Improvements in wheeled packaging boxes

Abstract

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Description

Cross-Reference to Related Applications

[0001] The present application claims priority from Australian Provisional Patent Application No 2024904143 filed on 13 December 2024 and Australian Provisional Patent Application No 2025902018 filed on 23 May 2025, the contents of which are incorporated herein by reference in their entirety. Technical Field

[0002] This invention relates to a packaging box, carton, giftbox or the like, particularly for transporting bulky or heavy items for ultimate delivery to an end consumer. Background

[0003] Most consumer goods are sold in one form of packaging or another. For bulky and / or heavy items, such as televisions, these are typically packaged in cardboard boxes or cartons, with the item secured against movement inside the box, using an expanded polystyrene or foamed plastic insert and / or folded cardboard insert, or the like, which cushions the item against damage during transport and handling.

[0004] The items are packaged in the boxes at the factory and then shipped in containers, or the like, to retail stores or warehouses for online sales and delivery. Once purchased, they are either delivered to the end customer via a courier, or other delivery service, or in some cases the customer will pick up the item in store and drive it home.

[0005] The customer will sometimes carry the item or put it on a trolley. Couriers and delivery drivers will typically use a two wheeled hand truck or the like for making deliveries. Even after the product has been delivered however, the packaged item will often need to be moved subsequently by the customer to another location, e.g. the room where it is to be used.

[0006] Handling such bulky and heavy items can be awkward both for couriers and the end customers, and incorrect handling can lead to serious injuries including back injuries or the like. 2025271431   27 Nov 2025

[0007] Recently the mattress industry has been somewhat revolutionised by the direct sale to customers of mattresses which can be compressed, vacuum packed, and rolled up for storage. Even when compressed, mattresses are bulky, and they are also very heavy. It is known to provide boxes and cartons which include external wheels mounted on a corner for extremely heavy and bulky items such as mattresses.

[0008] However, mounting external wheels is complex and increases costs and often requires a wooden insert to which the wheels can be attached externally. The process can be quite time consuming and the end result not particularly attractive and makes the packaging look less attractive to the customer.

[0009] There have been a number of proposals have been made in the past for packaging boxes including retractable wheels, including US 3462171, US 10328961, US 20050217071, US 20050269791 and others. However, these proposals have not been successful for a number of reasons including cost, as the additional wheels are a significant added cost for the packaging, and the designs are complex and unreliable and generally too expensive to implement, and in many cases require too many changes to the cardboard box and design to implement in a costeffective manner.

[0010] The present invention seeks to address that issue and provide a carton which may address and at least partially alleviate some of those issues.

[0011] Any discussion of documents, acts, materials, devices, articles or the like which has been included in the present specification is not to be taken as an admission that any or all of these matters form part of the prior art base or were common general knowledge in the field relevant to the present disclosure as it existed before the priority date of each of the appended claims. Summary

[0012] According to the present invention there is provided a wheeled, typically cardboard, box having a first wall and a second wall opposite the first wall and side walls extending between the first wall and the second wall and a wheel unit mounted in a recess at a corner of the box for wheeling the box, wherein holes extend into opposed sides of the box at the corner, and into the 2025271431   27 Nov 2025 packaging inside the box, and an axle or axles locate inside the holes supporting wheels for use in wheeling the box. The hole may be lined.

[0013] In one embodiment, there is a single hole that extends from one side of the box to the opposite side, an axle located in the hole and a wheel is mounted on each end of the axis. The hole may be about the same diameter as the axle or bigger.

[0014] In an alternative embodiment, wheels are mounted on stub axles which are inserted into two holes on opposed sides of the box. The holes may be about the same diameter or narrower than the axles. The axles may be fixed in the holes using adhesive. The holes are preferably coaxial.

[0015] In a related aspect the invention provides a kit of parts for forming a wheeled box, comprising box having a first wall and a second wall opposite the first wall and side walls extending between the first wall and the second wall, wherein holes extend into opposed walls of the box at the corner, and into the packaging inside the box, and further including an axle or axles for insertion into the holes, and wheels fixed to or for attachment to the axles.

[0016] Typically, the box will be initially transported to a store with the wheels uninstalled and the wheels are mounted on the box for delivery to the customer.

