BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with a general description of the invention given above and the detailed description of the embodiments given below, serve to explain the principles of the invention.
FIG. 1 is a perspective view of one embodiment of collapsible container in accordance with the present invention, showing the container erected with a dunnage structure shown in phantom in an erected position for holding product for shipment or storage;
FIG. 1A is a perspective view of one rear corner of the collapsible container of FIG. 1;
FIG. 1B is a cross-sectional view showing the locking mechanism for locking a pivotal front frame of the container of FIG. 1 in an erected position;
FIG. 2 is a perspective view of the collapsible container of FIG. 1, showing a portion of the frame being collapsed, the dunnage shown in phantom;
FIG. 3 is a side elevational view of the container of FIG. 1 showing the frame collapsed;
FIG. 4 is a side elevational view of the container of FIG. 1 showing the rear wall and frame collapsed;
FIG. 5 is a front elevational view of the container of FIG. 1 showing the side structures being collapsed;
FIG. 6 is a front elevational view of the container of FIG. 1 in a collapsed position;
FIG. 7 is a cross sectional view of the collapsible container of FIG. 1 in accordance with one aspect of the present invention;
FIG. 7A is a cross-sectional view of one type of dunnage which may be used in a collapsible container in accordance with the present invention;
FIG. 7B is a cross-sectional view of an another type of dunnage which may be used in a collapsible container in accordance with the present invention;
FIG. 7C is a cross-sectional view of an another type of dunnage which may be used in a collapsible container in accordance with the present invention;
FIG. 8 is a cross-sectional view of another embodiment of collapsible container in accordance with the present invention;
FIG. 9 is a perspective view of a portion of the collapsible container of FIG. 8 showing one type of dunnage suspended by dunnage supports;
FIG. 10 is a cross-sectional view of another embodiment of collapsible container in accordance with the present invention; and
FIG. 11 is a perspective view of a portion of the collapsible container of FIG. 10 showing another type of dunnage suspended by dunnage supports.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1, there is illustrated a reusable and returnable collapsible container 10 with interior dunnage 24 shown only in phantom for clarity. As explained below, many different forms or types of dunnage in accordance with the present invention may be used in a collapsible container like the one shown in FIG. 1.
The reusable and returnable collapsible container 10, as shown, comprises a body 12 having a base 13 comprising a bottom portion 14 and three fixed, upstanding vertically oriented wall portions 16a, 16b and 16c extending upwardly from the perimeter of the bottom portion 14 of the base 13. A rear wall 18b and side walls 18a, 18c are hingedly connected to the vertically oriented wall portions 16b and 16a, 16c of the base 13, respectively. Side wall 18a is hingedly or pivotally joined to the wall portion 16a of the base 13 with a hinge pin 20a so that the side wall 18a may move or pivot from a collapsed position shown in FIG. 6 to an erected position shown in FIG. 3. Similarly, rear wall 18b is hingedly or pivotally joined to the wall portion 16b of the base 13 with a hinge pin 20b (see FIG. 3) so that the rear wall 18b may move or pivot from a collapsed position shown in FIG. 4 to an erected position shown in FIG. 1. Lastly, side wall 18c is hingedly or pivotally joined to the wall portion 16c of the base 13 with a hinge pin 20c so that the side wall 18c may move or pivot from a collapsed position shown in FIG. 6 to an erected position shown in FIG. 4. Although one type of hinge is illustrated to connect the rear and side walls 18b, 18a, 18c to the base 13, any other type of hinge or connection may be used as desired.
The combination of the wall portion 16a of the base 13 and the side wall 18a make up a side or wall structure 22a. Similarly, the wall portion 16c of the base 13 and the side wall 18c make up another side or wall structure 22c on the opposite side of the collapsible container 10. Lastly, the rear or back wall portion 16b of the base 13 and the rear wall 18b make up a rear wall or side structure 22b. A fourth side structure 22d comprises a frame 28 as described below.
The container 10 may also have a front or side cover (not shown) in addition to the frame 28 shown and described below opposite rear side or wall structure 22b. The base 13 may be a pallet-type base having a plurality of slots or grooves 15 formed therein for receiving the forks of a lift truck or any other configuration. Although one configuration of base 13 is illustrated, other types or configurations of bases may be used in accordance with the present invention.
