Information
-
Patent Grant
-
6631822
-
Patent Number
6,631,822
-
Date Filed
Saturday, October 28, 200024 years ago
-
Date Issued
Tuesday, October 14, 200321 years ago
-
Inventors
-
Original Assignees
-
Examiners
-
CPC
-
US Classifications
Field of Search
-
International Classifications
-
Abstract
A collapsible container includes a floor member having first and second pairs of opposed edges, a first pair of opposing side walls each pivotably attached to the first pair of opposed edges of the base, where each of the first pair of opposing side walls have a pair of lateral edges and a latch member extending therefrom. Also included is a second pair of opposed side walls each pivotably attached to a corresponding one of the second pair of opposed edges of the base, each of the second pair of opposed side walls have a pair of opposed lateral flanges inwardly depending therefrom and formed integrally therewith. Each lateral flange has an inner surface with a latch receiving portion formed therein, the latch receiving portion includes at least one clip member which has a spring portion flexible between a first position and a second position for accepting the latch member. Thus, when the container is oriented in an assembled position, the clip receives a corresponding latch member, and wherein to move the container to an inwardly collapsed position from the assembled position, a force is exerted against an exterior surface of each of the first pair of opposed sidewalls, the force sufficient for the latch member to overcome the spring portion and be released from the clip member.
Description
TECHNICAL FIELD
This invention relates to a collapsible container adaptable for the storing and transporting produce items and other goods.
BACKGROUND ART
Plastic containers and crates are commonly used today to transport and store a variety of items. When in use, such containers are typically rectangular in shape and have a base surrounded by four upstanding side panels. When not in use, many of the plastic containers employed by the produce and food industries have panels which are capable of folding both outwardly and inwardly. The folding feature, and particularly the inwardly folding feature, allows the containers to be folded or otherwise reduced in size for conserving storage space. In practicality, while the outwardly collapsing feature allows the container to generally have a lower profile than when in the inwardly folded position, the outwardly folding feature is underutilized, as the container with outwardly folded panels is often bulky, awkward to carry, and may not nest or stack easily with like folded containers.
Furthermore, folding containers are often formed of various components, including the side panels and the base, which are molded separately. In particular, the walls typically include strengthening ribs on their outer surfaces in order to provide strength and torsional resistance to the parts. However, during the molding process, the components having ribs may be subject to slight warpage and deformation during cooling, when plastic tends to shrink. The warping may particularly occur at the edges of the parts. Under these circumstances, the parts may have lower dimensional accuracy individually as well as with mating components, and may result in scrapped parts, and elevated manufacturing and part costs.
When assembled and in use, adjoining walls of some present containers are typically locked together by a latch mechanism, requiring additional user handling and manipulation of the latch in order to unlock and unfold the walls prior to storage. One such container and latch mechanism is disclosed in U.S. Pat. No. 6,015,086, which is assigned to the assignee of the present invention. While such locking latch mechanisms are sturdy and effective, the user in the field may not be able to apply the extra handling and manual disengagement necessary to release the latch and collapse the locked container. In fact, on some containers, it is sometimes necessary to use both hands to release the locking features.
In present containers, the side panels and base have adjoining hinge features, whereby the side panels are typically snapped into the base via an interference fit. This often requires strength and effort, and once snapped together the panels may be difficult to separate from the base, whereby separating the components may result in deformation of the parts.
Consequently, an improved container is desired which has walls which are relatively easy to latch and unlatch without excessive user handling and manipulation. The container, when in the assembled orientation, should also have the requisite strength properties capable of supporting the load and forced placed on these walls. The container and its components should also be resistant to warpage during the molding and cooling process. The container should provide for a relatively low profile when the walls are in the inwardly folded position. The components (particularly walls from base) should also be easily assembled and disassembled without deformation. The container should also allow for efficient wall movement and usage.
DISCLOSURE OF INVENTION
It is an object according to the present invention to provide a container which is relatively easy to latch and unlatch without excessive user handling of the latch mechanism.
It is another object according to the present invention to provide a container which is capable of supporting the forces and load placed on the container walls, particularly during handling and during the unlatching and latching of the container.
It is still another object according to the present invention to provide a container having components which are resistant to warpage during the cooling and/or curing phases of the molding process.
Still other objects according to the present invention are to provide a container that is relatively easy to collapse, which has a very low profile when in the collapsed orientation, and which is easily assembled and disassembled.
In keeping with the above objects and goals according to the present invention, provided is a collapsible container which includes a floor member having first and second pairs of opposed edges, and a first pair of opposing side walls each pivotably attached to the first pair of opposed edges of the base. Each of the first pair of opposing side walls has a pair of lateral edges and a latch member extending therefrom. Also included is a second pair of opposed side walls each pivotably attached to a corresponding one of the second pair of opposed edges of the base, each of the second pair of opposed side walls having a pair of opposed lateral flanges inwardly depending therefrom and formed integrally therewith, each lateral flange having an inner surface with a latch receiving portion formed therein. The latch receiving portion includes at least one clip member having a spring portion flexible between a first position and a second position for accepting the latch member, such that when the container is oriented in an assembled position, the at least one clip member receives a corresponding latch member, and wherein to move the container to an inwardly collapsed position from the assembled position, a force is exerted against an exterior surface of each of the first pair of opposed sidewalls. The force sufficient for the latch member to overcome the spring portion and be released from the at least one clip member. Preferably, when the container is oriented in the inwardly collapsed position, the first pair of opposing side walls are pivotably folded inward adjacent the base, and the second pair of opposing sidewalls are pivotably folded inward such that the first pair of opposed side walls is layered between the second pair of opposed side walls and the base.
