TECHNICAL FIELD
The present invention relates generally to shipping and storage containers and methods, and in particular, embodiments relate to collapsible containers that may be integrated into a motor carrier's current operations without any additional equipment or disruption of service.
BACKGROUND
Containers are utilized by industry and consumers to ship freight from one location to another. Containers are also commonly used to store items for a length of time. Conventional containers, although effective when full of freight, become a source of lost revenue for a motor carrier when the container is empty because the space taken up by the empty container could be used by a full container or other freight. Similarly, in the case of residential or commercial use, an empty container undesirably takes up a great deal of space in a residential or commercial user's basement, attic, storage space, warehouse or other similar location. A user may desire to keep an empty container in his or her possession for future use but for the undesirable space the empty container requires.
Conventional containers are also difficult for a commercial or residential user to load and unload. The top-loading of a shipping container can be a harrowing experience, especially when the item to be shipped or stored is being loaded into a tall container. For example, the article may be accidentally dropped while it is being loaded into the container from the top. Additionally, articles positioned at the bottom of a full top-loaded container may be difficult, if not impossible, to locate or remove if the need arises.
Additionally, conventional containers are not easily integrated into a motor carrier's current less than load (“LTL”) operations. LTL freight, unlike full truckload freight, is collected from various shippers and consolidated onto a trailer. Non-uniformity of conventional container dimensions create inefficiencies in LTL linehaul operations by causing large gaps of dead space in between freight and containers. Similarly, conventional shipping containers are not dimensioned to fit in trailers with overhead, roll-up doors.
Accordingly, a shipping and storing container that takes up minimum space when empty, is easily loaded and unloaded, and integrates into a motor carrier's operations is desired.
SUMMARY
According to one embodiment, a collapsible container is provided. The collapsible container includes a base, a pair of first opposing walls, each first opposing wall comprising a top edge, two side edges and a bottom edge, a pair of second opposing walls, each second opposing wall comprising a top edge, two side edges and a bottom edge, a top panel removably attached to the top edge of the pairs of first and second opposing walls and a plurality of engaging devices positioned along the perimeter of the base and the top panel and along the two side edges and top and bottom edges of the pairs of first and second opposing walls. The plurality of engaging devices are configured to removably connect the pair of first opposing walls to the pair of second opposing walls and to removably connect the pairs of first and second opposing walls to the base and top panel.
According to another embodiment, a collapsible container is provided. The collapsible container includes a pair of first opposing walls, each first opposing wall including a top edge comprising a plurality of top male fastening components and a bottom edge comprising a plurality of bottom male fastening components, and two side edges including a plurality of side male fastening components. The collapsible container also includes a pair of second opposing walls, each second opposing wall including a top edge comprising a plurality of top male fastening components, a bottom edge comprising a plurality of bottom male fastening components, and two side edges comprising a plurality of side female fastening components configured to accept the plurality of side male fastening components. A base including a plurality of base female fastening components along a perimeter of the base, the plurality of base female fastening components configured to accept the plurality of bottom male fastening components of the pairs of first and second opposing walls. A top panel including a plurality of top panel female fastening components along a perimeter of the top panel, the plurality of top panel female fastening components configured to accept the plurality of top male fastening components of the pairs of first and second opposing walls.
According to yet another embodiment, a collapsible container includes a pair of first opposing walls, each first opposing wall including a plurality of engaging hooks positioned outwardly along two opposing edges, a plurality of first engaging tabs positioned outwardly along the edges adjacent to the two opposing edges and an exterior face comprising a graphic. The collapsible container also includes a pair of second opposing walls, each second opposing wall including a plurality of slots positioned along two opposing edges configured to accept the plurality of engaging hooks of the pair of first opposing walls, a plurality of second engaging tabs positioned outwardly along the edges adjacent to the two opposing edges, and an exterior face comprising a graphic. The collapsible container also includes a base comprising a plurality of base slots that are sized and positioned to accept the first and second engaging tabs of the respective pairs of first and second opposing walls to form a receptacle and a top panel comprising a plurality of top slots that are sized and positioned to accept the first and second engaging tabs of the respective pairs of first and second opposing walls to form a receptacle.