The base 13 and walls 18a-18c of the container 10, are typically made of a suitably rugged material, such as a strong, durable plastic or the like but may be made of any desired material. Containers which may be adapted or configured to include various invention features in accordance with the aspects of the present invention, are available from Ropak Corporation of Georgetown, Ky. A Ropak collapsible container may be retrofitted in accordance with the principles of the present invention to yield the inventive container having the various benefits discussed herein. Other collapsible containers may be adapted in accordance with the present invention.
Although one type of container is illustrated, the present invention may be used with any type or configuration of box or container. For example, the present invention may be used in other styles of container in which one or more of the walls or sides of the container is hinged for the container to be more easily erected and/or compacted for storage. The present invention may also be used in a rack type of container which has four corner posts extending upwardly from a base. A cover (not shown) may also be included to enclose the container 10 and further protect and secure products 26 during shipment. See FIG. 7.
The walls or side structures 18a-18c of the container 10 are configured for being selectively moved, hinged or pivoted between an erected position and a collapsed position. In the erected position, as shown in FIG. 1, the container 10 is suitable for containing product for shipment (not shown). In the collapsed position, as shown in FIG. 6, the size of the container 10 is reduced so that the container 10 may be return shipped in a more cost effective manner. To that end, the side structures or walls 18a-18c in the illustrated embodiment are hinged so that the walls 18a-18c may be moved from a locked, erected position to an unlocked, collapsed position. Any conventional locking mechanism may be used to lock them in an erected position.
Therefore, each wall or side structure 22a-22c essentially has a movable top or upper portion 18a-18c, respectively, and a stationary bottom or lower portion 16a-16c, respectively. The top portion 18a-18c is hinged inwardly (see FIG. 6) with respect to the lower portion 16a-16c to generally reduce the size of the container 10 by half when the container 10 is in the collapsed position. The bottom portions 16a-16c of each wall or side structure 22a-22c remain in a vertically upright position, even when the container 10 is in a collapsed position (see FIG. 6).
Container 10 further comprises a front wall or side structure 22d which comprises a frame 28 in combination with the bottom portion 14 of the base 13. The frame 28 and bottom portion 14 of the base 13 define an open side or front 23 which allows side access to product 26 (See FIG. 7) supported or suspended in dunnage 24 inside the interior of the container 10. Front wall or side structure 22d, like side structures 22a-22c has a movable or hinged top or upper portion and a stationary bottom or lower portion as will be described below, in the illustrated embodiment. For purposes of the present document, any of the structures 22a-d may be considered a collapsible side structure.
In the container 10 illustrated, the base 13, walls 18a-18c and frame 28 make up the body 12 of the container 10. Therefore, the embodiment of the container illustrated in FIG. 1 has a box-like shape with one open side. This type of container is known in the industry as a side loading, front loading or horizontal dispensing container.
As best illustrated in FIG. 1, frame 28 includes a pair of stationary lower frame members 30 and a pivotal upper frame 32 comprising a pair of upper side frame members 33 and a top frame member 34 extending between the upper side frame members 33. The stationary lower frame members 30 are fixed to the wall portions 16a, 16c of the base 13 in any desired manner. See FIGS. 1 and 2. The pivotal upper frame 32 is hingedly coupled to the wall portions 16a, 16c of the base 13 to be selectively pivoted between a collapsed position and erected position about a horizontal pivot axis 35 which is defined by pins 37. See FIGS. 1 and 2.
As best illustrated in FIGS. 1B and 2, generally U-shaped locking brackets 38 are secured to the collapsible side wall structures 18a and 18c in strategic locations to help lock pivotal upper frame 32 in its erected position as shown in FIG. 1. Each locking bracket 38 has a semicircular notch 39 within which end portions 41 of handle 40 rest when upper frame 32 is in an erected, locked position. Each of the frame members 33 of pivotal upper frame 32 has an oval opening or slot 43 inside which rides one of the end portions 41 of handle 40. The length of the slot 43 is such that it allows a user to lift the handle 40 enough so that the end portions 41 of the handle 40 disengage from the notches 39 of the locking brackets 38 and the pivotal upper frame 32 may be collapsed.