[0017] A further aspect of the invention provides a wheeled, typically cardboard, box having a first wall and a second wall opposite the first wall and side walls extending between the first wall and the second wall and a wheel unit mounted on a bracket fixed at a corner of the box for wheeling the box.

[0018] A yet further aspect of the invention provides a wheeled, typically cardboard, box having a first wall and a second wall opposite the first wall and side walls extending between the first wall and the second wall and a wheel unit mounted on a bracket fixed at a corner of the box for wheeling the box wherein the wheels and / or brackets are mounted on biasing means, typically springs and can be retracted or at least partly retracted by compression of the biasing means.

[0019] Also disclosed is a wheelable, typically cardboard, box having a first wall and a second wall opposite the first wall and side walls extending between the first wall and the second wall a 2025271431   27 Nov 2025 base and a top, wherein one or more rigid plates are defined at the base of the box, typically within the box, the one or more rigid plates defining apertures for receiving the stem of a caster type wheel at or near corners of the base, the box including caster type wheels for insertion into the apertures.

[0020] Typically, the one or more plates are located inside the box adjacent the base of the box and are held in place by packaging in the box or by fasteners, or adhesive or by adhesive tape.

[0021] Also disclosed is a wheelable, typically cardboard, box having a first wall and a second wall opposite the first wall and side walls extending between the first wall and the second wall a base and a top, and including an attachable wheel support system comprising a plurality of L-shaped frames supported by a wheel, the frames having a laterally extending base part defining a distal end and a side wall wherein two frames can be attached together under the base of the box with the distal ends of the frames connected, typically by magnetic attraction, for supporting the box.

[0022] Also disclosed is a wheeled, typically cardboard, box having a first wall and a second wall opposite the first wall and side walls extending between the first wall and the second wall a base and a top, and wherein a recess is defined in the base of the box at or adjacent a first end of the base, and a pair of wheels are mounted on a axle inside the recess, with a part of the wheels extending beyond the plane of the base for wheeled movement of the box.

[0023] The box may further include an aperture defined in a second end of the base opposite the first end and a castor type wheel defining a stem mounted in, or mountable in, the aperture.

[0024] A recess may be defined in a second end of the base opposite the first end of the base, and a pair of wheels may be mounted on an axle inside the recess, with a part of the wheels extending beyond the plane of the base for wheeled movement of the box.

[0025] Advantageously, the various embodiments can generally be used with any existing cardboard box and do not need to be manufactured with the box or to be part of the box. Consequently, the wheel assembly is significantly more practical and cheaper to use than previous attempts to produce a wheeled box. 2025271431   27 Nov 2025

[0026] Throughout this specification the word "comprise", or variations such as "comprises" or "comprising", will be understood to imply the inclusion of a stated element, integer or step, or group of elements, integers or steps, but not the exclusion of any other element, integer or step, or group of elements, integers or steps. Brief Description of Drawings

[0027] A specific embodiment of the invention will now be described by way of example only, and with reference to the accompanying drawings, in which:- Figure 1 is a schematic side view of a first embodiment of a packaging box illustrating a hole for receiving a wheel axle; Figure 2 shows the box of Figure 1 with wheels inserted; Figure 3 is an end view illustrating the insertion of wheels into the box; Figure 4 is an end view with the wheels inserted; Figure 5 is a schematic side view of a second embodiment of a packaging box; Figure 6 is an end view of the box of Figure 5; Figure 7 is a schematic side view of a third embodiment of a packaging box; Figure 8 is an end view of the box of Figure 5; Figure 9 is a schematic side view of a fourth embodiment of a packaging box; Figure 10 is an end view of the box of Figure 9; Figure 11 is an enlarged view of a corner of the box of Figure 9; Figure 12 is a front view of a fifth embodiment of a packaging box; Figure 13 is a front view of the fifth embodiment of Figure 12 showing wheels removed; 2025271431   27 Nov 2025 Figure 14 is an underneath plan view of the fifth embodiment prior to the attachment of wheels; Figure 15 is a front view of the fifth embodiment showing hidden detail; Figure 16 is a side view of the fifth embodiment of Figure 15 showing wheels to be attached; Figure 17 is a side view of the fifth embodiment of Figure 15 showing wheels attached; Figure 18 shows a caster type wheel for use with the fifth embodiment; Figure 19 is an exploded side view of a sixth embodiment of a packaging box; Figure 20 is a side view of the sixth embodiment with magnetic wheels attached; Figure 21 is a side view of the sixth embodiment; Figure 22 is a perspective view of the sixth embodiment; Figure 23 is an enlarged corner view of the sixth embodiment; Figure 24 is a bottom plan view of the sixth embodiment; Figure 25 is a front view of a seventh embodiment; Figure 26 is a front view of the seventh embodiment prior to the attachment of a caster wheel; Figure 27 is a bottom view of the seventh embodiment; Figure 28 is a close-up view of one corner prior to the attachment of a wheel; Figure 28 shows a corner of a box prior to the attachment of a wheel; Figure 29 shows the corner of the box after the attachment of a wheel; Figure 30 shows the other side of the box; Figure 31 shows an eighth embodiment having hidden wheels mounted on an axle; and 2025271431   27 Nov 2025 Figure 32 shows a side view of the eighth embodiment. Description of Embodiments

