COLLAPSIBLE CRATE

BACKGROUND

Various different styles of crates are available for industrial packaging. In certain applications, these crates must be strong enough to support large payloads. For example, industrial packaging crates are used for the protection, shipment and/or storage of all-terrain vehicles (ATVs), snowmobiles, motorcycles, boat motors, and other heavy payloads. Often, these crates are collapsible so that they can be disassembled and returned once empty. For ATVs and other payloads, these crates typically use an all-steel construction, which is expensive. To reduce cost, others have used crates made at least partially from cardboard, but these crates are not strong enough for stacking. Other crates have used wood, but these are often configured to be disposed of after one use, and are not collapsible or returnable. Other wood crates are collapsible and may be returnable/reusable, but these require additional hardware to assemble and collapse, and are typically not designed to be durable enough for more than a few uses.

BRIEF SUMMARY

According to one embodiment of the invention, a collapsible crate includes a structural base having at least one corner, and a collapsible corner post assembly coupled to the base. The corner post assembly includes a post mount coupled to the corner and an elongated post coupled to the post mount. The elongated post is moveable relative to the post mount between an upright position in which the elongated post extends substantially vertically and a collapsed position in which the elongated post lies substantially horizontally.

According to another embodiment of the invention, a collapsible corner post assembly for a crate includes a post mount and an elongated post coupled to the post mount. The elongated post is moveable relative to the post mount between an upright position in which the elongated post extends upwardly from the post mount and a collapsed position in which the elongated post extends laterally from the post mount.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings:

FIG. 1 is a perspective view of a crate according to a first embodiment of the invention, with the crate shown in an assembled configuration;

FIG. 2 is a side view of the crate of FIG. 1;

FIG. 3 is an end view of the crate of FIG. 1;

FIG. 4 is a perspective view of two stacked assembled crates of FIG. 1;

FIG. 5 is a side view of the stacked assembled crates of FIG. 4;

FIG. 6 is an end view of the stacked assembled crates of FIG. 4;

FIG. 7 is a perspective view of two stacked collapsed crates of FIG. 1;

FIG. 8 is a side view of the stacked collapsed crates of FIG. 7;

FIG. 9 is an end view of the stacked collapsed crates of FIG. 7;

FIG. 10 is an exploded view of a corner portion of the crate of FIG. 1;

FIG. 11 is a perspective view of a corner post assembly of the crate of FIG. 1, where the corner post assembly is in an upright and extended position;

FIG. 12 is a perspective view of the corner post assembly of FIG. 11, where the corner post assembly is in an upright and retracted position;

FIG. 13 is a perspective view of the corner post assembly of FIG. 11, where the corner post assembly is in a collapsed position;

FIGS. 14-16 are views showing the movement of the corner post assembly from the upright position to the collapsed position;

FIG. 17 is a perspective view of a crate according to a second embodiment of the invention, with the crate shown in an assembled configuration;

FIG. 18 is a perspective view of two stacked assembled crates of FIG. 17;

FIG. 19 is a perspective view of two stacked collapsed crates of FIG. 17;

FIG. 20 is an exploded view of a corner portion of the crate of FIG. 17;

FIG. 21 is a close-up perspective view of the top of one of the corner post assembly of the crate of FIG. 17;

FIG. 22 is a close-up view of an interface between the stacked crates shown in FIG. 18;

FIGS. 23-24 are views showing the movement of the corner post assembly from the upright position to the collapsed position;

FIG. 25 is a side view of a portion of a corner post assembly for a crate according to a third embodiment of the invention, with the corner post assembly shown in an assembled position;

FIG. 26 is a side view of a portion of the corner post assembly from FIG. 25, with the corner post assembly shown in a collapsed position; and

FIG. 27 is a perspective view of a portion of the corner post assembly from FIG. 25, with the corner post assembly shown in a collapsed position.