As shown in FIG. 1, the handle 40 of the pivotal upper frame 32 may be lifted from a lower locked position shown in FIG. 1 to a raised unlocked position in order to collapse the pivotal upper frame 32 and therefore begin collapsing the container 10. When the pivotal upper frame 32 is locked in its locked position, the end portions 41 of handle 40 reside in the notches 39 of the locking brackets 38. When the handle 40 is raised by an operator, the end portions 41 of handle 40 disengage from the locking brackets 38, thereby allowing the weight of the dunnage 24 to help pivot the pivotal upper frame 32 downwardly and inwardly towards its collapsed position shown in FIG. 2.
As shown in FIG. 1B, a plurality of eye bolts 42 are secured to the top frame member 34 of the pivotal upper frame 32. The purpose of the eye bolts 42 is to receive and retain and thereby secure a dunnage support 44 in the form of a rod to the pivotal upper frame 32 and more particularly to the top frame member 34 of the pivotal upper frame 32. Although the dunnage support 44 is illustrated as a straight rod, it may assume any other form or configurations and may be secured to any portion of the pivotal upper frame 32 in any desired manner.
Similarly, as shown in FIG. 1A, a plurality of eye bolts 42 are secured to the collapsible rear side or wall structure 18b of the container 10. The purpose of these eye bolts 42 is to receive and retain and thereby secure another dunnage support 44 in the form of a rod to the collapsible rear side or wall structure 18b. Although the dunnage support 44 is illustrated as a straight rod, it may assume any other form or configuration and may be secured to the collapsible rear side or wall structure 18b in any desired manner.
Also shown in FIG. 1A is a locking mechanism 46 for maintaining the collapsible portion of the rear wall structure in an erected position. The locking mechanism 46 includes a pull tab 48 attached to an elongated flexible member 50 extending between and joined to two locking pins 52 inside housings 54. The locking pins 52 are sized and adapted to be received inside holes 53 in the collapsible side or wall structures 18a and 18c. See FIG. 1A. The housings 54 are located in a generally U-shaped channel 56 attached to the collapsible rear or side wall structure 18b of the container 10.
As shown in FIGS. 1, 1A, 1B, 2 and 7, dunnage 24 comprises a plurality of collapsible, flexible generally U-shaped pouches 58. Each pouch 58 comprises a pair of flexible sidewalls or wall portions 60 connected by an arcuate bottom portion 62. As shown in FIG. 1A, the upper rear corner of each sidewall 60 of each pouch 58 has a grommet 64 surrounding an opening 66 which is sized and adapted to receive dunnage support 44. Similarly as shown in FIG. 1B, the upper front corner of each sidewall 60 of each pouch 58 has a grommet 64 surrounding an opening 66 which is sized and adapted to receive dunnage support 44. Thus, each of the sidewalls 60 of each pouch 58 is suspended from its upper corners in a manner that enables the pouch 58 to slide or move horizontally in the container 10 to help either insert or remove products 26 therein. See FIG. 7.
As shown in FIG. 7, dunnage 24 and more particularly, one of the sidewalls 60 of each of the pouches 58 has a stabilizer 70 secured thereto. Although FIG. 7 shows dunnage 24 comprising one piece of material formed into a plurality of pouches 58, each pouch 58 may be formed from its own piece of material. The stabilizers 70 are configured and positioned relative to the sidewalls 60 of the pouches 58 such that products 26 may be suspended by the stabilizers 70 in a position which is safe for transport and easy for an operator to load or unload products 26 when the container 10 and associated dunnage 24 are erected. Although one configuration of stabilizer 70 is illustrated in FIG. 7 stabilizing one configuration of product 26, any desired configuration of stabilizers may be used to support and protect any configuration of product 26 during shipment. Likewise, any number of stabilizers 70 may be secured at any desired locations to the dunnage 24, regardless of whether the dunnage comprises pouches or assumes any other form such as flexible partitions. Preferably the stabilizers are placed in locations to best protect the products in the dunnage for transport or shipping.