In further keeping with the teachings and goals of the present invention, also provided is a collapsible container orientable between an assembled position and an inwardly collapsed position and includes a base member having a floor with a pair of opposed upstanding flanges integrally formed therewith, the upstanding flanges having an upper surface. Also included is a pair of first opposed walls which are pivotably mounted to the base, where each of the first opposed walls have side edges with at least one latch portion extending laterally therefrom, the latch portion including at least one latch member. Further included is a pair of second opposed side walls pivotably attached to a corresponding upstanding flange proximate the upper surface thereof, each of the pair of second opposed side walls having a pair of opposed, inwardly directed flanges having an inner surface with a latch receiving area formed therein, the latch receiving area defined by at least one latch acceptance member having a flexible portion for receiving a corresponding latch member therein in an interference fit when the container is oriented in the assembled position, and wherein to move the container to the collapsed position, a force sufficient to overcome the interference fit is applied to an exterior surface of each of the first opposed side walls. As disclosed, the base includes a periphery having a plurality of lower hinge members, each lower hinge member having a hook portion with a downwardly directed edge, and each of the pairs of first and second opposed sidewalls having a plurality of corresponding upper hinge members extending from a lower edge thereof. Each upper hinge member has a cam-shaped member for engaging the hook portion, such that as the container is moved from the inwardly collapsed position to the assembled position, the edge of the hook member limits the vertical movement of the cam-shaped member, thereby preventing each of the pairs of first and second opposed sidewalls from separating from the base when in the assembled position.
In further keeping with the goals and objects according to the present invention, a foldable container is provided which is orientable in an assembled position and an inwardly folded position. The container includes a bottom panel having a pair of integrally formed opposed upstanding flanged edges and a pair of opposed edges, and a pair of opposed end walls pivotably mounted to the pair of opposed edges, where each of the opposed end walls have a latching member extending from a corresponding lateral edge of the end wall and co-planar with the end wall. Also included is a pair of opposed side walls, each pivotably mounted to a corresponding upstanding flanged edge and having a U-shaped cross-section including a longer main wall portion and a pair of relatively shorter flanged portions attached to the main wall portion and inwardly directed therefrom, each flanged portion having an inner surface with a latch receiving portion formed therein for receiving the pair of latching members in an interference fit, wherein when the container is in the assembled position, the latching member is substantially co-planar with the flange inner surface. In a preferred embodiment, the pair of opposed end walls includes an anti-rotation member which engages the inner surface of the flanged portion when the container is in the assembled position in order to impede rotational movement of the pair of opposed side walls.
In further keeping with the goals and objects, a collapsible container includes a base which has first and second pairs of opposing edges, where one of the first and second pairs of opposing surfaces is defined by an upstanding base wall, and each of the first and second pairs of opposing edges includes a plurality of lower hinge members, each lower hinge members defined by an clearance opening and an adjacent hook portion having a downwardly directed edge. Also included is a first and second pair of opposed side walls, each having at least one upper hinge member having a bar with a projection extending therefrom, each of the second pair of opposed side walls mounted to a corresponding upstanding base wall and having a pair of opposed lateral flanges inwardly depending therefrom and integral therewith. Each lateral flange has a latch receiving portion formed therein, and each of the first pair of opposed side walls each has a pair of opposing lateral edges, each having a latch member extending therefrom. When the container is oriented in an assembled position, each latch receiving portion receives a latch member therein, and the projection of the upper hinge member engages the downward edge of the hook portion, thereby impeding the movement of the sidewalls outward beyond the assembled position.
In accordance with the objective and goals according to the present invention, provided is a collapsible container having a base member, and first and second pairs of opposed side walls, each pivotably attached to a periphery of the base member and each having an upper surface. At least one of the first and second pairs of opposed side walls includes an upper wall portion having an interior surface and an exterior surface, the upper wall portion including at least one first row portion and at least one second row portion. Each of the first and second row members extend at least partially across the length of the upper wall portion and oriented substantially parallel to the upper surface of the sidewall, each of the first and second row portions further having a first surface and second surface co-planar with the interior and exterior surface, respectively, of the upper wall portion. The first row portion has a peaked first surface and recessed second surface, and the second row portion has recessed first surface and a peaked second surface.
Further provided in accordance with the goals and objects herein is a wall structure for a collapsible container, where the wall structure has an inner surface and an opposed outer surface, and includes an upper edge and a plurality of row portions extending at least partially across the length of the wall structure proximate the upper edge and oriented substantially parallel thereto. A first of the plurality of row portions has an interior surface defining the inner surface of the wall structure, and an recessed outer surface defining the outer surface of the wall structure. A second of the plurality of rows is disposed parallel to the first row portion and has an exterior surface and a recessed interior surface.
Also disclosed herein is a collapsible container which is orientable between an assembled position and an inwardly folded position including a floor member, a first pair of opposed side walls having a first latch portion including at least one latch member, and a second pair of opposed side walls having a second latch portion including a flexible clip portion having a latch member acceptance area and a flex portion. When the container is moved from the inwardly folded position to the assembled position, the second pair of opposed side walls is rotated upward until it is oriented substantially perpendicular to the base, and the first pair of opposed side walls is rotated upwardly such that the at least one latch member is inserted into the opening of the flex portion, thereby expanding it until is it received within the latch member receiving area and the flex portion returns to its rest position, impeding the release of the at least one latch member. The at least one latch member is a dowel member having a bulbous head for being received by the clip portion in an interference fit. Also, the flexible clip portion is a C-shaped clip member and the flex portion is defined by an end of the C-shaped clip.