DETAILED DESCRIPTION

The invention relates to a crate for industrial packaging. In one of its aspects, the invention relates to an improved crate that is collapsible, stackable, and, optionally, returnable. The crate can be reusable, and can be easily and conveniently assembled or disassembled as needed. Areas in which the invention has potential application include the protection, shipment and/or storage of goods, including a wide variety of products. The crate may be primarily used for industrial, mid-stream payload transport, and can be used in any number of transport modalities. One particular application in which the crate is contemplated for use is the protection, shipment and/or storage of all-terrain vehicles (ATVs). Other particular applications in which the crate is contemplated for use is the protection, shipment and/or storage of snowmobiles, motorcycles, boat motors, and other heavy payloads

FIGS. 1-3 show a collapsible, stackable, and returnable crate 10 according to one embodiment of the invention. There are three primary component groups of the crate 10, including a structural base 12, collapsible corner post assemblies 14, and various mechanical fasteners, described in more detail below. For purposes of description related to the figures, the terms “upper,” “lower,” “vertical,” “horizontal,” and derivatives thereof shall relate to an orientation of the crate 10 as shown in FIG. 1, with a lower side of the crate facing and resting on a surface (not shown). However, it is to be understood that the invention may assume various alternative orientations, except where expressly specified to the contrary.

The structural base 12 defines a support surface for a payload. The structural base 12 can be preferably fabricated from wood, while the corner post assemblies 14 can be preferably fabricated from metal, such as steel. This combination of materials offers a reduced-cost, collapsible crate that is robust enough to support large payloads such as ATVs, and can further be stacked when assembled with at least one other crate 10 as shown in FIGS. 4-6 or stacked when collapsed with at least one other crate 10 as shown in FIGS. 7-9.

The structural base 12 may be customized based on the payload. The structural base 12 of the illustrated embodiment is customized for an ATV, and includes a plurality of boards or slats that are mechanically fastened to each other to create the structural base 12. The slats include a plurality of bottom deckboards 18 and a plurality of top deckboards 20 that are mechanically fastened to a plurality of stringer boards 22 running transversely to and between the deckboards 18, 20. Blocks 24 can also be provided between and mechanically fastened to the end deckboards 18, 20, and can lie between adjacent stringer boards 22. Mechanical fasteners such as nails, screws, pins, bolts, rivets, ties, or the like can be used for the mechanical attachments of the base 12. Furthermore, other joining methods of assembling the base 12 can also be used.

Other embodiments of the structural base 12 are possible, including different configurations of the slats than that shown herein. While a customized base 12 is shown herein, the base on which the corners posts 14 are mounted can be any type of base. For example, in one embodiment, the structural base 12 can be a pallet. Furthermore, the corner post assemblies 14 are adapted to be transferred between different types of bases, as described in further detail below. Also, while it is preferred that the structural base 12 be manufactured from a low-cost material such as wood, in other embodiments of the crate 10, the structural base 12 can be manufactured using a variety of materials including wood, plastic, composite, metal, fiberglass, wood-plastic composite, or some combination of these materials. In some applications of the crate 10, it is preferred that the structural base 12 be constructed of a material that is lower cost than the material used for the corner post assemblies 14.

FIG. 10 is an exploded view of a corner portion of the crate 10 of FIG. 1, and shows one of the corner post assemblies 14 exploded from a corner of the structural base 12. The collapsible corner post assemblies 14 are upright supports configured to provide lateral protection to the payload supported by the base 12, and are adapted to allow multiple crates to be stacked when assembled or when collapsed shown in FIGS. 4-9. The corner post assemblies 14 can include a telescoping post 26, a post mount 28 configured to couple the telescoping post 26 to the structural base 12, diagonal attachment plates 30 mountable to the structural base 12, and diagonal braces 32 extending between the telescoping posts 26 and the attachment plates 30. While in the illustrated embodiment, the corner post assembly 14 is shown as having a telescoping post 26, in other embodiments of the crate 10, the post 26 can be a single post having a fixed length.