Referring to FIG. 7, a portion or appendage 72 of the product 26 is specifically received in and/or secured in a product receptacle 74 in stabilizer 70. These product receptacles 74 are particularly machined or sized and located to receive, mate, and/or hold a portion or appendage 72 of the product 26. The product receptacles 74 furthermore are located and sized so that the maximum number of products 26 may fit snugly inside the container 10 without moving or shifting during shipment, thereby maximizing product density. Although one configuration of product 26 is illustrated and described, the present invention may be used to store and ship other configurations of products not shown or described. Similarly, depending on the configuration of the product, the product receptacles formed in the stabilizers 70 may be shaped or configured differently than those shown and described.
FIG. 7A illustrates another variation of collapsible dunnage 24a which may be used in collapsible container 10 or any other collapsible container. Collapsible dunnage 24a comprises one piece of material formed into a plurality of pouches 58a, each having two side walls or wall portions 60a. Each side wall 60a is secured to dunnage supports 44 in any desirable manner like the one described above and illustrated in FIG. 9, for example. However, any other type of dunnage such as individual pouches each made of its own piece of material, may be used in accordance with the present invention and secured to any type of dunnage supports in any desirable manner. The dunnage 24a shown in FIG. 7A has multiple stabilizers 70a parent welded (welded without any additional material using only heat) to each other on opposite sides of one of the flexible sidewalls 60a of one of the pouches 58a. The other sidewall 60a, which is the outermost sidewall of the outermost pouch 58a, has only one stabilizer 70a secured thereto. Each stabilizer 70a has a product receptacle 74a formed therein for receiving and retaining a portion of a product 26a. Although one configuration of stabilizer 70a is shown attached at selected locations to pouches 58a to protect products 26a, any suitable configuration of stabilizers 70a may be secured to any type of dunnage to protect any type or configuration of products. For example, the stabilizers may lack any product receptacles.
FIG. 7B illustrates another variation of collapsible dunnage 24b which may be used in collapsible container 10 or any other collapsible container. In this type of dunnage 24b, one piece of material is formed into a plurality of pouches 58b, each having opposed sidewalls or sidewall portions 60b secured to dunnage supports 44 in any desirable manner like the one described above and illustrated herein. The dunnage 24b shown in FIG. 7B has multiple stabilizers 70b secured to the flexible sidewalls 60b of pouches 58b at locations best suited to protect the individual products 26b being shipped. Although one configuration of stabilizer 70b is shown attached at selected locations to pouches 58b to protect products 26b, any suitable configuration of stabilizers 70b may be secured to any type of dunnage to protect any type or configuration of products.
FIG. 7C illustrates another variation of collapsible dunnage 24c which may be used in collapsible container 10 or any other collapsible container. In this type of dunnage 24c, one piece of material may be formed into pouches 58c, each one of which is secured to dunnage supports 44 in any desirable manner as described above and illustrated in FIG. 9. The collapsible dunnage 24c shown in FIG. 7C has multiple stabilizers 70c parent welded (welded without any additional material using only heat) to each other on opposite sides of one of the flexible sidewalls 60c of pouch 58c. The other sidewall 60c, which is the outermost sidewall of the outermost pouch 58c, has multiple stabilizers 70c secured thereto. Although one configuration of stabilizer 70c is shown attached at selected locations to pouches 58b to protect products 26c, any suitable configuration of stabilizers 70c may be secured to any type of collapsible dunnage to protect any type or configuration of products.
Although not illustrated, other forms of collapsible dunnage having stabilizers attached thereto such as the collapsible dunnage shown in FIGS. 8-11 may be used in a collapsible container made in accordance with the present invention.
FIGS. 3-6 illustrate the method of collapsing the container 10 and its associated dunnage 24. FIG. 3 illustrates an erected container 10 with the pivotal upper frame 32 collapsed about horizontal pivot axis 35. The collapsible walls or structures 18a-18c remain erected. The next step after collapsing the pivotal upper frame 32 is to collapse the rear wall 18b of the container 10 in the direction of arrow 52. Rear wall 18b is coupled to another end of the dunnage structure 24. Therefore, when rear wall 18b is collapsed, the dunnage structure 24 is located thereunder. FIG. 4 illustrates the partially collapsed container 10.