In further keeping with the goals and objects according to the present invention, provided is collapsible container having inwardly folding walls including a base member having a first hinge portion disposed proximate a periphery of the base member, the first hinge portion having an arcuate member with an first edge extending downwardly therefrom. Also provided is a first and second pair of opposed sidewalls having a second hinge portion pivotably attached to the first hinge portion of the base, wherein the second hinge portion comprises a semi-circular member having a edge extending therefrom such that to assemble the side walls and the base, each second hinge portion is received by the first hinge portion, and wherein when the wall is moved to its assembled position, the tooth of the second hinge portion is rotated to contact the first inner tooth of the first hinge portion, such that an interference fit exists between the teeth, preventing the walls from separating from the base member.
Further provided is a collapsible container adapted to move between a collapsed orientation position and an assembled orientation, including a base having first and second pairs of opposed edges, and a first pair of opposed side walls each pivotably attached to a corresponding one of the first pairs of opposed edges of the base. Each of the first pair of opposed side walls have a pair of opposed lateral edges, each lateral edge having a latch member disposed thereon. Also provided is a second pair of opposed side walls each pivotably attached to a corresponding one of the second pair of opposed edges of the base, each of the second pair of opposed side walls having a pair of opposed flanges inwardly depending therefrom, each flange having a surface with at least one latch receiving member formed therein having a flexible portion. When the container is moved from the collapsed orientation to the assembled orientation, each wall rotates upward such that the at least one latch receiving member receives by interference a corresponding latch member thereby displacing the flexible portion from a rest position to the second position, and wherein when the container is in the assembled position, the flexible portion returns to the rest position for securing the latch member. Preferably, when the container is oriented in the collapsed position, the first and second pairs of opposed side walls are folded inward so that one of the first and second pairs of opposed side walls is layered between the other of the first and second pairs of opposed side walls and the base. Also, the first and second pairs of opposed edges include a plurality of lower hinge members having an hinge opening at each end for pivotably receiving therein a pivot member disposed on a corresponding side wall.
Also provided according to the goals and objects herein is a collapsible container orientable between an assembled position and a collapsed position and including a base having a pair of opposed end edges and a pair of opposed side edges extending between the pair of opposed end edges, and a pair of opposed end walls pivotably attached to a corresponding one of the opposed end edges of the base. Each opposed end wall has a lateral edge and a latch member disposed thereon. Also included is a pair of opposed side walls each having a pair of flanges inwardly depending therefrom. The flanges have an inwardly directed surface with a flexible clip portion having an expandable opening portion such that as the container is rotated from the collapsed position to the assembled position, and the latch member is secured by the clip portion in the assembled position.
Further provided herein is a wall structure for a container, preferably collapsible, includes an upper wall portion having an inner surface and an outer surface, the upper wall portion including a plurality of alternating row members extending at least partially across the length of the wall structure proximate an upper surface of the wall structure and oriented substantially parallel thereto. Each of the plurality of row members has a first surface and second surface co-planar with the inner and outer surface, respectively, of the upper wall portion, wherein at least one of the plurality of row members has a peaked first surface and recessed second surface. An other of the plurality of row members has a recessed first surface and a peaked second surface, and members extending between the adjacent first and second peak. Preferably, adjacent ones of said peaked first surfaces define a recessed first surface therebetween, and adjacent ones of said peaked second surfaces define a recessed second surface therebetween.
The above objects and other objects, features, and advantages of the present invention are readily apparent from the following detailed description of the best mode for carrying out the invention when taken in connection with the accompanying drawings.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1
of the drawings illustrates a perspective view of a container according to the present invention;
FIG. 2
illustrates a top plan view of the container of
FIG. 1
;
FIG. 3
illustrates a side elevational view of the container of
FIG. 1
, the opposite side being a mirror image thereof;
FIG. 4
illustrates an end elevational view of the container of
FIG. 1
, the opposite side being a mirror image thereof;
FIG. 5
is a bottom plan view of the container of
FIG. 1
;
FIG. 6
is a partial elevational view of the container, showing the side wall, similar to that shown in
FIG. 3
;
FIG. 7
is a cross-sectional view taken along the line
7
—
7
of
FIG. 6
;
FIG. 8
is a cross-sectional view taken along the line
8
—
8
of
FIG. 6
;
FIG. 9
is a cross-sectional view taken along the line
9
—
9
of
FIG. 6
;
FIG. 10
is a cross-sectional view taken along the line
10
—
10
of
FIG. 6
;
FIG. 11
is an exploded partial perspective view of the container of
FIG. 1
;
FIG. 12
is an interior corner perspective view of the container of
FIG. 1
;
FIG. 13
is a partial elevational view of the container showing the end wall, similar to that shown in
FIG. 4
;
FIG. 14
is a cross-sectional view taken along line
14
—
14
of
FIG. 6
;
FIG. 14
a
is a cross-sectional view similar to that of
FIG. 14
, but with the sidewall in the inwardly collapsed position;
FIG. 15
is a cross-sectional view taken along the line
15
—
15
of
FIG. 13
;
FIG. 15
a
is a cross-sectional view similar to that of
FIG. 15
, but with the end wall in the inwardly collapsed position;
FIG. 16
is a quarter cross-sectional view taken along the line
16
—
16
of
FIG. 6
;
FIG. 17
is a quarter cross-sectional view taken along the line
17
—
17
of
FIG. 6
;
FIG. 18
is a quarter cross-sectional view taken along the line
18
—
18
of
FIG. 13
;
FIG. 18
a
is a magnified view of the latching system of
FIG. 18
;
FIG. 18
b
is a magnified view of the latching system similar to
FIG. 18
a
, but with the first and second latching portions slightly separated;
FIG. 19
is a partial perspective view of the container of
FIG. 1
, with the end wall collapsed inwardly, and the side wall upstanding; and
FIG. 20
is a partial perspective view of the container of
FIG. 1
, with both the end wall and the side wall in the inwardly collapsed position;
FIG. 21
is a partial cross-sectional view taken along line
21
—
21
of
FIG. 19
, showing the upper end wall resting in the recess of the floor member;
FIG. 22
a
is a partial perspective view of the interior surface of the side wall flange, showing the latch acceptance area;
FIG. 22
b
is a partial perspective view of the latch assembly in the assembled position; and
FIG. 23
illustrates a bottom perspective view of the container.
