FOLDING BOX WITH PRE-STRETCHED WALLS

Description

[0001] The present invention relates to the technical field of collapsible boxes for all uses and more particularly those intended for animals.

[0002] Cleaning pet litter boxes, which involves direct or indirect contact with waste, is unpleasant and poses health risks, particularly for pregnant women. It also becomes complicated when traveling outside the home.

[0003] Products with a hinged grid, as well as those equipped with a drawer or sieve system, are well-known. These products are generally bulky and difficult to transport. Furthermore, since they are not intended to be thrown away, they only partially eliminate contact with soiled litter.

[0004] Foldable and disposable products offer savings in cleanliness, time, and space. They also better address cleaning issues. The following methods are known in this area: GB2305348 describes a collapsible litter container, but its volume when closed does not save any space and therefore does not facilitate transport. FR2742308 describes a device where a plastic bag with an absorbent, collapsible cardboard base can be closed and disposed of, but requires use with a receiving tray. FR2718607 describes a collapsible, leak-proof tray equipped with a bag for closing and disposing of the tray and its contents. WO2000032493 describes a container made up of modules which, when folded, form a container without an opening. FR3013560 describes a collapsible, disposable unit consisting of a tray and absorbent litter with reinforced corners, closed by assembly. FR2754421 describes a disposable litter box with litter, the assembly of which requires gluing or stapling. FR2666194 describes disposable packaging with litter.waterproofed on the inner face and glazed on the outer face, the lid of which can be opened on three of its four sides and simply folded down under said packaging without any other means of fastening, WO2006072674 which describes a disposable and airtight box with bedding whose walls are joined together by the tabs of the front and rear flaps which snap into the side flaps, US 4164314 which describes a ready-to-use package whose walls are held together by the mutual engagement of tabs and slots formed by perforations in the upper sections, FR2706243 which describes a device in which a briefcase is transformed into a box by the articulated action of the bellows, nesting, lattice, folding, or other hinges of the side walls.

[0005] US patents 2011 / 308991 A1, 3,343,660 A, and 2003 / 102363 A1 disclose a box with prestressed walls. French patents 2,933,329 A1 and 3,756,495 A describe a method for obtaining a box.

[0006] These various techniques have drawbacks and only offer partial solutions to the problem. Their main disadvantage lies in their design, which forces the manufacturer or end user into manual tasks such as folding, gluing, or stapling. These tasks are often difficult to understand and perform, and may require additional supplies (scissors, glue, stapler) or extra parts to ensure the overall rigidity. Furthermore, improper execution of these operations can compromise the container's watertightness and stability, rendering it unsuitable for animal use and jeopardizing its hygienic effectiveness.

[0007] Of the known techniques, only those with very low side walls, even at the minimum litter level required, allow for assembly without manual labor. However, such low side walls do not effectively contain the litter inside the tray by preventing it from being scattered, and again call into question the hygienic effectiveness of the solution.

[0008] From an economic point of view, the multitude of components and rework required for assembly significantly increases the cost price of this disposable product, which tends to make it difficult to distribute via a classic distribution chain due to the number of intermediaries.

[0009] The prior art of temporary litter boxes does not adequately address the qualitative aspects of an industrially manufactured product in terms of design, hygiene, odor control, moisture resistance, and end-of-life recycling. The present invention overcomes the limitations of the prior art.

[0010] The present invention relates to a temporary litter box that eliminates the need for cleaning and thus reduces contact with excrement in a simple, efficient, and hygienic manner. Its simple design and construction require no additional parts or manipulation to assemble the litter box.

[0011] Such a litter box can be used, for example, as a travel solution when taking your pet away from your home, or as a solution for everyday use at home. This litter box can be used with or without litter, creating an all-in-one solution that is immediately ready to use.

[0012] The litter box according to the invention is defined in claim 1 and provides a novel solution to the construction problem by imposing a spring effect and shape memory in the form of a prestressed arc on the side walls of said box, such that they adopt a rigidity in the open position that guarantees the functionality of said box, without requiring any manipulation during assembly. This technique allows the use of sufficiently high side walls despite the absence of prior assembly work.

[0013] The invention relates to a litter box composed of a multilayer complex combining several sheets bonded together, each having its own purpose with respect to the mechanical, aesthetic, biodegradable, recyclable, waterproof, non-staining, and deodorizing properties of the invention. For example, the deodorizing effect can be achieved by inserting a sheet impregnated with activated carbon among the layers constituting the complex.