FIG. 5 illustrates the side walls or structures 18a, 18c being collapsed inwardly as shown by arrows 54 to provide a completely collapsed structure, as shown in FIG. 6. The hinge lines or hinge structures of the first-collapsing rear wall 18b are generally located below the hinge lines or structures of the latter collapsing side walls 18a, 18c, so that the side walls 18a, 18c overlie rear wall 18b and the collapsed pivotal upper frame 32. When the container 10 is collapsed, along with the collapsible dunnage 24, as shown in FIG. 6, the empty container may be returned in a generally 2:1 volume ratio with respect to an erected, full container. In that way, shipping and storage costs are reduced. As may be appreciated, the figures only illustrate one embodiment of a container in accordance with the aspects of the invention. Other different types of containers might be made to include the inventive features of the present invention.
FIGS. 8 and 9 illustrate another aspect of the present invention. The collapsible reusable and returnable container 10d, as shown in FIGS. 8 and 9, is identical to the container 10 described above, excluding the collapsible dunnage. In this embodiment, the collapsible dunnage 24d inside the container 10d is different than the collapsible dunnage 24 shown in FIGS. 1-7, dunnage 24a shown in FIG. 7A, dunnage 24b shown in FIG. 7B and dunnage 24c shown in FIG. 7C. Instead of pouches, the dunnage 24d comprises a plurality of flexible, collapsible members or webs 76. These members or webs 76 are generally vertically oriented when the container 10d is erected as shown in FIGS. 8 and 9. As shown in FIG. 9, the upper corners of each member or web 76 each has a grommet 78 surrounding an opening 80 which is sized and adapted to receive dunnage support 44. Thus, each member or web 76 is suspended from its upper corners in a manner that enables the member or web 76 to slide or move horizontally in the container 10d relative to dunnage supports 44 to help either insert or remove products 26 therein. See FIG. 9.
As shown in FIGS. 8 and 9, the dunnage 24d and more particularly, each of the webs or members 76 has multiple pairs of opposed stabilizers 70d secured thereto and secured to each other, i.e. parent welded together. The stabilizers 70d are configured and positioned relative to the webs or members 76 such that products 26 may be supported, at least in part, by the stabilizers 70d in a position which is not only safe for transport but easy for an operator to load or unload when the container 10d and associated dunnage 24d are erected. One or more stabilizers 70d may have a recess 86 formed in an upper surface 88 of the stabilizer 70d adapted to receive a portion of a product or part 26d. See FIG. 9. Although one configuration of stabilizer 70d is illustrated in FIGS. 8 and 9 stabilizing one configuration of product 26d, the stabilizers may be any desired configuration to support or protect different configurations or types of product during shipment or storage. Likewise, any number of stabilizers 70d may be secured at any desired locations to the dunnage 24d, regardless of whether the dunnage comprises pouches or assumes any other form such as flexible partitions or webs 76. Preferably the stabilizers 70d are secured in locations to best protect the products 26d in the dunnage 24d for transport or shipping.
As illustrated in FIGS. 8 and 9, a portion or appendage of the product 26d may be specifically received in and/or secured in a product receptacle or recess 86 in one or more stabilizers 70d. These product receptacles or recesses 86 may be particularly machined or sized and located to receive, mate, and/or hold the portion or appendages of one of the products 26d. The product receptacles 86 furthermore are located and sized so that a maximum number of products 26d may fit safely inside the container 10d without moving or shifting during shipment. Although one configuration of product 26d is illustrated and described, the present invention may be used to store and ship other configurations of products not shown or described. Similarly, depending on the configuration of the product, the product receptacles or recesses formed in the stabilizers 70d may be shaped or configured differently than those shown and described.
FIGS. 10 and 11 illustrate a collapsible reusable and returnable container 10e according to another aspect of the present invention. The reusable and returnable container 10e, as shown, is nearly identical to the container 10 described above. However, tracks 82 are secured to opposed side wall 18b and pivotal upper frame 32 of the body 12 of the container 10e in any desired manner. Additionally, the dunnage 24e is different from that described above. Instead of pouches, the dunnage 24e comprises a plurality of flexible, collapsible members or webs 89. These members or webs 89 are generally vertically oriented when the container 10e is erected as shown in FIGS. 10 and 11.