[0028] Referring to the drawings, Figures 1 to 4 show a first embodiment of the invention. A packaging box or giftbox 10 includes a cardboard box exterior 12 containing a product, such as, but not limited to a television, and packaging surrounding and protecting the product for transport. Figure 1 shows the first wall or front 16 of the box and two sides / ends 13 and 15 The packaging will typically be made from a foamed plastic or expanded polystyrene and may comprise several pieces which together enclose or partly enclose the product. The packaging materials may also include paper or fibre based packaging.

[0029] As is best seen in Figure 1, a hole 14 is defined in a bottom rear corner of the box 12 as oriented in Figure 1. The skilled person will appreciate that the hole may be located at any corner of the box, or at more than one corner. As is best seen in Figures 3 and 4 there are holes 14A and 14B on both front and rear faces of the box. The holes 14 may extend from one first or front face 16 of the box 10 to the opposite second back side 18 or each hole 14A, 14B may extend only part way into the box and into the internal packaging, however the axes of the holes 14A and 14B should ideally be substantially coaxial and not deviate by more than say 5o from coaxial.

[0030] As is best seen in Figure 3 two wheel units each unit including wheels 20 and each including a stub axle on which the wheel is mounted are each plugged into or inserted into a respective one of the holes, 14A, 14B. The stub axles may be retained in the holes using adhesive or may be retained by friction and gripped in part by the friction with / expansion of the internal packaging, if the holes 14A, 14B are narrower than the diameter of the stub axles. The holes may be lined.

[0031] The wheels 20 may be attached to the exterior of the box at the factory, as shown in Figure 4, but in some embodiments, will be kept separate, e.g. in a bag attached to the exterior of the packaging box or even inside the box, with instructions how the attach the wheels for transportation / wheeling of the box either for delivery to a customer or by the customer moving the packaging box around their residence. 2025271431   27 Nov 2025

[0032] Figures 5 and 6 show a second embodiment of a packaging box 10A which is similar to the first embodiment except that wheels 30 are mounted at the end of a single axle 32 that extends through a hole 38 that extends through the front 16 and rear faces 18 of the box and through the interior packaging. The box 10A may have the same or similar contents and packaging as box 10.

[0033] The hole 38 is defined in a bottom rear corner of the box 12 as oriented in Figure 1. The skilled person will appreciate that the hole may be located at any corner of the box or at more than one corner. The hole 38 may extend from one side 16 of the box 10A to the opposite side 18. The hole may be lined with a hollow tube or may be unlined.

[0034] As with the first embodiment, the wheels 30 may be attached to the exterior of the box at the factory, but in some embodiments will be kept separate, for example, in a bag attached to the exterior of the packaging box or indeed inside the box, with instructions how the attach the wheels for transportation of the box for delivery to a customer, or by the customer / end user. In this case, at least one wheel is attached to one end of the axle after insertion of the axle through the hole 38 by the end user. The axle may be supplied with one wheel already attached.

