Collapsible box and methods of using same

Abstract

The disclosed systems and methods relate to an improved collapsible box for securely storing and transporting products. The collapsible box can include a fixed upper frame, a fixed lower frame, a first foldable sidewall, a second foldable sidewall, and two end walls. The collapsible box can have an assembled configuration wherein a first upper section and a first lower section of the first foldable sidewall are substantially coplanar, and a second upper section and a second lower section of the second foldable sidewall are substantially coplanar. The collapsible box can include a collapsed configuration wherein the first foldable sidewall, the second foldable sidewall, and the two end walls are substantially parallel such that the first foldable sidewall is folded and the second foldable sidewall is folded.

What is claimed is: 
     
         1 . A collapsible box comprising:
 a fixed upper frame;   a fixed lower frame;   a first foldable sidewall, the first foldable sidewall comprising a first upper portion and a first lower section hingeably connected to each other, the first upper section of the first foldable sidewall hingeably connected to the fixed upper frame, the first lower section of the first foldable sidewall hingeably connected to the fixed lower frame;   a second foldable sidewall, the second foldable sidewall comprising a second upper section and a second lower section hingeably connected to each other, the second upper section of the second foldable sidewall hingeably connected to the fixed upper frame, the second lower section of the second foldable sidewall hingeably connected to the fixed lower frame;   two end walls, each end wall hingeably connected to one of the fixed upper frame or the fixed lower frame,   wherein the collapsible box has an assembled configuration wherein the first upper section and the first lower section are substantially coplanar, and the second upper section and the second lower section are substantially coplanar,   wherein the collapsible box has a collapsed configuration wherein the first upper section, the first lower section, the second upper section, the second lower section, and the two end walls are substantially parallel.   
     
     
         2 . The collapsible box of  claim 1 , further comprising a first lid piece and a second lid piece, each lid piece comprising a curved side and a second side, the second side hingeably connected to the fixed upper frame, wherein the curved sides of each of the lid pieces can interlock with each other into a closed configuration when the two lid pieces are substantially planar. 
     
     
         3 . The collapsible box of  claim 2 , further comprising a sliding latch disposed on at least one of the first lid piece or the second lid piece, wherein the sliding latch can slide into a side aperture in the fixed upper frame to prevent the first lid piece and the second lid piece from changing position. 
     
     
         4 . The collapsible box of  claim 3 , wherein, in the collapsed configuration:
 the first upper section of the first foldable sidewall and the first lower section of the first foldable sidewall are folded into a substantially parallel position;   the second upper section of the second foldable sidewall and the second lower section of the second foldable sidewall are folded into in a substantially parallel position;   the two end walls are parallel to the first upper section, the first lower section, the second upper section, and the second lower section and are disposed above or below the first upper section, the first lower section, the second upper section, and the second lower section; and   the sliding latch is engaged with the side aperture in the fixed upper frame to keep the collapsible box in the collapsed configuration.   
     
     
         5 . The collapsible box of  claim 2 , wherein the first lid piece comprises a first upper aperture, wherein the second lid piece comprises a second upper aperture, wherein the fixed upper frame comprises a first upward facing tab and a second upper facing tab, and wherein the apertures on the two lid pieces meet with the upward facing tabs on the fixed upper frame. 
     
     
         6 . The collapsible box of  claim 1 , wherein each of the two end walls comprise four first locking features that are sized and shaped to engage with second locking features disposed on each of the first upper section, the first lower section, the second upper section, and the second lower section, wherein the first locking features are a tab or a notch, and the second locking features are a corresponding notch that can engage with the tab or a corresponding tab that can engage with the notch. 
     
     
         7 . The collapsible box of  claim 6 , wherein, in the assembled configuration:
 the first foldable sidewall is in a substantially planar position;   the second foldable sidewall is in a substantially planar position; and   the two end walls are engaged with the first foldable sidewall and the second foldable sidewall via the first locking features and the second locking features.   
     