As best illustrated in FIG. 11, each track 82 has an upper wall 90, a lower wall 92 joined to upper wall 90 by a side wall 94 and lips 96 extending downwardly from the upper wall 90 and upwardly from the lower wall 92, thereby defining an interior 98 of the track 82. Although one type of track is illustrated, the tracks may be grooves formed in the side structures or frame or any other configuration of retainer or track.
Dunnage 24e in the form of a plurality of collapsible members or webs 89 are suspended by and supported by a plurality of support member assemblies 100. Although the dunnage 24e shown comprises collapsible members or webs 89, the dunnage may assume other shapes or configurations. A generally rectangular piece of fabric 89 shown in FIG. 11, is supported by one support member assembly 100. The fabric is sewn or otherwise secured together along a seam 102 to make a pocket 104 in which is located a flexible support 106 of the support member assembly 100. See FIG. 11.
As shown in FIG. 11, a collapsible support member assembly 100 includes a pair of end members 108 (only one shown) and a flexible middle support 106 extending therebetween. The end members 108 may be made of injection molded plastic, such as nylon, or any other suitable material. The flexible support 106 is preferably a cable but may be made of nylon or other suitable material. As shown in FIG. 11, the ends of the flexible support 106 may be tied or otherwise secured to the end members 108. As shown in FIG. 11, the fabric of pocket 104 of web 89 may be secured to the end members 108 with fasteners 109.
Although one configuration of collapsible support member assembly 100 is illustrated, the present invention may be used with any type or configuration of support member assembly for supporting dunnage so the dunnage may slide or move inside the container.
As shown in FIGS. 10 and 11, the dunnage 24e and more particularly, each of the webs or members 89 has multiple pairs of opposed stabilizers 70e secured thereto and secured to each other, i.e. parent welded together. The stabilizers 70e are configured and positioned relative to the webs or members 89 such that products 26e may be supported, at least in part, by the stabilizers 70e in a position which is not only safe for transport but easy for an operator to load or unload when the container 10e and associated dunnage 24e are erected. One or more stabilizers 70e may have one or more holes 110 therethrough, one or more recesses 112 formed in an upper surface 116 of the stabilizer 70e adapted to receive a portion of a product or part 26e or one or more projections 114 formed in an upper surface 116 of the stabilizer 70e adapted to receive hold or retain a portion of a product or part 26e. See FIG. 11. Although one configuration of stabilizer 70e is illustrated in FIGS. 10 and 11 stabilizing one configuration of product 26e, the stabilizers may be any desired configuration or size to support or protect different configurations or types of products.
As shown in FIG. 11, any track of any of the embodiments described herein may have a cutout or opening 116. A pair of threaded holes 118 may be formed in the upper wall 90 of track 82 which are sized and adapted to receive fasteners 120. Although fasteners 120 are illustrated as being screws, they may be any other desirable fastener. A cap 122 is removably secured to the track 82 to cover the opening or cutout 116 formed in the upper wall 90 of track 82. As shown in FIG. 11, cap 122 has a generally inverted L-shaped cross-sectional configuration including a top portion 124 and side portion 126. Holes 128 are formed through the top portion 124 of cap 122 and sized to receive fasteners 120. The fasteners 120 are adapted to pass through the holes 128 in the cap 122 and into the holes 118 in the upper wall 90 of track 82. If any portion of a support member assembly 100 is damaged, it may be removed and repaired quickly and easily through openings 116 in tracks 82.
While various embodiments of the present invention have been illustrated and described in considerable detail, it is not the intention of the applicant to restrict or in any way limit the scope of the claims to such detail. For example, the dunnage of the present invention may be used in a non-collapsible container. Additional advantages and modifications will readily appear to those skilled in the art. The invention in its broader aspect is, therefore, not limited to the specific details, representative system, apparatus, and method, and illustrative example shown and described. Accordingly, departures may be made from such details without departing from the spirit or scope of the applicant's general inventive concept.
Patent Application
20080017638