The various components of the corner post assembly 14 can be attached using mechanical fasteners; alternatively, some of the various components can be welded, or otherwise attached. While the corner post assemblies 14 can be preferably fabricated from metal, and more particularly from steel, in other embodiments, the corner post assemblies 14 can be manufactured using a variety of materials including metal, plastic, composite, wood, fiberglass, wood-plastic composite, or some combination of these materials. In some applications of the crate 10, it is preferred that the corner post assemblies 14 be constructed of a material that is more robust than the material used for the structural base 12, so that the corner post assemblies 14 can withstand the repeating stacking and collapsing required of the collapsible, stackable, and returnable crate 10.

The telescoping post 26 can include multiple segments that can be expanded or retracted as needed to change the length of the telescoping post 26, and as illustrated herein includes a corner post main upright 34 and a corner post insert 36 that fits into the main upright 34. Additional telescoping segments may be provided.

The main upright 34 includes an elongated tubular body 38 defining an at least partially hollow interior and having an open upper end 40 in which the post insert 36 can be at least partially received and an open lower end 42 which couples with the post mount 28. Tabs 44 extend from the lower end 42 of the tubular body 38 and include slots 46 which are elongated generally in the lengthwise direction of the main upright 34. The slotted tabs 44 can comprise a pair of plates or flat bodies provided on opposing sides of the tubular body 38. A series of holes 48 are formed along the same opposing sides of the tubular body 38, and are spaced along the length of the tubular body 38. Each hole 48 on one side of the tubular body 38 is aligned with a hole 48 on the opposing side, though only one holes 48 on the opposing side is visible in FIG. 10. Brace tabs 50 extend from the tubular body 38 and each has a hole 52 formed near a free end of the tab 50 for coupling with the diagonal braces 32 as described in more detail below. In the illustrated embodiment, the brace tabs 50 extend laterally from adjacent sides of the tubular body 38. Alternative configurations of attaching the diagonal braces 32 to the main upright 34 are possible, as long as the braces 32 are able to collapse, as described in more detail below.

The post insert 36 includes an elongated tubular body 54 defining an at least partially hollow interior and having an upper end 56 and a lower end 58 which is received with the main upright 34. A series of holes 60 are formed along opposing sides of the tubular body 54, though only the holes 60 on one of the opposing sides are visible in FIG. 10, and are spaced lengthwise along the tubular body 54. Each hole 60 on one side of the tubular body 54 is aligned with a hole 60 on the opposing side. In the illustrated embodiment, two holes 60 are provided, though the number can vary in other embodiments of the corner post assembly 14. The spacing between the holes 60 can be in line with the spacing between the holes 48 in the main upright 34.

The post insert 36 can be slidingly received within the main upright 34 and adjusted to a desired overall height of the corner post assembly 14. To fix the corner post assembly 14 at a desired height, one of the holes 60 in the post insert 36 is aligned with one of the holes 48 in the main upright 34, and a mechanical fastener is then inserted through the aligned holes 48, 60 to secure the main upright 34 and post insert 36 in place at the desired height. The mechanical fastener illustrated herein comprises a bolt 62 and a nut 64 which can be threaded onto the bolt 62; optionally, a washer 66 can also be provided. Other mechanical fasteners are possible, as long as the mechanical fastener can temporarily join the main upright 34 and post insert 36 to allow the height of the corner post assembly 14 to be adjusted as needed. Any fastener can be used, as long as there is enough sheer strength in the fastener to carry the load on the corner post assembly 14.

The upper end 56 includes a top plate 68 and a locator pin 70. The plate 68 can extend outwardly from the tubular body 54 and the locator pin 70 can extend upwardly from the plate 68. The locator pins 70 are adapted to nest into the post mount 28 of another corner post assembly 14 for securely stacking the crates 10 (see, for example, FIGS. 4-6). As illustrated, the locator pins 70 have a generally conical shape which can guide an upper crate 10 in the stack into proper alignment with a lower crate 10. Alternative configurations of the locator pin 70 are possible, as long as the crates 10 can be securely stacked, with the locator pins 70 of the lower crate 10 in the stack securely nested within a portion of the corner post assemblies 14 on the crate 10 above.

