I am baffled by the contrast of your seemingly serious inquiry while at the same time you seem to not realize that there is no such thing as a "Perfect Box"!?
Perhaps I mean "optimum box" ?There has to be a box that is aesthetically pleasing, ergonomic, and functional....
I forgot to measure it, but this is one of the sort of thing I am talking about - simple box thrown together with offcuts of plywood and some screws. (in rough numbers, it'd be around 900x400x300)I don't recall what this one was originally for, and now it sits empty. Most (actually I think all) of it's brothers and sisters have been repurposed into garden boxes.Right or Wrong - I believe these are proportions I find appealing - wider than it is deep, and about twice as long as it is wide.I am interested in what someone said about pallets - a pallet is approx 1100 square, so if I made the boxes (say) 700 x 400mm, they would stack nicely in a pattern....if I use 1100 as an upper limit for L + W, and maybe work the golden ratio into it (which I did spend some time with a pad and pen trying different sizes), perhaps I can find the Correct Dimensions.I wonder what happens if I make a Box Z Deep, Z*1.61 Wide and Z*1.61*1.61 long.... (if Z is 260, then this will also meet the first criteria)Will the universe survive such a thing?
The only Right or Wrong is whether the box works for the Load,right?It sounds like you are trying to design something pretty too?So if building for that rough size and pallet transport I would build more like a crate than a box myself.It seems clear that you want something too big for a 1 person carry and I would make sure then that it has wheels and much better handles and also reinforced edges all the way around as well.I would also build in some form of indexing to enable safer stacking so that the boxes interlock to some degree when stacked.I would reinforce the edges so that the screws can bite not only onto the plywood endgrain but also to actual wood for strength.If this is not what you want then look to inside cleats maybe so that you can get additional fastener strength?By using 1x3 for example on each edge you can also easily build in the tops and bottoms to lock together when stacked and you might even need forklift guides of enough lift under the box for forks depending on the weight and how you intend to get these loaded in the first place?I probably also build a sealed box and then cut the lid from around the circumference of the box so that the lid is not just a flat piece but instead another structure that will resist bowing and flexing better.I have had crates like this just "Explode" sort of when dropped too hard and depending on the contents that mat be more frequent than you might think but is never a welcome event.
The pallet constraint was just a thing of interest, I'm not terribly likely to need to stack on a pallet in this instance, and as pictured, I like to put handles on the boxes so meshing them together is not really going to work anyway.I am shooting for the "upper limit of one person lift/carry".So far I've been putting them together with construction adhesive (sikaflex) and washer head screws, and I have not been able to break them if I tried.I have put skids on larger boxes in the past - which would allow MHE use, but mostly to avoid having a giant moisture trap. These ones should not be so large.Though a simple hinged flat lid is by far the easiest, it's not a massive step out of my way to do something like https://cdn11.bigcommerce.com/s-80qxgw/images/stencil/1280x1280/products/101/1902/Wooden-BoxLarge-Flat-TopHinged-Lid-Baltic-6-5__04274.1494402899.jpg?c=2&imbypass=onwhich would give it some rigidity.I can also put an internal frame in, in the event that the material itself doesn't provide enough strength and rigidity.However, I am a habitual tightarse, and these things are always made of "scrap" ply that I have around, cut, glued, and screwed in an afternoon, painted whatever colour of weatherproof/exterior housepaint I have spare, and then I move on - So elegance of form is not a huge consideration, especially if it is going to include a tax of time and materials in order to achieve it.