[0014] According to another particular feature, the present invention overcomes the difficulties of the prior art by offering both a functional solution requiring no prior construction work and a solution that combats unpleasant odors and litter scattering outside the box. By combining these advantages, the box according to the invention is more practical, more hygienic, and has a lower manufacturing cost than prior techniques.

[0015] Depending on other specific features, the invention may include: A multilayer complex composed of 2 to 5 sheets strongly adhered to each other, the thickness of each sheet ranging from 0.05 millimeters to 5 millimeters depending on the desired degree of rigidity; at least one sheet of said multilayer complex has water-resistant properties on at least one face of said box for improved durability; a sheet composed of activated carbon with or without micro-perforations to limit odors; at least one sheet of said multilayer complex is a plastic film composed of at least one material; at least one sheet of said multilayer complex is a bi-layer plastic film co-laminated with polyethylene (PE) on one of its faces to improve its adhesion; at least one sheet of said multilayer complex is a biodegradable plastic film for environmental protection.At least one sheet of said multilayer complex is a plastic film with heat-sealing properties on a paper-based fiber substrate to improve industrial productivity; at least one sheet of said multilayer complex is a plastic film with thermoforming properties for good shape definition; at least one sheet of said multilayer complex is micro-perforated and allows pressurized air to pass through its thickness to enable heat sealing or thermoforming of one of the sheets composing the complex; at least one sheet of said multilayer complex is naturally microporous and allows pressurized air to pass through its thickness to enable heat sealing or thermoforming of one of the sheets composing the complex; at least one sheet of said multilayer complex is a cardboard sheet for improved recycling.At least one sheet is pre-impregnated with a perfume or deodorizer to limit unpleasant odors; at least one sheet of said multilayer complex is a corrugated cardboard sheet onto which a sheet of paraffin-coated paper with moisture-resistant and stain-resistant properties is previously laminated for improved durability and appearance; at least one sheet of said multilayer complex is a honeycomb cardboard sheet for increased rigidity; at least one sheet of said multilayer complex is a printed sheet with a design to enhance the aesthetic appearance of the product; at least one sheet of said multilayer complex is a sheet coated with a varnish with waterproof or microporous properties to improve the finish of the finished product; the box according to the invention has a square or rectangular shape with four chamfered corners to prevent deformation during transport.The box according to the invention comprises a base and at least four vertical walls on which several folds have been pre-marked using a tool to create gussets allowing for better subsequent shaping. These vertical walls and gussets are braced together at the top in the unfolded position for greater rigidity. The box according to the invention can be equipped with a lid that can be printed with text and designs enhancing the box's design or product communication. The box according to the invention can be equipped with a lid whose top has pre-cut dotted lines and fold markings allowing for the creation of pre-made accessories related to its use. A scoop for removing excrement from the litter can be obtained after detaching the pre-cut lid and folding it. A litter mat with a printed design can be obtained after detaching the pre-cut lid.which thus finds a new use. The box according to the invention can be equipped with a peripheral folded edge, angled from 45° to 90° inwards, also produced under stress with an arc-shaped shape memory, so as to stiffen said box and constitute a solution against litter projections. The pre-stressed arc-shaped shape memory of the multilayer complex is obtained according to the invention by means of at least one adhered sheet with a geometry and dimensions slightly larger than the sheet it covers and to which it adheres. Said sheet, which it covers and to which it adheres, has been cut with a flat pattern (for example, with straight lines), while the sheet with the slightly larger geometry and dimensions is positioned and cold- or hot-bonded to the box, which has already been shaped and held on a pre-stressing matrix by an air gap.The shape memory of the pre-stressed arc of the multilayer complex is obtained, according to another unclaimed example, by hot stretching of the last sheet which is thermoformed onto the multilayer complex already shaped on a pre-stressing matrix. The thickness of the box according to the invention in the folded position is less than 15 millimeters for a standard low version and less than 100 millimeters for a raised version allowing the inclusion of animal bedding. Other special features and advantages of the invention will become apparent during the following description, which is made with reference to the accompanying drawings, in which: There fig.1 is a schematic perspective view of the box according to the invention, in the unfolded position, showing the folds of the folding bellows and the arched edge of said box, The fig.2 is a schematic cross-sectional view of the box according to the invention, in its unfolded position, with a rim, which shows the different layers of materials that can compose the multilayer complex. fig.3 , is a schematic cross-sectional view of the box according to the invention, in its unfolded position, without edges, which shows the different sheets of materials that can compose the multilayer complex according to a simplified version, The fig.4 is a schematic view of the top of the box according to the invention, in the folded position, without the lid. fig.5 is a schematic perspective view of the box according to the invention, in the unfolded position, showing the folding line of said box, according to a raised version, The fig.6 is a schematic perspective view of the box according to the invention, positioned in its prestressing matrix and in the closed position. fig.7 is a schematic perspective view of the box according to the invention, in its unfolding action, The fig.8 is a schematic perspective view of the box according to the invention, in its unfolding action, according to an enhanced version, The fig.9 is a schematic view of the flat-fabricated lid of the box according to the invention. fig.10 is a schematic view developed from the box according to the invention, manufactured flat, printed with a design. fig.11 is a schematic perspective view of the box lid according to the invention, showing the pre-cut dotted lines to obtain two shovels. fig.12 is a schematic perspective view of the box according to the invention, in a folded position, without a lid, according to a raised version, The fig.13 is a schematic view of the developed shape of the shovel manufactured flat, The fig.14 is a schematic view of the shovel in the rolled and folded position.