[0035] Figures 7 and 8 show a third embodiment of a packaging box 10B. In this embodiment, wheels 50 are mounted on brackets 52 which are biased using springs 54 (spring loaded) and which can be at least partly recessed / retracted into holes 56 in the corner of the box 10B depending on the weight or compressive forces applied to the spring. This may allow the wheels to be retracted for storage of transport of the packaging but extended for use in moving the box by hand. In some embodiments, the aperture in the box through which the wheels extend may initially be closed or partly closed to keep the wheels retracted.

[0036] Figures 9 to 11 show a fourth embodiment 10C in which the wheels 60 are mounted on fixed brackets / mountings 62 located at one corner 58 of the packaging box 10C. The brackets may be glued or otherwise fixed to the exterior of the packaging box. In this embodiment, the wheels do not retract and as a consequence may hinder stacking and transport of the boxes more than the embodiments with the retractable or removable wheels.

[0037] Although the above-described embodiment has just two wheel units in one lower corner 58, it will be appreciated that wheel units may be provided on two or more corners. It will also 2025271431   27 Nov 2025 be appreciated that while the described embodiment relies to two spaced apart wheels, it would be possible, to provide just one wheel or wheel assembly on one corner.

[0038] Figures 12 to 18 show a fifth embodiment 10D in which the box is transported without attached wheels and wheels are attached later for use in moving the box by hand. In particular, as is best seen in Figure 15, the base of the box 10D defines two solid / rigid plates 70 for receiving the stems of clip in wheels 72 (refer to Figure 18). The wheels 72 are 360o swivel caster type wheels of the type that are often used on office chairs and they include a stem 73 which is received in a series of holes 74 in the underside of the base 76 of the box (and in the plates 70) best seen in Figure 17. The plates 70 themselves can be made from any suitable rigid material such including plastic or wood. The plates can be located inside the box prior to the insertion of the packaging and TV or whatever product is being packaged and could be held in place by the packaging itself or by adhesive or by adhesive tape. The wheels could be supplied inside the box with instructions how to insert them for use when moving the box, or could be attached to the exterior of the box in a bag or package.

[0039] Figures 19 to 24 show a yet further embodiment 10E in which the wheels 80 are provided on and under an L-shaped frame 82 which attaches around the exterior of the base of the box. As is best seen in Figure 19 two L-shaped frames 82 having a laterally extending base 84 and a side wall 86 are placed facing each other. The distal ends of the laterally extending base or tips of the frames are magnetic and of opposite polarities so they are attracted to each other as shown in Figure 20. As shown in Figure 20, the weight of the box and TV contents on the base of the frame will apply pressure to the frames and hold the box from the sides.

[0040] Figures 25 to 30 show a yet further embodiment 10F. In this embodiment there are two recessed wheels 90 mounted on an axle on one side of the bottom of the box. The other end includes a hole 94 for insertion of a swivel or caster type wheel 72 which is typically inserted for use in moving the box once the box has been shipped and sold. The separate wheel 72 could be transported inside the box or in a package attached to the box.

[0041] Figures 31 and 32 show a final embodiment 10G where the wheels 30 are mounted on an axle as in the case of the embodiment shown in Figures 5 and 6, but in this case the axle 32 is located entirely with the box, in an area at the corner of the box typically in a hollow in the packaging, adjacent a hole in the base to allow the wheels to roll. The ends of the axle may be supported by the walls of the box or by the packaging. 2025271431   27 Nov 2025

[0042] The packaging box will typically be used to transport heavier items including large appliances such as larger televisions which are bulky and heavy but could be used for any appliance or product, electrical or otherwise, although smaller and lighter appliances which can easily be carried are unlikely to require wheels.

[0043] As used herein the term “cardboard” encompasses any heavy paper based products used for packaging, from paperboard to corrugated fibreboard made from multiple plies of material, including corrugated cardboard / corrugated paperboard, corrugated fibreboard.

[0044] While the specific embodiment as described is a cardboard box as that is the most commonly used disposable packaging for products and parcels, it will be appreciated that the box could be made of other similar materials such as corrugated plastics or mixtures of plastics and cardboard.