BRIEF DESCRIPTION OF THE DRAWINGS
The following detailed description will be more fully understood in view of the drawings in which:
FIG. 1 is a perspective view of a collapsible container with one side removed according to one or more embodiments of the present invention.
FIG. 2 is an exploded view of a collapsible container according to one or more embodiments of the present invention.
FIG. 3 is a perspective view of a collapsible container with one side removed according to one or more embodiments of the present invention.
FIG. 4 is a perspective view of a collapsible container with one side removed according to one or more embodiments of the present invention.
FIG. 5 is a perspective view of a first opposing wall being inserted into a base of a collapsible container according to one or more embodiments of the present invention.
FIG. 6A is a front view of a first and second opposing wall of a collapsible container according to one or more embodiments of the present invention.
FIG. 6B is a top view of a base and a bottom view of a top panel of a collapsible container according to one or more embodiments of the present invention.
FIG. 7A is a front view of a first and second opposing wall of a collapsible container according to one or more embodiments of the present invention.
FIG. 7B is a top view of a base of a collapsible container according to one or more embodiments of the present invention.
FIG. 7C is a bottom view of a top panel of a collapsible container according to one or more embodiments of the present invention.
FIG. 7D is a side view of a top panel of a collapsible container according to one or more embodiments of the present invention.
FIG. 8 is a perspective view of an access point on a side wall of a collapsible container according to one or more embodiments of the present invention.
FIG. 9A is a perspective view of a first opposing wall being inserted into a base of a collapsible container according to one or more embodiments of the present invention.
FIG. 9B is a perspective view of a second opposing wall being inserted into a base of a collapsible container according to one or more embodiments of the present invention.
FIG. 9C is a close up perspective view of a collapsible container according to one or more embodiments of the present invention.
FIG. 9D is a front view of a collapsible container covered with a tarp according to one or more embodiments of the present invention.
FIG. 10 is an exploded view of a collapsible container according to one or more embodiments of the present invention.
FIG. 11 is a perspective view of a collapsible container with one side removed according to one or more embodiments of the present invention.
The embodiments set forth in the drawings are illustrative in nature and are not intended to be limiting of the invention defined by the claims. Moreover, individual features of the drawings and the invention will be more fully apparent and understood in view of the detailed description.
DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS
In one embodiment, a collapsible storage and shipping container is provided. According to the embodiment, the container may be used for both commercial and residential shipping and storing applications. The container, which may be made of a wood, composite and/or plastic material such as natural HDPE, for example, is designed and dimensioned to allow a motor carrier to integrate pickup and delivery of the container into the motor carrier's current operations without any additional equipment or disruption of service. One exemplary embodiment of such operations is less than load (LTL) operations. For example, according to some embodiments, the container may be loaded and unloaded at a dock or with a liftgate on the trailer so the user or carrier is not required to provide equipment such as a forklift, pallet-jack or flatbed trailer. As described herein below, embodiments are dimensioned such that they are easily integrated current LTL operations. Dimensioning of the containers ensures that space is not wasted within the trailer by minimizing gaps caused by oddly-dimensioned freight and containers. According to some embodiments, the container will fit in all linehaul trailers, including, as an example and not a limitation, curtain side linehaul trailers, trailers with overhead roll-up doors and other types of linehaul trailers. Embodiments are also dimensioned to allow the shipping and storage of oversized items, such as couches, other large furniture, machines or equipment. The container may be custom-sized to suit the user's shipping and storage needs.
The container is fully collapsible to provide efficient storage and/or transport of the container when the container is empty, as well as provide increased loading and unloading flexibility for the user. According to some embodiments, engaging tabs and hooks are configured to be inserted into mating slots for easy assembly and collapsibility of the container. The container of this embodiment may be assembled and disassembled without the use of, or need for, tools. Because the container is collapsible, it may be collapsed during transport when the container is empty, thereby decreasing the required volume of the container within the linehaul trailer. This significantly increases the load capacity of the trailer, which frees up the motor carrier to load the trailer with more freight. Likewise, the user may collapse the container when he or she is not presently using the container, thereby taking up less space within the storage area. The collapsibility also allows for increased loading and unloading flexibility. As an example, the freight to be loaded into the container for shipping and/or storage may be placed on the base of the container before the attachment of the sides and top panel. A user may choose to remove just the top panel of the container when unloading an item from the container, or he or she may additionally remove one or more sides to unload items that are difficult to access from the container.
