside layer 31 has the same features as the previously discussed V-Box embodiments. In this particular embodiment of V-Box with two side pieces, the female locking elements of the outer layer protrude outside of its inner surface.

Fig. 10A shows the top view of one of the identical side pieces 33. The side view of the side piece is given in Fig. 10B. The enlarged side view of the side piece is shown in Fig. 10D. As have the inner layers of the previously discussed embodiments of this invention, the side piece has two mirror-image locking elements 350 at its outer edges. Once the locking elements of the side pieces are interlocked with the corresponding locking elements of the outer layer, the locking lips of the female locking elements of the outer layer enter into the locking grooves 351 of the side pieces to prevent their coming apart. They are disengaged by sliding the side pieces out of the outer layer.

As in the above discussed embodiments, the locking grooves 351 are extruded or otherwise formed into the outer surface 312 of the side pieces. As in the above discussed embodiments, the corners of the side pieces have to be cut to make room for folding the outer layer. The cuts of this particular embodiment 317 are made at 45°; other embodiments can have different shape comer cuts.

As in the second V-Box embodiment, the closed lid is kept from opening by the interaction of the retention lip of the female locking element of the lid with the retention grooves of the side pieces. One of the embodiments of such a lid retention groove is shown in the front view of the side piece of fig. 10C, and in the enlarged view of Fig. 10E. By choosing the depth and the slope of the retention groove 391 for a given female locking element of the inner layer, we can choose the force needed to open the lid. However, unlike in the previously discussed V-Box embodiment, a similar retention groove 391 will interact with the locking element in the bottom portion of the outer layer keeping the side piece in place within the limits of some specified retention force.

In order to disassemble a V-Box of the third preferred embodiment, the lid is opened and each of the side pieces 33 is slid out of the engagement. In doing so, the friction between the locking lips of the outer layer along the locking grooves 351 of the side piece, and the retention force between the lip on the bottom portion of the outer layer and retention groove 391 along the bottom portion of the side piece 33 must be overcome.

It is apparent to one skilled in the art that the retention force between the bottom portion of the outer layer and the bottom portion of the side piece can be varied by choosing different shape and depth retention grooves for the bottom portion of the side piece. In the third preferred V-Box embodiment, the retention forces

for a closed lid and for the bottom engagement of the side piece are made the same by making both retention grooves alike. In other embodiments, these retention grooves in the side pieces are different.

Fig. 11 is an isometric view of the fourth, equally preferred V-Box embodiment 40. This embodiment differs from the third embodiment in that the female locking elements of the outer layer 41 do not protrude outside the inner surface of the outer layer. In altemate embodiments of the invention, the outer layer of this embodiment resembles that of the second V-Box embodiment, and its side pieces 43 resemble those of the third V-Box embodiment.

Fig. 12 is an isometric view of a fifth equally preferred embodiment 50 of the V- Box of the invention, in which the lid is made as a separate piece 54. In all its extruded aspects, the lid is identical to the outer layer.

Fig. 13 is an isometric view of the partitioned V-Box 60 according to the sixth embodiment of the invention. In this particular embodiment, the separation of the interior space defined by the box is obtained by removably joining a partition 65 within the interior space of the V-Box to at least one extruded female locking element. The female locking elements may be located on either, or both, of the inner and outer layers.

Fig. 14 shows an isometric view of the sixth embodiment of the invention 67 having multiple partitions 66. It is apparent to one skilled in the art that partitions can be held in place not only by special matching locking elements in the outer or inner layers, but by the product stored in the V-Box, or by making partitions in such a way that they themselves remain in the required position.

Fig. 15A is an isometric view of a seventh equally preferred embodiment 70 of the V-Box of the invention. Fig. 15B is an enlarged view of a selected area in Fig. 15A. In this embodiment, the outer layer 77, shown in the top view of Fig. 16A, is locked with itself to form an outer box, defining an interior space for the inner layer 78, as is shown in the side view of Fig. 16B. Four additional locking elements 761 are extruded into the inner surface 701 of the outer layer for capturing the corresponding outer edges 713 of the inner layer to keep it in place.

Enlarged views of both locking element 740 and 750 are given in Figs. 16E and 16C.