BEST MODE FOR CARRYING OUT THE INVENTION
With reference to
FIGS. 1 and 23
of the drawings, illustrated therein is a collapsible container
10
according to the present invention. Container
10
is also appropriately referred to as a collapsible crate or box. Container
10
is formed of a thermoplastic resin, such as polypropylene, via an injection molding process or other plastic molding process suitable to this application. While container
10
is suitable for many uses, it is particularly well-suited for the storage and transport of perishable goods and produce such as fruits and vegetables, and more particularly bananas, where the circulation of air and other gases within container
10
assists in developing and maintaining the produce freshness and ripening during shipment to the market. This circulation is fostered through venting apertures
11
provided throughout container
10
.
As shown in
FIGS. 1-5
, container
10
includes a base member
12
having a bottom wall
14
which serves as the lower support for container
10
. As best shown in
FIGS. 2 and 5
, bottom wall
14
is generally rectangular in shape and has four perimeter edges—namely, a first pair of opposed edges
16
and
18
(side edges), and a second pair of opposed edges
20
and
22
(end edges). In this embodiment, base
12
further includes integrally molded upstanding flanges
24
and
26
(or base side walls) which are oriented substantially perpendicular to bottom wall
14
, each defining an upper side surface
25
and
27
, respectively. The wall thickness of each of the walls and components illustrated and disclosed herein may vary depending on the intended usage and other characteristics desired from container
10
. Moreover, while container
10
is illustrated as having a rectangular shape, it is fully contemplated that the teachings according to the present invention are equally applicable to a square container, or various other container shapes. Moreover, bottom wall
14
has a centrally disposed raised portion
17
for accommodating the natural shape of a banana bunch when in the hands down position.
As shown in
FIGS. 1-4
, container
10
also includes a first pair of opposed side walls
28
,
30
, and a second pair of opposed side walls
32
,
34
(referred to as a pair of opposed end walls
32
,
34
.) Walls
28
,
30
,
32
,
34
are each attached to base
12
by way of a hinging system
80
(disclosed herein and best shown in
FIGS. 14
,
14
a
,
15
,
15
a
), located at an upper portion of upstanding flanges
24
,
26
. Thus, side walls (
28
,
30
) fold or pivot relative to base
12
proximate to upper surfaces
25
,
27
, at a distance remote from bottom panel
14
. The height of upstanding base wall flanges
24
,
26
defines the aforementioned distance from which side walls
28
,
30
are remote from bottom panel
14
. Such base and wall configuration, in addition to hinging system
80
, allows walls
28
,
30
,
32
,
34
to have two orientations: the assembled container orientation of container
10
as illustrated in
FIG. 1
, and an inwardly collapsed orientation as illustrated in FIG.
20
.
As best shown in
FIGS. 1
,
2
and
19
, each side wall
28
,
30
has a U-shaped cross section formed by a main side wall portion
40
, and two shorter flange portions
42
and
44
integrally attached to main side wall portion
40
and located on either side of main side wall portion
40
. Flange portions
42
,
44
are each oriented perpendicular to main side wall portion
40
and, in the assembled orientation of
FIG. 1
, are directed inward toward the opposite side wall (
28
or
30
), and disposed adjacent end walls
32
,
34
. As shown in
FIGS. 1 and 4
, each end wall (
32
,
34
) includes a hand opening
41
, which along with the wall portion located thereabove is ideally suited to be used as a handle in order to carry container
10
when assembled and in use.
According to the teachings of the present invention, container
10
includes a latching system (or wall retention system)
50
for retaining side walls (
28
,
30
) together with end walls (
32
,
34
) when container
10
is oriented in the assembled orientation, as in
FIGS. 1
,
7
and
18
. Latching system
50
includes a first latch portion
52
on end walls
32
,
34
(FIG.
11
), and a second latch portion
62
disposed on the side walls
28
,
30
(
FIGS. 18
b
,
21
,
22
). Particularly, each end wall
32
,
34
has a pair of lateral edges
36
,
38
which include the first latch portion
52
(latch member) extending therefrom. First latch portion
52
is shown as co-planar to its adjacent end wall. First latch portion
52
is disposed at the upper portion of lateral edges
36
,
38
proximate upper edge
33
,
35
, and includes at least one, and preferably a pair of male latch portions
54
,
56
such as the dowels or pins having a bulbous portion illustrated herein, the dowels spaced apart from each other. An opening
58
is disposed between dowels
54
,
56
and an outer member
59
is disposed parallel to lateral edges
36
,
38
and extends between dowels
54
,
56
. (See
FIGS. 11
,
18
b
.)