Embodiments may also comprise additional features. Freight securing mechanisms may be provided on the interior surface of the base according to some embodiments. The freight securing mechanisms allow freight to be tied down or secured to the base of the container, thus preventing damage to the freight during transport. Other embodiments may also include a tarp that covers the container for all-weather protection when the container is subject to the elements. Because conventional containers may be unsightly, residential and commercial users may be reluctant to store items in a container in the exterior of their home or place of business where the container may be seen from the road, sidewalk or other public vantage point. However, exterior storage may be desirable where the user does not have adequate interior storage space, does not wish the store the item indoors, or for other reasons. Therefore, according to some embodiments, the exterior of the container may comprise an aesthetically pleasing design. As an example and not a limitation, the design may include a playhouse, club house, fence, landscape scene, or any other pleasing design to disguise the container. In a further embodiment, one or more of the sidewalls may comprise a window. Exemplary windows could be comprised of glass, plastic or other transparent/semi-transparent materials. In one embodiment, the window is configured to allow a user to visually inspect one or more contents in the collapsible container.
As shown in the illustrated embodiment of FIGS. 1 and 2, a collapsible shipping and storage container 10 is provided. The embodiment illustrated in FIGS. 1 and 2 is of a square geometry (e.g., 48″×48″×48″ among others). As described and illustrated herein, other geometries and sizes that integrate into motor carrier operations are also provided. The container comprises a base 16, a pair of first opposing walls 12, a pair of second opposing walls 14 and a top panel 18 that are configured to easily attach to one another to form the collapsible container 10 without the use of tools. The base 16, top panel 18 and the opposing walls 12, 14 comprise engaging devices that are configured to interlock the base 16 and the opposing walls 12, 14 to each other.
According to the embodiment of FIGS. 1 and 2, the engaging devices comprise a plurality of male fastening components (e.g., 20, 24 and 26) and a plurality of female fastening components (e.g., 21, 25 and 27). More particularly, the male fastening components may include a plurality of engaging hooks 20 (e.g., three on each side of the first opposing walls 12 in this embodiment) and engaging tabs 24, 26, and the female fastening components may comprise a plurality of slots 21, 25, 27. The engaging hooks 20 of the illustrated embodiment are located along two opposing sides of the pair of first opposing walls 12. It is contemplated that the engaging hooks 20 may also be provided along two sides of the pair of second opposing walls 14. The engaging hooks 20 are configured to be inserted and secured to matching slots 21 provided along two opposing sides of the pair of second opposing walls 14. Other engaging device configurations are also possible. More specifically, rather than an fastening hook, an engaging tab with a hole or a notch configured for the insertion of a locking pin to fasten the walls together may also be employed.
The slots 25, 27 located on the base 16 and top panel 18 are configured to accept the corresponding engaging tabs 24, 26 of the pairs of first and second of opposing walls 12, 14 (i.e., slot 25 is configured to accept engaging tab 24 and slot 27 is configured to accept engaging tab 26). In one exemplary embodiment, the slots 25, 27 and engaging tabs 24, 26 are dimensioned such that the pairs of first and second opposing walls 12, 14 may only be inserted in the correct position on the base and/or top panel. For example, slot 25 and engaging tab 24 may be of a length that is longer than slot 27 and engaging tab 26 or visa versa. Similarly, slot 25 and engaging tab 24 may be of a width that is wider than slot 27 and engaging tab 26 or visa versa. As is shown in FIG. 9A, the base 16 comprises support blocks 30 that provide additional support for the container, as well as depth for the slots 25, 27 to accept the engaging tabs 24, 26. The depth of the slots 25, 27 increases the strength and rigidity of the container. In one exemplary embodiment, illustrated in FIG. 5, the support block 30 is configured to provide an opening 150 to allow a pin 160 to be inserted through the support block 30, wherein the opening 150 is positioned corresponding to the slot 25 on the base 16. In one exemplary embodiment, the engaging tabs 24, 26 have a corresponding hole 152 such that a pin 160 may be inserted into the opening 150 of the support block 30 and through the hole 152 of the engaging tab, thus securing the side wall 12, 14 to the base 16.