The inner layer 78, shown in the top view of Fig. 17A, is locked with itself to form an inner box defining an interior space, as is shown in the side view of Fig. 17B. Enlarged views of both locking elements 760 and 770 are given in Figs. 17C and 17D. In this embodiment, all corner regions and bending creases, all the wall thicknesses in cross-sections across the length of the layers, and all the locking elements of both layers are shaped by corresponding extrusion dies.

In altemate embodiments of the invention, all locking elements are of different design as long as the corresponding interlocking elements are in compliance with one another. In the seventh embodiment, the male and female locks 760, 770 for joining two ends of the inner layer have rounded shaped. The primary locking elements 740 and 750 for interlocking the ends on the outer layer when closing the V-Box have an arrow-like design. It will be appreciated by one skilled in the art that different amounts of female locking elements may be used. If no additional female locking elements 761 are used, the V-Box can have a slidably removable inner box, like a matchbox.

The primary purpose of these additional female locking elements 761 is to position the inner layer and keep it in place during filling of the V-Box. The secondary purpose of the additional female locking elements is to add strength and stability to the V-Box.

One of the advantages of the seventh preferred embodiment of the invention is that, since both layers are cut out perpendicular to the direction of extrusion, no additional operation is needed for creasing the layers. The designated corner areas 790 are extruded into the layers. Furthermore, the extrusion process is readily adapted to forming different shapes and thicknesses of the layers.

The inner layer and outer layer of this V-Box embodiment can have similar design locking elements. However, the larger the ratio of the length of an inner layer, and the less rigid the layer is to twisting, the easier it becomes to open the lock of the inner layer by simply sliding the male locking element 760 sideways out of the female locking element 770.

Fig. 16B and Fig. 17B show how areas for bending are designed into the extruded layers of the seventh embodiment. Thus, areas 780 and 790 are designed having in mind both the economical use of the material and the desired ease of bending the outer and the inner layers, respectively. The enlarged views of these bending areas are given in Figs. 16D and 17E, correspondingly.

Fig. 16F is a side view of the prying tool 79 of the invention. The prying tool is adapted for use with the arrow-like design of the outer layer locks with a specially shaped, protruding locking lip of the seventh preferred embodiment of the invention. The interlocked elements 740 and 750 on the outer layer are pried open by sliding such a tool under the protruding lip of the female locking element 740.

It is readily apparent that the female locking element of an outer layer can be designed in such a way that its outer lip can be opened without a special tool. For example, the outer layer can have a combination of an opening lever and fulcrum already extruded as a flexibly attached extension to its outer lip.

Fig. 18A is an isometric view of an eighth equally preferred embodiment 80 of the V-Box of the invention. An enlarged view of the locking area is shown in Fig. 81 B. This embodiment differs from the fourth embodiment in two respects. First, both ends of the female locking elements adapted for joining the inner layer to the outer layer are notched off 817, so that the corners of the inner layer no longer need to protrude outside of the outer layer, thereby simplifying the design of the inner layer. Second, a crease 820, or a set of creases, is extruded into the lid portion 806 of the outer layer, so that the lid can be partially opened.

Fig. 19A and Fig. 19B are isometric views, respectively, of the inside layers of two variations of the ninth preferred embodiment of the invention 91 and 93. Only these V-Boxes are actually shown. These variations have various partitions to divide the inner space of the box into compartments. The variation of Fig. 19A shows interlocked partitions 95, 96. The embodiment of Fig. 19B has an inner layer 98 with two corrugated sides to increase the stability and the load-carrying capacity of the V-Box, as well as a non-straight partition 99. In alternate embodiments of the invention, the partitions have different shapes, including straight, curved and angled configurations.

Figs 20A and 20B are top and front views, respectively, of a single-layer V-Box, according to the tenth embodiment of the invention 1010. Enlarged views of selected areas are given in Figs. 20C, 20D, and 20E. In this embodiment, a male locking element 1050, having locking groove 1051 is extruded into one edge of the single layer. A complementary female locking element 1040, having a locking lip 1042 adapted for releasable interengagement with the male locking element, is extruded into the opposite edge of the layer. Creases 1020 facilitate the folding of the layer to form the box.

Although the invention is described herein with reference to the preferred embodiment, one skilled in the art will readily appreciate that other applications may be substituted for those set forth herein without departing from the spirit and scope of the invention. For example, the size and thickness of the layers can be varied to accommodate the particular storage and strength requirements of various boxes. The V-Box can be ground up and recycled when its use is no longer required. Accordingly, the invention should only be limited by the Claims included below.