With reference to
FIGS. 7 and 22
b
, second latch portion
62
(latch receiving portion) is formed on the inner surface of inwardly directed flanges
42
,
44
of side walls
28
,
30
. Latch receiving portion
62
corresponds to, and mates with latch member
60
. As best illustrated in
FIGS. 18
,
18
a
,
18
b
, latch receiving portion
62
includes a female latch portion
64
,
66
, such as the pair of spaced apart, flexible, deformable spring C-clips
64
,
66
for receiving a corresponding dowel
54
,
46
, respectively, when the walls are moved into the assembled orientation. Upper C-clip
64
has an fixed upper edge
68
integrally formed with side walls
28
,
30
, and a flexible lower edge
70
defining a dowel receiving area
71
having an opening
72
thereto. Lower C-clip
66
has a fixed lower edge
74
(integrally formed with side walls
28
,
30
) and a flexible upper edge
76
defining an opening
78
thereto for a receiving area
75
.
Thus, in use, when container
10
is moved from the inwardly folded orientation (
FIG. 20
) to the assembled orientation (FIG.
1
), side walls
28
,
30
are rotated upwardly around hinge assembly
80
, which stops at an angle substantially perpendicular to bottom panel
14
due many factors, including the interference of base wall surfaces
25
,
27
(extending between hinge portions
80
) with the adjacent lower surfaces of side walls
28
,
30
, the interference with the legs
93
of wall hinge
80
with base
12
during rotation (FIGS.
11
and
14
), and also the configuration of hinge system
80
. Subsequently, end walls
32
,
34
are rotated upwardly around hinge
80
′ (
FIGS. 15
,
15
a
), wherein the protrusion or bulbous portion
55
,
57
of dowels
54
,
56
are inserted via an interference fit and received in the respective openings
72
,
78
of C-clips
64
,
66
. This interference fit causes lower edge
70
of upper clip
64
to expand and flex downward, thereby allowing dowel
54
be received within dowel receiving or acceptance area
71
, under an interference fit. When dowel
54
is disposed in area
71
, lower clip edge
50
springs back and returns to its original position, thereby impeding the dowel's
54
movement. Lower C-clip
66
operates similarly, except that upon insertion, upper flexible edge
76
flexes upward for allowing dowel
56
to move past. Thus, end walls
32
,
34
are prevented from folding outwardly through not only their hinge configuration
80
(see FIG.
15
), but by their interference with sidewalls
28
,
30
when assembled. Accordingly, when assembled, latch member
52
is generally co-planar with inner surface of flanges
42
,
44
and with latch receiving area
62
.
As further illustrated in
FIGS. 8
,
18
and
22
, inner surfaces
43
,
45
of flange portions
42
,
44
, also include an anti-rotational portion (proximate latch receiving portion
62
) having a member
77
, and a recess
79
adjacent member
77
, the recess corresponding to latch outer member
59
of end walls
32
,
34
. In the assembled orientation, latch outer member
59
is received within recess
79
, and is sandwiched between member
77
and sidewall panel
28
,
30
(
FIG. 22
b
). Latch outer member
59
, through its interference with the anti-rotational portions
77
,
79
, impedes any lateral and rotational movement of sidewalls
28
,
30
when in the assembled position, particularly in the outward direction beyond 90° or any other predetermined angle.
In use, in order to collapse the assembled walls of container
10
, a force (referred to as a kick-down or knock-down force) is applied to the exterior surfaces of end walls
32
,
34
, sufficient to overcome the interference fit of C-clips
54
,
56
, thereby causing dowels
54
,
56
to push out from opening
72
and release from C-clips
54
,
56
. Thus end walls
32
,
34
are easily unlatched from the side walls and free to rotate inwardly (FIG.
20
).
End walls
32
,
34
pivot inwardly around hinges
80
until they are disposed against bottom wall
14
, whereby the upper portion
33
,
35
of end walls
32
,
34
are disposed in the corresponding recesses
19
,
21
in upper surface
14
of bottom wall
14
(FIG.
21
). Moreover, end walls
32
,
34
have a lower inner surface
31
(
FIG. 1
) shaped to mate with and correspond to the raised portion
17
of floor
14
when in the inwardly folded position. Accordingly, through the use of recesses
19
/
21
and
31
, container
10
provides for a lower profile when nested in the inwardly folded orientation, thus resulting in more efficient stacking height when such containers are stacked together. Recesses
19
/
21
and
31
allow for a more aggressive nesting increment not found on prior art containers, while still maintaining strength in the base through use of the central raised member
17
. Subsequently, side walls
28
,
30
are rotated inwardly, pivoting around hinges
80
, and resting on top of end walls
32
,
34
(FIG.
20
). Accordingly, no extra handling is necessary to release the walls, as in the prior art wherein, for example, a user often needed to use both hands to unlock and move a single wall, which was often awkward and inconvenient. Further, as illustrated in
FIGS. 19-20
, when in the inwardly collapsed position, end wall
34
rotates away from the base periphery, giving outboard clearance for the flanged portions
42
,
44
of side wall
28
to engage portion
13
of base
12
when in the inwardly folded position (
FIG. 20.
) Such folding configuration wherein the end wall is folded inwardly first, and the side wall is rotated from an upstanding base flange, also permits the construction of a taller container.