Referring again to FIGS. 1 and 2, the base 16 may contain support blocks 30 as described above. The support blocks 30 form gaps within the base 16 in which a forklift, pallet-jack or other transporting device may be inserted to move the container 10 to a specific location. The support blocks 30 also ensure that the container 10 is sufficiently raised from the ground to prevent water from entering the container 10. According to some embodiments, freight securing mechanisms 28 may be provided throughout the floor of the base 16. In FIG. 2, the exemplary freight securing mechanisms 28 are positioned along the perimeter of the floor of the base 16. The freight securing mechanisms 28 may be used to secure freight to the base and therefore container 10 by running a strap, bungee cord, rope, twine or other similar device under the latch or ring of the freight securing mechanisms 28 and around the freight (FIG. 9A). Many other freight securing mechanism configurations are possible.
Additional embodiments may comprise handles 22 that are located on each wall of the container 22. These handles 22 may be attached to the opposing walls 12, 14. Or, according to other embodiments and as illustrated in FIGS. 1 and 2, the handles 22 may be recesses that are formed into the one or more of the opposing walls during the molding or formation of the opposing walls 12, 14. The handles 22 may be used to lift and carry the container 10 from one location or another. The handles 22 also aid in erecting and collapsing the container 10, as well as assist in carrying and moving the opposing walls 12, 14.
In another exemplary embodiment, at least one of the sides and the base are configured to be secured to each other. For example, as illustrated in FIG. 3, a strap 210 with a ratcheting mechanism (alternatively an elastic element) might be utilized and looped through an opening or ring 212 on the side 12 and the base 16 and the strap 210 tightened to secure one or more of the sides 12 to the base 16 to minimize the chance of the side walls disengaging from the base. In another example, a spring clamp can be utilized. Alternatively, a cam-door lock or similar device could be utilized. In yet another example, illustrated in FIG. 5, a pin and clevis arrangement could be utilized, wherein the base and the side walls are configured to allow a pin 160 to be inserted an opening 150 on the base 16 or alternatively on the support block 30 and through a corresponding opening 152 in the engaging tab 24 of the side wall 12, thereby minimizing the ability of the side wall 12 to become disengaged from the base 16. In another exemplary embodiment, the top panel may also be configured with one or more securing mechanisms to secure the top panel to the side walls. In addition to minimizing the ability of the side walls to become disengaged from the base and/or top panel, the securing mechanisms also provide the ability to create a secure container for shipment needs which require such security (such as high value items, pharmaceuticals or confidential materials).
In another exemplary embodiment, the top panel comprises one or more slots configured to engage one or more corresponding tabs of the side walls. In one further embodiment, illustrated in FIG. 4, the tabs 24, 26 of the side walls 12, 14 pass through the slots 25, 27 of the top panel when the top panel 18 is placed onto the side walls. The tabs 24, 26 can then be secured to the top panel through a variety of securing mechanisms such as pin and clevis, straps, latch or clamps and the like in a similar manner as illustrated in FIGS. 3 and 5 and as discussed above. In yet a further embodiment, the support blocks 30 are configured to allow a second container to be stacked on a first container. The tabs of the side walls are positioned such that the support block of a second container can be placed on top of the first container. In one embodiment, the underneath portion of the support block has a corresponding slot to accept the engaging tab that extends through the slot of the top panel of the first container. This embodiment can also help prevent the second container from sliding or slipping off the first container. In yet a further embodiment, the tabs of the first container's side walls can be secured to the support block utilizing a similar opening and securing mechanism as illustrated in FIGS. 3 and 5.