The post mount 28 includes a vertical mounting plate 72 and a horizontal mounting plate 74 coupled with a post receiver 76 configured to receive the telescoping post 26. The mounting plates 72, 74 are configured to mount to the structural base 12, thereby mounting the telescoping post 26 to the structural base 12. Specifically, the vertical mounting plate 72 is coupled to the stringer board 22 and the horizontal mounting plate 74 is mounted to the top deckboard 20, though in other configurations of the base, the plates 72, 74 may mount to other portions of the base. The mounting plates 72, 74 can be fabricated from one flat plate that is bent to define the corner between two plates 72, 74, and then welded or otherwise attached to the post receiver 76. Alternatively, the plates 72, 74 can be fabricated separate flat plates that are welded or otherwise attached to form the corner.

Each plate 72, 74 includes at least one hole 78 configured to receive a mechanical fastener, illustrated herein as a carriage bolt 80, used to secure the plates to the structural base 12. Other mechanical fasteners are possible, as long as the mechanical fastener can temporarily join the mounting plates 72, 74 to the base 12 to allow the post mount 28 to be removed from the structural base 12 as needed. As illustrated, the vertical mounting plate 72 includes two holes 78 that are spaced and vertically offset. Offsetting the holes 78 vertically distributes the forces from the payload over a greater area within the stringer board 22. In general, the holes 78 can be aligned vertically, aligned horizontally, and/or offset depending on the application and constraints. Also, in the illustrated embodiment, two holes 78 are provided, though the number can vary in other embodiments of the corner post assembly 14.

The post mount 28 can be configured as a universal mount, such that the corner post assemblies 14 can be attached to any base, not just the structural base 12 illustrated herein. The mounting plates 72, 74 can be sized to accommodate attaching the post mount 28 to a base 12 having boards or slats in a range of sizes. For example, the vertical mounting plate 72 and horizontal mounting plate 74 can be sized to accommodate attaching the post mount 28 to a 2×3 or larger stringer board 22 and a 1× or larger deckboard 20, respectively. In one specific example, the plates 72, 74 can be sized to accommodate attaching the post mount 28 to a 2×3 stringer board 22 and a 2× deckboard 20. In another specific example, the plates 72, 74 can be sized to accommodate attaching the post mount 28 to a 2×4 stringer board 22 and a 1× deckboard 20. The plates 72, 74 could be sized to work with smaller or larger stringer board/deckboard combinations as well.

The post receiver 76 includes an elongated tubular body 82 defining an at least partially hollow interior and having an open upper end 84 which engages with the main upright 34 and an open lower end 85 (FIG. 11). A locator device, shown herein as locator tabs 86, can extend from the upper end 84 of the tubular body 82, and can extend generally in the lengthwise direction of the post receiver 76. The locator tabs 86 illustrated comprise a pair of plates or flat bodies provided on opposing sides of the tubular body 82 and project from an inner surface of the tubular body 82. The locator tabs 86 can be welded, bolted, or otherwise formed with the post receiver 76. The locator device can take other forms besides the tabs 86, including, but not limited to, round or square tubing or bar stock.

At least one pair of holes 88 is formed along the same opposing sides of the tubular body 82 as the locator tabs 86, though only the hole 88 on one of the opposing sides is visible in FIG. 10. In the illustrated embodiment, two spaced holes 88 are provided and are spaced lengthwise along the tubular body 82, though the number of holes 88 can vary in other embodiments of the corner post assembly 14. Here, the upper hole 88 is primarily used for the connection between the telescoping post 26 and post mount 28, while the lower hole 88 is used for heavy duty loads, as described in more detail below.