To return container
10
to the assembled position, side walls
28
,
30
are raised upwards, pivoting around hinges
80
, until they stop upon being oriented perpendicular to base
12
through the aforementioned interference between base and wall, assisted by the hinge system
80
, thereby impeding the outward rotation of end walls, and also acting as a stop feature such that the sidewalls are positioned upright do not have to be manually held during the subsequent raising of the end walls. End walls
32
,
34
are then pivotably raised from base
12
until dowels
54
,
56
are received by C-clips
64
,
66
as described above.
As shown in
FIGS. 11
,
14
,
14
a
,
15
,
15
a
hinging mechanism
80
includes adjoining base hinge portions
82
(or lower hinge members) and wall hinge portions
92
(or upper hinge members.) Base hinge portions
82
are spaced around the periphery of base
12
and include members
84
having a backdrafted portion
86
with a barbed edge
87
(resembling a hook member
86
having a downwardly directed tooth edge
87
) and also having an opening
88
disposed therebehind. Each corresponding wall hinge portion
92
includes a plurality of elongate members
94
or bars extending from the lower edge of the respective side wall
28
,
30
,
32
,
34
. Each wall hinge member
94
is substantially cam-shaped in cross-section, as illustrated in
FIGS. 14
,
14
a
. More particularly, member
94
is a semi-circular member having a radially extending projection tooth
96
and a flat surface portion
97
adjacent tooth
96
. In order to attach the walls to the base
12
via hinge portions
82
,
92
, each wall hinge member
94
is press fit into base opening
88
and is disposed under hook portion
86
. Mounting of wall to base is preferably done when the respective wall is in the inwardly folded orientation (or non-upright orientation) such that tooth
96
of member
94
is directed downward and away from any interference with backdrafted portion
86
(
FIG. 15
a
.)
As the wall is raised to the upright assembled position, the movement of tooth
96
is impeded by hook portion
86
due to interference between the parts, such that hook portion
86
hinders the movement of cam member
84
in the vertical direction. Thus, this feature makes separating the walls from the base while in the upright position relatively difficult. However, as noted above, disassembly may be done with little or no deformation when the wall is away from the upright position and at or proximate to the inwardly folded position. FIGS.
15
,
15
a
illustrate the hinge system
80
′ for end walls
32
,
34
, where reference numerals corresponding to those features in FIGS.
14
,
14
a
have a prime (′) designation. With reference to
FIG. 15
b
, it is noted that when tooth
96
is oriented downwardly, the corresponding cam-shaped member
94
can be removed from opening, thereby disassembling the wall portion from base
12
.
The resistance of the walls to being outwardly collapsed is illustrated in
FIG. 14
, wherein the wall shown in phantom has an interior force applied thereto, which could be applied manually or in the field if a crate is overfilled with product. Thus, as illustrated in
FIG. 14
, while the upper portion of wall
28
may deform temporarily under a given load, the rotational interference of latch portions
59
and
79
when container
10
is assembled prevents any permanent undesired outward folding of the wall.
In accordance with the present invention, container
10
further includes an improved wall configuration particularly applicable to withstand the knock-down forces to which container
10
may be subjected. The improved wall configuration also serves to counter-act part warpage during the molding and cooling processes. As illustrated in
FIGS. 1
,
7
, and
9
-
10
, each of side walls
28
,
30
and end walls
32
,
34
includes, respectively, an upper edge
46
,
48
,
33
,
35
. Proximate upper edges
46
,
48
,
33
,
35
, each corresponding wall
28
,
30
,
32
,
34
includes an upper portion
100
having a configuration allowing for transferred stiffness and strength across the upper portion (for example, effectively transferring laterally outward a knock-down force which is applied to the area above handle
41
to the latch area.) This configuration also provides for improved strength and warping resistance of the walls. As illustrated representatively in
FIG. 7
, the vertical cross-section through upper portion
100
of wall
28
resembles a wave-form configuration defined by a pattern of alternating rows
102
,
103
oriented horizontally, parallel to, and adjacent each other proximate their respective upper edges
46
,
48
,
33
,
35
.
As illustrated in
FIGS. 7
,
9
-
10
, upper wall portion
100
is a single-walled member and preferably has a continuous undulating wave-like configuration having an inner (inwardly facing) surface
104
defined by a plurality of inwardly directed peaks
106
, and an outer (outwardly facing) surface
108
defined by a plurality of outwardly directed peaks
110
. Preferably, as shown in
FIG. 7
, upper portion
100
may have peaks
106
,
110
which are generally flat, and connected by band connect members (slightly tapered portions
112
), to resemble a step wave or modified square wave. To enhance the strength properties of the walls, it is desirous to have as much material on the inner and outer surfaces
104
,
108
as possible, and also that such material is generally distributed uniformly away from a central plane
109
. By way of example, as illustrated in
FIG. 7
, a plane
109
is shown parallel to and oriented mid-way between surfaces
104
,
108
, illustrating that approximately half the material forming upper portion
100
is disposed on either side of plane
109
, thus allowing for a more uniform distribution of plastic material and weight at the perimeter of the walls, where warping and deformation is most likely to occur, as well placing the most material away from plane
109
. Thus, a wall that is 0.5 inch wide will have 50% wall material on one side of plane
109
, and 50% inch wall material on the other side. To the contrary, prior art containers having ribs and cross-ribbing in these areas accordingly tend to have an uneven material distribution. In fact, for many containers, the ribs themselves are tapered, being thicker on the inside and smaller on the outside, thereby creating a more uneven material distribution, and thus a greater potential warping and bowing.