As described above, the container 10 may be designed and dimensioned in a number of sizes that allow the container 10 to be integrated into motor carrier operations. For example, in one exemplary embodiment, LTL operations. FIGS. 6A and 6B illustrate an embodiment that is dimensioned as a rectangular container that is taller than the square embodiment of FIGS. 1 and 2 (e.g., 48″×48″×75″). As an example, this embodiment may be useful for storing and/or transporting a refrigerator or other tall items. According to the embodiment of FIGS. 6A and 6B, the opposing side walls 12, 14 have four engaging hooks 20 and slots 21 along each side. FIGS. 7A-7C illustrate an embodiment in which the container 10 has a geometry suitable for storing and transporting large, oversized items (e.g., 48″×90″×55″). For example, this embodiment may be utilized to transport bicycles, four-wheelers, dressers, and other relatively long items. The engaging tabs 24a (FIG. 7A) and slots 25a are relatively longer than the engaging tabs 24 and slots 25 provided in the embodiments illustrated in FIGS. 1 and 2 and FIGS. 6A and 6B. The increased length of the engaging tabs 24a and slots 25a increase the stability of the container 10. Referring to FIG. 7C, the top of the container 10 is composed of three top panel sections 18a, 18b, and 18c. The top panel sections comprise engaging slots 25a and 27. The three section embodiment allows for easy access to the container 10 as only a small section needs to be removed to access items within the container 10. Additionally, the three sections 18a-18c are easy for a single person to install and remove as the pieces are smaller and lighter than one large top panel. According to one exemplary embodiment, the top panel(s) may further comprise an interior engaging lip 29b along portions of the three sections 18a-18c to increase the stability of the container 10. Some embodiments comprising the three top sections 18a-18c may employ a notch fit to assemble the top 18 onto the top of the container 10. As illustrated in FIG. 7D, 18b may comprise notch 52 which is configured to rest upon corresponding notches 50 located on 18a and 18b. In this manner, all three sections 18a-18c may be securely attached to first and second opposing walls 12, 14. In another embodiment, top sections 18a-18c also comprise one or more corresponding slots configured to engage the tabs of the side walls.
In one exemplary embodiment, illustrated in FIG. 8, one or more of the side walls comprise an access point 300 to allow visual inspection and/or entry into the collapsible container when assembled. For example, in one embodiment, the access point comprises a door 300 configured to allow a visual inspection of one or more items placed in the container. In another embodiment, the access point comprises a larger door(s) which allows the ability to load/unload items into/from the assembled container. The access point in one exemplary embodiment comprises a roll-up door. The access point may also comprise a securing mechanism which can secure the access point from being opened. In another exemplary embodiment, the access point is transparent or semi-transparent. [00421FIGS. 9A-9D illustrate a method of erecting a collapsible container 10 according to one embodiment. Referring initially to FIG. 9A, the base 16 is placed on level surface. Freight may be placed on the base 16 at this time, or any other time in the assembly process. Next, a first opposing wall 12 (i.e., a wall having male engaging structures 20) may be lifted by the handles 22 (not shown) so that the engaging tabs 24 are aligned with the engaging slots 25. The wall 12 and engaging tabs 24 are then pushed down into the engaging slots 25. This is repeated for the other second opposing wall 12.
Now referring to FIG. 9B, a second opposing wall 14 (i.e., a wall having female engaging structures) may be lifted over the base 16 such that the engaging tabs 26 are aligned with the slots 27 on the base 16, and the engaging hooks 20 of the pair of first opposing walls 12 are aligned with the slots 21 of the second opposing wall 14. After positioning the second opposing wall 14 into place, the wall 14 is then pushed down so that the engaging tabs 26 enter the slots 27 and the engaging hooks 20 of wall 12 grip and secure the wall 14. This is repeated for the remaining second opposing wall 14 having slots 21 such that all four opposing walls 12, 14 are fitted and locked together to the base 16.
After the opposing walls 12, 14 are in place and the freight has been loaded, the top panel 18 may be placed on the top portion of the opposing walls 12, 14 and fit into place, as illustrated in FIG. 9C. In one embodiment, the top panel 18 comprises one or more corresponding slots 25, 27 configured to engage one or more tabs 24, 26 of the opposing walls. The container 10 is now fully assembled and ready for storage and/or transport. According to some embodiments, a tarp 40 may be fitted over the container to protect the container 10 from the elements, including wind, rain, frost, snow and sun, for example (FIG. 9D). The tarp 40 may be secured to the container 10 by flaps 42. The flaps 42 may be secured by attachments 44a, 44b which may be Velcro, or a loop in which a hook or a clip may use to engage attachment 44a to attachment 44b, for example. The container 10 may be collapsed by removing the top panel 18, then removing the pair of second opposing walls 14 and finally the pair of first opposing walls 12. The base 16, opposing walls 12, 14 and top panel 18 may then be stacked into a compact form for later use.