[0045] As used herein, the term “wheel” encompasses any wheel, castor or other rotating device which turns on an axle bearing.

[0046] It will be appreciated by persons skilled in the art that numerous variations and / or modifications may be made to the above-described embodiments, without departing from the broad general scope of the present disclosure. The present embodiments are, therefore, to be considered in all respects as illustrative and not restrictive.

Claims

1. A wheeled, typically cardboard, box having a first wall and a second wall opposite the first wall and side walls extending between the first wall and the second wall and a wheel unit mounted at a corner of the box for wheeling the box, wherein holes extend into opposed first and second walls of the box at the corner, and into the packaging inside the box, and an axle or axles of the wheel units locate inside the holes supporting the wheels for use in wheeling the box.

2. A wheeled box as claimed in claim 1 wherein the hole is lined.

3. A wheeled box as claimed in claim 1 or 2 wherein there is a single hole that extendsfrom one wall of the box to the opposite wall, an axle is located in the hole, and a wheel is mounted on each end of the axle.

4. A wheeled box as claimed in claim 3 wherein the hole is about the same diameter as the axle.

5. A wheeled box as claimed in claim 1 or 2 wherein wheels are mounted on stub axles which are inserted into two holes located on opposed sides of the box.

6. A wheeled box as claimed in claim 5 wherein the holes are about the same diameter or narrower than the axles and wherein the axles are optionally fixed in the holes using adhesive and the holes are preferably co-axial.

7. A kit of parts for forming a wheeled box as claimed in claim 1, comprising box having a first wall and a second wall opposite the first wall and side walls extending between the first wall and the second wall, wherein holes extend into opposed walls of the box at the corner, and into the packaging inside the box, and further including an axle or axles for insertion into the holes and wheels fixed to or for attachment to the axles.

8. A wheeled, typically cardboard, box having a first wall and a second wall opposite the first wall and side walls extending between the first wall and the second wall and a wheel unit mounted on a bracket fixed at a corner of the box for wheeling the box.

9. A wheeled, typically cardboard, box having a first wall and a second wall opposite the first wall and side walls extending between the first wall and the second wall and a wheel unitmounted on a bracket fixed at a corner of the box for wheeling the box wherein the wheels and / or brackets are mounted on biasing means, typically springs and can be retracted or at least partly retracted by compression of the biasing means.

10. A wheeled box as claimed in claim 9 wherein the brackets and wheel are mounted in a recess or partially mounted in a recess in the corner of the box.

11. A wheelable, typically cardboard, box having a first wall and a second wall opposite the first wall and side walls extending between the first wall and the second wall a base and a top, wherein one or more rigid plates are defined at the base of the box, typically within the box, the one or more rigid plates defining apertures for receiving the stem of a caster type wheel at or near corners of the base, the box including caster type wheels for insertion into the apertures.12 A wheeled box as claimed in claim 11 wherein the one or more plates are located inside the box adjacent the base of the box and are held in place by packaging in the box or by fasteners, or adhesive or by adhesive tape.13 A wheelable, typically cardboard, box having a first wall and a second wall opposite the first wall and side walls extending between the first wall and the second wall a base and a top, and including an attachable wheel support system comprising a plurality of L-shaped frames supported by a wheel, the frames having a laterally extending base part defining a distal end and a side wall wherein two frames can be attached together under the base of the box with the distal ends of the frames connected, typically by magnetic attraction, for supporting the box.

14. A wheeled, typically cardboard, box having a first wall and a second wall opposite the first wall and side walls extending between the first wall and the second wall a base and a top, and wherein a recess is defined in the base of the box at or adjacent a first end of the base, and a pair of wheels are mounted on a axle inside the recess, with a part of the wheels extending beyond the plane of the base for wheeled movement of the box.

15. A wheeled, typically cardboard, box as claimed in claim 14 further including an aperture defined in a second end of the base opposite the first end and a castor type wheel defining a stem mounted in, or mountable in, the aperture.

16. A wheeled, typically cardboard, box as claimed in claim 14 further including a recess is defined in a second end of the base opposite the first end of the base, and a pair of wheels are mounted on an axle inside the recess, with a part of the wheels extending beyond the plane of the base for wheeled movement of the box.

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