Particularly, the present design allows for optimal material distribution at the surfaces of the walls, particularly for container
10
which has walls
32
,
34
which are subject to the knock-down type force for unlatching the walls when moved to an inwardly folding position.
FIG. 7
upper wall portion
100
may also be described as an inner surface
104
having a plurality of alternating inwardly-directed plateaus
106
and outwardly-directed recesses
107
, which define a corresponding outer surface
108
having, respectively, a plurality of alternating inwardly-directed recesses
111
and a outwardly-directed plateaus
110
. The wave-like design of the upper side and end walls enhances the warping resistance of the side walls by improving the material distribution in upper wall portion
100
, and also distributes strength and force bearing properties laterally across the sidewalls, for example when subject to a kick-down force during disassembly.
FIG. 9
is a cross-sectional view taken along the line
9
—
9
of
FIG. 6
, where band
102
has an outer peak
110
defining outer surface
108
.
FIG. 10
is taken along line
10
—
10
of
FIG. 6
, showing band
103
with an inner peak
106
, defining inner surface
104
. As illustrated therein, band
102
has a peak
106
with a flat profile directed inward (
FIG. 10
) and band
103
has a peak
110
with a flat profile directed outward (FIG.
9
). This design again produces a more even material distribution between the inner and outer surfaces of the relevant component, in this case walls
28
,
30
,
32
,
34
as well as more material placed as far from the center plane
109
.
With respect to the venting holes
11
, container
10
according to the present invention is particularly well-suited for storing bananas therein. Central portions
47
,
49
of side and end walls, respectively, generally serve as the locations of contact for bananas which are generally stored in container
10
in a “hands down” orientation, with their tips and crowns disposed downward (but of course may also be stored in the “hands up” position.) It is preferable for the bananas to contact a solid and continuous construction of these portions of side walls
28
,
30
and end walls
32
,
34
, which therefore increases the surface area of container
10
which is otherwise capable of submitting an opposite reactive force against the bananas when positioned in container
10
. The bananas, accordingly, are shaped and oriented such that they do generally not contact the venting holes disposed on the upper and lower portions of the side and end walls.
It is understood, of course, that while the forms of the invention herein shown and described include the best mode contemplated for carrying out the present invention, they are not intended to illustrate all possible forms thereof. It will also be understood that the words used are descriptive rather than limiting, and that various changes may be made without departing from the spirit or scope of the invention as claimed below.
Claims
- 1. A collapsible container orientable between an assembled position and an inwardly collapsed position, comprising:a base member having a floor with a pair of opposed upstanding flanges integrally formed therewith, the upstanding flanges having an upper surface, wherein the base includes a periphery having a plurality of lower hinge members, each lower hinge member having a hook portion with a downwardly directed edge; a pair of first opposed walls pivotably mounted to the base, each of the pair of first opposed walls having side edges with at least one latch portion extending laterally therefrom, the latch portion including at least one latch member; and a pair of second opposed side walls pivotably attached to a corresponding upstanding flange proximate the upper surface thereof, each of the pairs of first and second opposed sidewalls having a plurality of corresponding upper hinge members extending from a lower edge thereof, each upper hinge member having a cam-shaped member for engaging the hook portion, such that as the container is moved from the inwardly collapsed position to the assembled position, the edge of the hook member limits the vertical movement of the cam-shaped member, thereby preventing each of the pairs of first and second opposed sidewalls from separating from the base when in the assembled position, each of the first pair of opposed side walls having a pair of opposed, inwardly directed flanges having an inner surface with a latch receiving area formed therein, the latch receiving area defined by at least one latch acceptance member having a flexible portion for receiving a corresponding latch member therein in an interference fit when the container is oriented in the assembled position, and wherein to move the container to the collapsed position, a force sufficient to overcome the interference fit is applied to an exterior surface of each of the first pair of opposed side walls.
- 2. A collapsible container, comprising:a base having first and second pairs of opposing edges, one of the first and second pairs of opposing edges defined by an upstanding base wall, and each of the first and second pairs of opposing edges including a plurality of lower hinge members, each lower hinge members defined by a clearance opening and an adjacent hook portion having a downwardly directed edge; and first and second pairs of opposed side walls, each having at least one upper hinge member having a bar with a projection extending therefrom, each of the second pair of opposed side walls mounted to a corresponding upstanding base wall and having a pair of opposed lateral flanges inwardly depending therefrom and integral therewith, each lateral flange having a latch receiving portion formed therein, each of the first pair of opposed side walls each having a pair of opposing lateral edges, each lateral edge having a latch member extending therefrom, wherein when the container is oriented in an assembled position, each latch receiving portion receives a latch member therein, and the projection of the upper hinge member engages the downward edge of the hook portion, thereby impeding the movement of the sidewalls outward beyond the assembled position.
- 3. A collapsible container orientable between an assembled position and an inwardly folded position, the container comprising:a floor member; a first pair of opposed side walls having a first latch portion including at least one latch member; and a second pair of opposed side walls having a second latch portion including a flexible clip portion having a latch member acceptance area and a flex portion, wherein the at least one latch member is a dowel member having a bulbous head for being received by the clip portion in an interference fit, and wherein when the container is moved from the inwardly folded position to the assembled position, the second pair of opposed side walls is rotated upward until it is oriented substantially perpendicular to the base, and the first pair of opposed side walls is rotated upwardly such that the at least one latch member is inserted into the opening of the flex portion, thereby expanding it until the latch member is received within the latch member acceptance area and the flex portion returns to its rest position, impeding the release of the at least one latch member.