In one exemplary embodiment, illustrated in FIG. 10, the container 10 further comprises one or more stability bars 85 which are configured to minimize inward and outward movement of the side walls 12, 14. The stability bars 85 are connected to the side walls through a connection mechanism 88 on the interior side of the at least one pair of opposing side walls 12, 14. As one skilled in the art will appreciate, various locations and connection mechanisms may be employed, including multiple stability bars in a container. In a further embodiment, the stability bars 85 can be utilized to secure and/or separate items within the container 10.
Another exemplary embodiment of the container 10 is illustrated in FIG. 11. The container 10 comprises a base 16, a pair of first opposing walls 12, a pair of second opposing walls 12 and a top panel 18 that are configured to easily attach to one another to form the collapsible container 10 without the use of tools. The base 16 and the opposing walls 12, 14 comprise engaging devices that are configured to interlock the base 16 and the opposing walls 12, 14 to each other. According to this particular embodiment, the engaging devices comprise a plurality of male fastening components (e.g., 20, 24 and 26) and a plurality of female fastening components (e.g., 21, 25 and 27). More particularly, the male fastening components may include a plurality of engaging hooks 20 (e.g., three on each side of the first opposing walls 12 in this embodiment) and engaging tabs 24, 26, and the female fastening components may comprise a plurality of slots 21, 25, 27. The engaging hooks 20 of the illustrated embodiment are located along two opposing sides of the pair of first opposing walls 12. It is contemplated that the engaging hooks 20 may also be provided along two sides of the pair of second opposing walls 14. The engaging hooks 20 are configured to be inserted and secured to matching slots 21 provided along two opposing sides of the pair of second opposing walls 14. Other engaging device configurations are also possible. More specifically, rather than an fastening hook, an engaging tab with a hole or a notch configured for the insertion of a locking pin to fasten the walls together may also be employed.
In this particular embodiment, the slots 25, 27 located on the base 16 are configured to accept the corresponding engaging tabs 24, 26 of the pairs of first and second of opposing walls 12, 14 (i.e., slot 25 is configured to accept engaging tab 24 and slot 27 is configured to accept engaging tab 26). The slots 25, 27 and engaging tabs 24, 26 are dimensioned such that the pairs of first and second opposing walls 12, 14 may only be inserted in the correct position on the base. For example, slot 25 and engaging tab 24 may be of a length that is longer than slot 27 and engaging tab 26 or visa versa. Similarly, slot 25 and engaging tab 24 may be of a width that is wider than slot 27 and engaging tab 26 or visa versa. The base 16 may contain support blocks 30 as described above. The support blocks 30 form gaps within the base 16 in which a forklift or other transporting device may be inserted to move the container 10 to a specific location. The support blocks 30 also ensure that the container 10 is sufficiently raised from the ground to prevent water from entering the container 10. The top panel 18 of the container 10 is dimensioned such that there is an overhang above each opposing wall 12, 14. Under each overhang (i.e., around the perimeter of the underside of the top panel 18) is a vertical lip 29 that enfolds the walls 12, 14 when the container 10 is assembled, as may be viewed in the embodiment illustrated in FIG. 1. The vertical lip 29 therefore secures the top panel 18 to the top portions of the walls 12, 14 and ultimately, the container 10. The exterior side of the top panel further comprises one or more support block lips 94 which are configured to minimize movement of a second container stacked on top of a first container. The support block lips 94 are configured to minimize and/or prevent movement of the support blocks 30 of the second container. The support blocks lips 94 can be an integral part of the top panel 18 or can be an optional attachment that is secured to the top panel through known attachment processes such as adhesives, screws, rivets, latches, etc.
The foregoing description of the various embodiments of the invention has been presented for the purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise steps and/or forms disclosed. Many alternatives, modifications and variations will be apparent to those skilled in the art of the above teaching. Moreover, although multiple inventive aspects have been presented, such aspects need not be utilized in combination, and various combinations of inventive aspects are possible in light of the various embodiments provided above. Accordingly, the above description is intended to embrace all possible alternatives, modifications, combinations, and variations that have been discussed or suggested herein, as well as all others that fall with the principles, spirit and broad scope of the inventions as defined by the claims.
Patent Application
20100018966
