Collapsible container

Information

  • Patent Grant
  • 6631822
  • Patent Number
    6,631,822
  • Date Filed
    Saturday, October 28, 2000
    24 years ago
  • Date Issued
    Tuesday, October 14, 2003
    21 years ago
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.
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