- 4. A collapsible container orientable between an assembled position and an inwardly folded position, the container comprising:a floor member; a first pair of opposed side walls having a first latch portion including at least one latch member; and a second pair of opposed side walls having a second latch portion including a flexible clip portion having a latch member acceptance area and a flex portion, wherein the flexible clip portion is a C-shaped clip member and the flex portion is defined by an end of the C-shaped clip, and wherein when the container is moved from the inwardly folded position to the assembled position, the second pair of opposed side walls is rotated upward until it is oriented substantially perpendicular to the base, and the first pair of opposed side walls is rotated upwardly such that the at least one latch member is inserted into the opening of the flex portion, thereby expanding it until the latch member is received within the latch member acceptance area and the flex portion returns to its rest position, impeding the release of the at least one latch member.
- 5. A collapsible container arranged for movement between a collapsed orientation and an assembled orientation, comprising:a base; a first pair of opposed side walls each pivotably attached to the base, each of the first pair of opposed side walls having a pair of opposed lateral edges, each lateral edge having a latch member disposed thereon; and a second pair of opposed side walls each pivotably attached to the base, each of the second pair of opposed side walls having a pair of opposed flanges inwardly depending therefrom, each flange having a surface with at least one latch receiving member formed therein, the latch receiving member having a receiving area and a corresponding opening defined by a fixed edge and a flexible edge spaced apart from each other, the opening relatively smaller than the latch member, wherein when the container is moved from the collapsed orientation to the assembled orientation, the walls rotate upward such that the latch member enters the opening and displaces the flexible edge of the latch receiving member slightly in the vertical direction, whereupon the latch member is received within the receiving area for securing the latch member.
- 6. A collapsible container orientable between an assembled position and an inwardly folded position, the container comprising:a floor member; a first pair of opposed side walls having a latch member; and a second pair of opposed side walls having a clip member having an acceptance area defined by a pair of spaced apart edges, at least one of the pair of spaced apart edges being flexible, wherein when the container is moved from the inwardly folded position to the assembled position, the second pair of opposed side walls is rotated upward until it is oriented substantially perpendicular to the base, and the first pair of opposed side walls is rotated upwardly such that the at least one latch member is directly inserted into an opening defined by the pair of spaced apart edges, causing the flexible edge to temporarily deflect in the vertical direction until the latch member enters the acceptance area.
- 7. A collapsible container adapted to move between a collapsed orientation and an assembled orientation, comprising:a floor member; a first pair of opposed side walls each pivotably attached to the floor member, each of the first pair of opposed side walls having lateral edges with a first latch portion attached thereto; and a second pair of opposed side walls each pivotably attached to the floor member, each of the second pair of opposed side walls having a pair of opposed flanges inwardly depending therefrom, each flange having a surface with a second latch portion attached thereto, wherein the first latch portion includes one of a male latch portion and a female latch portion, and wherein the second latch portion includes the other of the male latch portion and the female latch portion, the female latch portion comprising a pair of spaced apart receiver members, each of the spaced apart receiver members having a corresponding pair of spaced apart edges defining an opening therebetween, wherein at least one of the edges is a flexible member, and the male latch portion comprising a pair of spaced apart latch members corresponding to the receiver members, wherein when the container is moved from the collapsed orientation to the assembled orientation, the walls pivot upward such that the openings of the female latch portion receive a corresponding latch member thereby displacing by interference fit the flexible member while the latch member rests therein.
- 8. The collapsible container of claim 7, wherein the flexible member is displaced in the vertical direction.
- 9. A collapsible container, comprising:a bottom wall having first and second pairs of opposing base edges, one of the first and second pairs of opposing edges defined by an upstanding base portion, and each of the base edges including a plurality of lower hinge members, the lower hinge members defined by an outer base surface, a spaced apart inner base member having a downwardly directed edge, and a hinge receiving opening disposed therebetween; and first and second pairs of opposed side walls, each having at least one upper hinge member having a bar with a projection extending therefrom, each of the second pair of opposed side walls mounted to a corresponding upstanding base wall and having a pair of opposed lateral flanges inwardly depending therefrom, each lateral flange having a first latch portion formed therein, each of the first pair of opposed side walls each having a pair of opposing lateral edges, each lateral edge having a second latch portion formed therewith, wherein one of the first and second latch portions comprises a male latch member, and the other of the first and second latch portions comprises a female latch member such that when the container is oriented in an assembled position, the latch receiving portion of the female latch member receives the male latch member therein, and the projection of the upper hinge member engages the downwardly directed edge of the inner base member, thereby impeding the movement of the sidewalls outward beyond the assembled position.
US Referenced Citations (73)
Foreign Referenced Citations (12)
Number |
Date |
Country |
27 34 964 |
Feb 1979 |
DE |
43 19 099 |
Dec 1994 |
DE |
0 127 414 |
Dec 1984 |
EP |
0 178211 |
Sep 1985 |
EP |
0 404041 |
Dec 1990 |
EP |
0 485 672 |
May 1992 |
EP |
0962 394 |
Aug 1999 |
EP |
1 160 169 |
Dec 2001 |
EP |
WO 8601182 |
Feb 1986 |
WO |
WO 9715502 |
May 1997 |
WO |
WO 0001586 |
Jan 2000 |
WO |
WO 0063084 |
Oct 2000 |
WO |