Interlocking Flaps for Reusable Plastic Corrugated Boxes

The patent removes heavy self-locking mechanisms (such as springs, guide tracks, buckles, or Velcro strips) from the box structure. Instead, it uses simple interlocking flaps and tabs that fold inward to secure side panels, eliminating the need for heavy locking components while maintaining structural integrity.

The box structure uses its own geometric form and interlocking features (flaps and tabs) to secure itself without requiring external heavy locking mechanisms. The side panels are held up by the interlocking geometry of the flaps and tabs, allowing the structure to self-secure through its design rather than heavy components.

The box is divided into separate panels (bottom panel and side panels) that are attached through simple fold lines. The flaps and tabs are segmented features that can be independently formed and interlocked, allowing for simple assembly without complicated procedures.

The flaps and tabs are pre-formed as integral parts of the blank during the die-cutting process. This preliminary formation eliminates the need for separate assembly steps to create these features, as they are already prepared for interlocking when the blank is folded into the box configuration.

The flaps and tabs are merged as integral features of the blank itself, formed through die-cutting and folding. This eliminates the need for separate accessories to secure the structure, as the interlocking features are built into the box design, reducing both complexity and manufacturing cost.

The patent uses simple, inexpensive interlocking features (flaps and tabs) that can be easily formed and discarded or reused, rather than expensive heavy locking mechanisms. These simple features provide sufficient strength for the application while being cost-effective to manufacture.