     
         8 . A collapsible box comprising:
 a fixed upper frame;   a bottom;   a first foldable sidewall, the first foldable sidewall comprising a first upper section and a first lower section hingeably connected to each other at a first hinge, the first upper section hingeably connected to the fixed upper frame, the first lower section hingeably connected to the bottom;   a second foldable sidewall, the second foldable sidewall comprising a second upper section and a second lower section hingeably connected to each other at a second hinge, the second upper section hingeably connected to the fixed upper frame, the second lower section hingeably connected to the bottom; and   two end walls, wherein each end wall is hingeably connected to one of the fixed upper frame or the bottom,   wherein the collapsible box has a collapsed configuration, wherein:
 the first upper section and the first lower section are folded at the first hinge and are substantially adjacent and parallel; 
 the second upper section and the second lower section are folded at the second hinge and are substantially adjacent and parallel; 
 when the two end walls are attached to the fixed upper frame, the two end walls are substantially adjacent and parallel and rest in a plane above the first sidewall and the second foldable sidewall; and 
 when the two end walls are attached to the bottom, the two end walls are substantially adjacent and parallel and rest in a plane below the first foldable sidewall and the second foldable sidewall. 
   
     
     
         9 . The collapsible box of  claim 8 , further comprising:
 two lid pieces, each lid piece comprising a curved side and a second side, the second side hingeably connected to the fixed upper frame, wherein the curved sides of each of the lid pieces can interlock with each other in a closed configuration when the two lid pieces are substantially parallel; and   a sliding latch on each lid piece, wherein each sliding latch can slide into a side aperture in the fixed upper frame to prevent the lid pieces from changing position from the closed configuration.   
     
     
         10 . The collapsible box of  claim 9 , wherein at least a portion of one of the lid pieces fits under a portion of the other lid piece to interlock with each other. 
     
     
         11 . The collapsible box of  claim 10 , wherein the fixed upper frame comprises an upward facing stacking tab, wherein the bottom comprising a stacking aperture, and wherein the upward facing stacking tab is sized and shaped to engage the stacking aperture on the bottom of a second collapsible box. 
     
     
         12 . A method of making a collapsible box, the method comprising:
 connecting a first upper section of a first foldable sidewall to a first lower section of the first foldable sidewall at a first hinge;   connecting a second upper section of a second foldable sidewall to a second lower section of the second foldable sidewall at a second hinge;   connecting the first lower section to a lower frame via a third hinge;   connecting the first upper section to an upper frame via a fourth hinge;   connecting the second lower section to the lower frame via a fifth hinge;   connecting the second upper section to the upper frame via a sixth hinge;   connecting a first end wall to the upper frame via a seventh hinge; and   connecting a second end wall to the upper frame via an eighth hinge.   
     
     
         13 . The method of  claim 12 , further comprising:
 forming upward facing stacking tabs on the upper frame; and   forming stacking apertures on the lower frame, wherein the upward facing stacking tabs of a first collapsible box can meet with the stacking apertures of a second collapsible box.   
     
     
         14 . The method of  claim 12 , further comprising:
 connecting a first lid piece to the upper frame via a ninth hinge, the first lid piece comprising a first curved side opposite the ninth hinge; and   connecting a second lid piece to the upper frame via a tenth hinge, the second lid piece comprising a second curved side opposite the tenth hinge,   wherein the curved sides of each of the lid pieces can interlock with each other into a closed configuration when the two lid pieces are substantially planar.   
     
     
         15 . The method of  claim 14 , further comprising inserting a sliding latch on each lid piece, wherein the sliding latches can slide into corresponding side apertures in the upper frame to prevent the lid pieces from changing position. 
     
     
         16 . The method of  claim 14 , wherein each lid piece further comprises an aperture, wherein the upper frame comprises an upward facing tab, and wherein the apertures on the two lid pieces meet with the upward facing tabs on the upper frame. 
     
     
         17 . The method of  claim 12 , further comprising:
 connecting four first locking features on the first end wall with second locking features disposed on each of the first upper section, the first lower section, the second upper section, and the second lower section; and   connecting four third locking features on the second end wall with fourth locking features disposed on each of the first upper section, the first lower section, the second upper section, and the second lower section,   wherein the first locking features and third locking features are a tab or a notch, and the second locking features and the fourth locking features are a corresponding notch that can engage with the tab or a corresponding tab that can engage with the notch.   
     
     
         18 . The method of  claim 12 , wherein the first foldable sidewall, the second foldable sidewall, the first end wall, and the second end wall comprise plastic. 
     
     
         19 . The method of  claim 12 , further comprising assembling the collapsible box into an assembled configuration wherein:
 the upper first section and the lower first section are substantially planar; and   the upper second section and the lower second section are substantially planar.   
     
     
         20 . The method of  claim 12 , further comprising transitioning the collapsible box into a collapsed configuration wherein:
 the first upper section and the first lower section are folded at the first hinge into a substantially parallel position; and   the second upper section and the second lower section are folded at the second hinge into a substantially parallel position.