[0016] On the fig.1 , we have schematically represented the box (1) according to the invention composed of a base and four vertical walls on which several folds (2) have been pre-marked with the tool to make bellows (16) allowing the folding of the walls of the box (1) after the flat cutting of all or part of the development of the said box (1).

[0017] On the fig.1 , we have schematically represented a folded edge (3) from 45° to 90° towards the inside of said box (1) so as to constitute a solution against the projection of litter.

[0018] On the fig.1 , we have schematically represented the cut sides (4) constituting the four corners of said box (1).

[0019] On the fig.1 , we have schematically represented the shape memory (17) of the walls of the said box (1) as a prestressed arc outwards ensuring good rigidity to the said box (1) in unfolded position, preventing it from folding.

[0020] On the fig.2 , we have schematically represented said folded edge (3) advantageously obtained by marking on 2 / 3 of the thickness of the walls with a non-cutting tool made on a peripheral strip of about 20 millimeters.

[0021] On the fig.2 Schematically, various sheets of materials that can compose the multilayer complex (15), constituting the box (1) according to the invention, such as a plastic film (7), a sheet of corrugated cardboard (6) and a sheet of paraffin-coated paper (5), or a sheet composed of activated carbon with or without micro-perforations, are shown, along with the manner in which these sheets are assembled. For this purpose, at least one sheet is coated with at least one highly adhesive material (8).

[0022] On the fig.3 A schematic representation has been made of a less rigid composition of the multilayer complex (15), constituting the box (1) according to the invention, such as being composed of a plastic film (7) and a simple cardboard sheet (9), and the manner in which these component sheets are assembled. For this purpose, at least one sheet is coated with at least one adhesive (8).

[0023] On the fig.4 , we have schematically represented the box (1) in folded position and the positioning of the cut sides (4) in this position.

[0024] On the fig.5 , we have schematically represented the box (1) according to the invention, according to a version where the bottom has been raised (18) to allow the inclusion of a litter, so that the box (1) constitutes a ready-to-use assembly.

[0025] On the fig.6 The box (1) according to the invention is shown schematically, positioned in its mold after being cut flat and its folds (2) having been marked. The mold serves both as a prestressing matrix (14) and as a tool for modifying the geometry of the flat-cut box (1). The box (1) is pressed against the mold walls by an air gap.

[0026] On the fig.7 , we have schematically represented the box (1) according to the invention, showing the trajectory followed by the cut sides (4), the folding bellows (16), and the folded edge (3) during the opening of said box (1).

[0027] On the fig.8 , we have schematically represented the box (1) according to the invention, in its raised version (18), showing the trajectory followed by the cut sides (4), the folding bellows (16), and the folded edge (3) during the opening of said box (1).

[0028] On the fig.9 , we have schematically represented the flat-made lid (10) of the box (1) according to the invention, showing the folds (2) of said lid (10) and the pre-cut dotted lines (11) allowing to obtain flat pre-made accessories related to the use.

[0029] On the fig.10 The box (1) according to the invention is shown schematically in its enhanced version (18), manufactured flat and printed with a design (13). In this example, all the lines are straight.