In the illustrated embodiment, the bodies 38, 82 of the main upright 34 and post receiver 76 can be square 2×2 tube stock and the body of the post insert 36 can be square 1.5×1.5 tube stock that can nest within the outer tube stock forming the main upright 34. Alternatively, tube stock can be substituted for a material that preserves the stacking and nesting functions of the corner post assembly 14. Also, while the tubular bodies are shown as having a square cross-section, other cross-sectional shapes are possible.

The main upright 34 can be slidingly received on the post receiver 76 to couple the telescoping body 26 with the post mount 28 and also selectively allow the telescoping body 26 to collapse, as described in further detail below. To fix the main upright 34 on the post receiver 76, a mechanical fastener such as a bolt 90 and a nut 92 which can be threaded onto the bolt 90 can be used; optionally, a washer 94 can also be provided. In the present embodiment, the bolt 90 is received by the slots 46 in the depending tabs 44 of the main upright 34 and the upper holes 88 in the post receiver 76. The bolt 90 and slotted tabs 44 form a pin-in-slot joint between the telescoping post 26 and the post mount 28, which has two degrees of freedom such that the bolt 90 can slide within the slot 46, and the tab 44, and therefore the post 26, can rotate about the bolt 90. Other joints permitting translational and rotating movement between the post 26 and post mount 28 can also be used. Also, while not shown, for heavy duty loads, an optional second bolt 90, along with an optional second nut 92 and washer 94 can be provided, and can be received through the slots 46 and lower hole 88. However, for some payloads, only the bolt 90 in the upper hole 88 is necessary. Other mechanical fasteners are possible, as long as the mechanical fastener can join the main upright 34 and post receiver 76 in a manner that allows the telescoping post 26 to collapse.

The diagonal braces 32 are configured to extend between the telescoping post 26 and the structural base 12 to support the telescoping post 26 and impart rigidity to the corner post assembly 14. As illustrated herein, the diagonal braces 32 include an elongated rigid body 96 having opposing terminal ends 98 with holes 100 therethough. In one embodiment, the elongated body 96 can be fabricated from ½″ tube stock having flattened ends 98 in which the holes 100 are formed. The holes 100 are configured to receive pins 102 that can define axes of rotation such that the brace 32 has the freedom to rotate about the pins 102, which may be useful when the corner post assembly 14 is being initially assembled and installed on the base 12, or when the corner post assembly 14 is being collapsed. The diagonal braces 32 can extend at roughly a 45 angle between the telescoping posts 26 and the attachment plates 30, although other angles are possible.

The diagonal attachment plates 30 are configured to removably attach one of the diagonal braces 32 to the structural base 12 via mechanical fasteners. As shown, one attachment plate 30 can be coupled to the stringer board 22 and the other attachment plates 30 can be coupled to the top deckboard 20, though in other configurations of the base, the attachment plates 30 may mount to other portions of the base. The diagonal attachment plate 30 can remain coupled to the base 12 in either the upright or collapsed positions of the corner post assembly 14, but can also be disconnected from the structural base 12 to remove the corner post assembly from the base 12 entirely, or when collapsing the corner post assembly 14 as described in further detail below.

As illustrated herein, the diagonal attachment plate 30 includes flat body 104 having an inverted T-shape with one upper hole 106 and two lower holes 108. The upper hole 106 is aligned with a corresponding hole 100 in the diagonal brace 32, and the pin 102 is inserted through the aligned holes 100, 106 to attach the diagonal brace 32 to the attachment plate 30. The two lower holes 108 are used in attaching the attachment plate 30 to the structural base 12, and can receive suitable mechanical fasteners (not shown) such as screws, but may also receive other types of mechanical fasteners such as nails, pins, bolts, rivets, ties, or the like.

FIG. 11 is a perspective view of the corner post assembly 14 is in an upright and extended position. In the upright and extended position, the corner post assembly 14 can be fully attached to the structural base 12 (not shown), i.e. the post mount 28 and attachment plates 30 can both be attached to the structural base 12, and the telescoping post 26 is fully extended, i.e. the post insert 36 is fully extended from the main upright 34.

FIG. 12 is a perspective view of the corner post assembly 14 in an upright and retracted position. In the upright and retracted position, the corner post assembly 14 can be fully attached to the structural base 12 (not shown), i.e. the post mount 28 and attachment plates 30 can both be attached to the structural base 12, and the telescoping post 26 is fully retracted, i.e. the post insert 36 is fully retracted into the main upright 34, with the top plate 68 abutting the upper end 40 of the main upright 34.

It is noted that the corner post assembly 14 may have other intermediate positions, not illustrated herein, in between the fully extended and fully retracted positions shown in FIGS. 11 and 12. The corner post assembly 14 of the illustrated embodiment may, for example, extend from 33″ to 50.5″ with 2″ increments as defined by the spacing between holes 48. These dimensions may be particularly appropriate when the structural base 12 uses 2×4 lumber for the deckboards 20 and stringer boards 22. Further, instead of being discretely adjustable as determined by the spacing of the holes 48, the length of the corner post assembly 14 can be infinitely adjustable between the fully extended and fully retracted positions shown in FIGS. 11 and 12.

FIG. 13 is a perspective view of the corner post assembly 14 in a collapsed position. In the collapsed position, the corner post assembly 14 can be collapsed to lie substantially horizontally, with the telescoping post 26 extending laterally from the post mount 28 rather than longitudinally. When collapsed, the corner post assembly 14 can remain partially attached to the structural base 12. For example, FIGS. 7-9 show stacked crates 10 in which the corner post assemblies 14 are collapsed, and remain attached to the structural base 12 via the post mounts 28 though the braces 32 are separated from the attachment plates 30, which remain on the structural base 12. Alternatively, the corner post assembly 14 can be fully removed from the structural base 12 when collapsed, as shown for example in FIG. 13; in this case, the attachment plates 30 can be removed from the structural base 12 and can remain coupled with the diagonal braces 32. It is noted that the diagonal braces 32 do not extend past the telescoping post 26 in the collapsed position, which can help protect the diagonal braces 32 from damage. Also in the collapsed position, the telescoping post 26 can be extended, retracted, or in some intermediate position in between.

FIGS. 14-16 are close-up views showing the movement of the corner post assembly 14 from the upright position to the collapsed position. Initially, when in the upright position, the main upright 34 is received with the lower end 42 engaging the upper end 84 of the post receiver 76, and the slotted tab 44 which receives the connecting bolt 90, abutting the top of the mounting plate 72. The telescoping post 26 is locked securely in place when the locator tabs 86 extend into the lower end 42 of the main upright 34 and the diagonal braces 32 are connected to the structural base 12 (see, for example, FIG. 1).

To collapse the corner post assembly 14, the diagonal braces 32 are disconnected, either by disconnecting them from the attachment plates 30, which may remain on the structural base 12, or by disconnecting the attachment plates 30 from the structural base 12. Then, the main upright 34 is moved or pulled upwardly away from the post receiver 76, as shown in FIG. 15. As the main upright 34 moves, the bolt 90 which fastens the main upright 34 to the post receiver 76 slides within the aligned slots 46 on the tabs 44, which limits the distance the main upright 34 can travel away from the post receiver 76 and ensures that the main upright 34 is not fully separated from the post receiver 76. The bolt 90 can optionally be loosened before moving the main upright 34 to permit the main upright 34 to slide a little easier. If a second bolt is in place of a heavy payload, the second bolt can be removed before collapsing the corner post assembly 14.

As shown in FIG. 15, the lower end 42 of the main upright 34 eventually clears the locator tabs 86 on the post receiver 76. The slot 46 can be configured such that the bolt 90 reaches the bottom end of the slot 46 when the lower end 42 is clear of the locator tabs 86. Once main upright 34 is free of the locator tabs 86, the main upright 34 (and thus the entire telescoping post 26) can be rotated about the bolt 90 to lie in a generally lateral or horizontal orientation, as shown in FIG. 16.