[0030] On the fig.11 , we have schematically represented the lid (10) of the box (1) according to the invention showing the pre-cut dotted lines (11) allowing to obtain prefabricated flat accessories related to the use.

[0031] On the fig.12 , we have schematically represented the box (1) according to the invention in its raised version (18) where the side walls and the cut sides (4) are folded down.

[0032] On the fig.13 The flat scoop (12), which can be obtained by detaching the lid (10) from the box (1) according to the invention, is shown schematically. The fold markings (2) are visible, which, after folding, allow for a ready-to-use scoop (12) to be obtained for removing excrement from the litter.

[0033] On the fig.14 , we have schematically represented the shovel (12) obtained after folding by following the markings of the folds (2).

[0034] The box (1) according to the invention can advantageously be made with materials, industrial means and machines commonly used in the paper, cardboard, printing and thermoforming industries. Its industrial application can bring together different machines on a single manufacturing site dedicated to this type of product.

[0035] A first industrial embodiment, given by way of non-limiting example, consists of producing the foldable box (1) in several preparation stages as a semi-finished product (19). Advantageously, film sheets in rolls of several hundred linear meters with a width adapted to the product are chosen. These rolls can be installed in a roller or belt laminating machine and unwound simultaneously. This machine, also called a laminating machine, provides a means of depositing adhesive in liquid or powder form and a means of continuously assembling the various components. A first semi-finished product (19) is thus obtained, composed, for example, of cardboard laminated with a strong adhesive agent onto a sheet of waxed paper (5), itself printed with a design (13).This initial assembly, thus obtained, comes in the form of large rolls or reels several meters long, ready to be further processed on another machine. Advantageously, these rolls or reels, as they emerge from the laminating machine, are automatically ready to be received by a die-cutting press, which will in turn perform the cutting and simultaneous marking of the folding grooves of the box (1) in flat lay, thus producing the semi-finished product (19). The semi-finished product (19) will then be further processed for its final shaping and finishing as explained below.

[0036] According to another particular embodiment, the box (1) is manufactured from several materials in the form of sheets pre-cut to size for further processing on another machine. Advantageously, these sheets, as they emerge from the laminating machine, are automatically ready to be received by a die-cutting press, which in turn performs the cutting and simultaneously marks the folding grooves of the box (1) in its flat unfolded state, thus producing the semi-finished product (19). The semi-finished product (19) is then further processed for final shaping and finishing as explained below.

[0037] According to another particular embodiment, for example, a production line is created with several successive workstations to obtain a finished product at the end of the line: At the first station, the flat assembly (15) of the sheets composing the box's unfolded form (1) is produced, except for the last sheet, whose geometry and dimensions will be slightly larger than the flat surface area of ​​the box's unfolded form (1). At the second station, the folds (2) and flat cuts are marked to create a semi-finished product (19). The third station consists of a thermoforming machine equipped with preheating, heating, air pressure, vacuum, a prestressing die (14), and a cutting station. The fourth station includes pressure bending equipment. The fifth station includes labeling equipment.

[0038] The following operations will be undertaken successively: The complex (15) is produced flat from the sheets composing the unfolded box (1), except for the last sheet, whose geometry and dimensions will be slightly larger than the flat surface area of ​​the unfolded box (1). A portion of the prefabricated multilayer complex (15), marked at the fold points (2) and cut flat into a semi-finished product (19), is positioned manually or automatically in the prestressing die (14) for intermediate shaping. The prestressing die (14), equipped with a vacuum system, will press the initial straight walls of the semi-finished product (19) against the curved walls (17) of the prestressing die (14) by suction. A plastic sheet (7) with an adhesive side is heated by the thermoforming machine and placed above the prestressing die (14), then drawn in and shaped by the vacuum system.After the plastic sheet (7) has cooled and hardened, shape-memory constrained walls (17) are obtained. The plastic sheet (7) is then cut in the prestressing die (14) or at another station of the thermoforming machine. After cutting, bending devices using pressure hold the box (1) in the folded position. The finished product is labeled and marked with product identification features such as barcodes.

Claims

1. Box (1) with foldable walls, without the need for handling, mainly intended to accommodate animal litter, and comprising a bottom and at least 4 vertical walls on which several folds (2) have been pre-marked with the tool to make bellows (16) enabling the folding and unfolding of the walls of the box (1), this box (1) is folded following its manufacture, and said box (1) is manufactured with several materials in the form of sheets adhering strongly to each other, thus forming a rigid and flexible multilayer complex (15) that is obtained thanks to the choice of the properties of the adhesives (8) and the resistance of the materials in terms of flexibility and compression to make prestressed walls, said box (1) being characterised in that the prestressed walls have an arc shape memory (17), which is obtained from the initial multilayer complex (15) and thanks to at least one adherent sheet (7) of dimensions slightly larger than the sheet it covers and to which it adheres.

2. Box (1) according to claim 1 characterised in that the successive manufacturing steps make it possible to obtain a spring effect and a shape memory (17) of the walls in an arc prestressed towards the outside to ensure that said box (1) has good rigidity in the unfolded position.

3. Box (1) according to claim 1, characterised in that it is equipped with a folded edge (3) from 45° to 90° inwards thanks to a stress with an arc shape memory (17), said folded edge (3) being advantageously obtained by marking 2 / 3 of the thickness of the walls with a non-cutting tool and made on a peripheral strip of about 20 millimetres, so as to constitute a solution against litter projections on the one hand, and to contribute to accentuating the rigidity of the box (1) in the unfolded position on the other hand.

4. Box according to claims 1 and 2 characterised in that the adherent sheet is formed by a plastic sheet (7) with an adhesive side (8) which is heated by thermoforming and is placed on a prestressing matrix: following the cooling and hardening of the plastic sheet (7), we obtain stressed walls with shape memory (17) of said box (1).

5. Box (1) according to claim 1, characterised in that the multilayer complex (15) is composed of 2 to 5 sheets, the thickness of each of which can vary from 0.05 millimetres to 5 millimetres depending on the desired degree of rigidity.

6. Box (1) according to claims 1 and 5 characterised in that at least one sheet of said multilayer complex (15) is a cardboard sheet (9) and is microporous in the natural state, allowing air to pass under pressure through its thickness to enable the heat-sealing or thermoforming of one of the sheets making up the complex (15).

7. Box (1) according to claim 5, characterised in that at least one sheet of said multilayer complex (15) is a biodegradable plastic film (7).

8. Box (1) according to claims 1 and 5 characterised in that said multilayer complex (15) comprises at least one sheet of corrugated cardboard (6) on which a sheet of waxed paper (5) with moisture resistance and anti-fouling properties has been previously laminated.

9. Box (1) according to claims 1 and 5 characterised in that the multilayer complex (15) comprises at least one sheet printed with a decoration (13).

10. Box (1) according to claims 1 and 5 characterised in that at least one sheet of said multilayer complex (15) is a co-laminated polyethylene (PE) bilayer plastic film (7) on one of its faces.

11. Box (1) according to claims 1 and 5 characterised in that at least one sheet of said multilayer complex (15) is a micro-perforated sheet that allows air to pass under pressure through its thickness to enable the heat-sealing or thermoforming of one of the sheets making up the complex (15).

12. Box (1) according to claims 1 and 5 characterised in that the multilayer complex (15) comprises at least one sheet covered with a varnish with microporous characteristics.

13. Box (1) according to claim 1 having a square or rectangular shape characterised in that the 4 corners are cut sections (4).

14. Box (1) according to claim 1, characterised in that the thickness of said box (1) in the folded position is less than 15 millimetres for a low standard version, and less than 100 millimetres for an enhanced version (18) allowing animal litter to be included before folding.

15. Box according to claims 1 characterised in that it is equipped with a lid (10), the top of which has pre-cutting dotted lines (11) and fold markings (2) enabling the obtaining of prefabricated flat accessories related to the use, such as at least one shovel (12) for removing excrement from the litter.

16. Method of obtaining the box (1) according to any one of claims 1 to 15 characterised in that a part of the multilayer complex (15) is prefabricated, marked at the location of the folds (2), and cut to form a flat semi-product (19), said semi-product (19) being subsequently positioned on a form serving on the one hand as a matrix (14) and on the other hand as tools for modifying the initial geometry of said flat semi-product (19) where it is force-plated on the walls of the matrix (14) by an air vacuum to receive at least one plastic sheet (7) with an adhesive face (8) stretched and hot-formed, then, after cooling, the entire complex (15) previously placed under stress becomes rigid and is cut to the dimensions of the finished product, consisting of a box (1) presented in the folded position thanks to the intervention of folding means using pressure.