The crate 10 can be initially assembled and collapsed in accordance with the following methods. The sequence of steps discussed is for illustrative purposes only and is not meant to limit the method in any way as it is understood that the steps may proceed in a different logical order, additional or intervening steps may be included, or described steps may be divided into multiple steps, without detracting from the invention.

To initially assemble the crate 10, holes for the post mount 28 can be pre-drilled into each corner of the structural base 12. The corner post assemblies 14 are connected to each corner of the structural base 12 using the carriage bolts 80. Before or after connection to the base 12, the height of the corner post assemblies 14 can optionally be adjusted. The diagonal braces 32 are then attached to the structural base 12 using the attachment plates 30 and screws that are drilled directly into the sides of the structural base 12. The assembled crate 10 is shown in FIGS. 1-3.

When assembled, the crates 10 are stackable by placing the open lower end 85 of the post receivers 76 of one crate 10 on the locator pins 70 of the corner post assemblies 14 of another crate 10, as shown in FIGS. 4-6. Also when assembled, the corners posts 14 of the crate 10 are collapsible when still attached to the structural base 12, as shown in FIGS. 7-9. Collapsing the corner post assemblies 14 allows them to lay essentially flat, and provides the ability to stack multiple collapsed crates 10 on top of one another. In addition to locking the telescoping post 26 in place when upright, the locator tabs 86 are adapted to nest into the post mount 28 of another corner post assembly 14 for securely stacking the collapsed crates 10. The locator tabs 86 can guide an upper crate 10 in the stack into proper alignment with a lower crate 10 and securely nest within the open lower end 85 of the post receiver 76 on the lower crate 10.

To collapse an assembled crate 10, the pins 102 attaching the diagonal braces 32 to the attachment plates 30 are removed, and the braces 32 are folded toward the telescoping posts 26. Alternatively, the attachment plates 30 can be initially removed from the base 12, leaving them attached to the braces 32 as they are folded closed. The corner post assembly 14 is then collapsed according to the steps described above with reference to FIGS. 14-16.

In an alternative embodiment, instead of having rigid bodies 96, the diagonal braces 32 can comprise flexible straps or cables which allow the corner post assemblies 14 to be collapsed without disconnecting the braces 32. When upright, the cables resist racking in tension as well as act as a support cable when the crate is carrying a payload and stacked on top of another crate.

FIG. 17 shows a collapsible, stackable, and returnable crate 110 according to a second embodiment of the invention. There are three primary component groups of the crate 110, including a structural base 112, collapsible corner post assemblies 114, and various mechanical fasteners, described in more detail below. For purposes of description related to the figures, the terms “upper,” “lower,” “vertical,” “horizontal,” and derivatives thereof shall relate to an orientation of the crate 110 as shown in FIG. 17, with a lower side of the crate facing and resting on a surface (not shown). However, it is to be understood that the invention may assume various alternative orientations, except where expressly specified to the contrary.

The structural base 112 defines a support surface for a payload. The structural base 112 can be preferably fabricated from wood, while the corner post assemblies 114 can be preferably fabricated from metal, such as steel. This combination of materials offers a reduced-cost, collapsible crate that is robust enough to support large payloads, and can further be stacked when assembled with at least one other crate 110 as shown in FIG. 18 or stacked when collapsed with at least one other crate 110 as shown in FIG. 19.

The structural base 112 may be customized based on the payload. The structural base 112 of the illustrated embodiment is customized for a motorcycle, and includes a plurality of slats that are mechanically fastened to each other to create the structural base 112. The slats include a plurality of bottom deckboards 118 and a plurality of top deckboards 120 that are mechanically fastened to a plurality of stringer boards 122 running between the deckboards 118, 120. Blocks 124 can also be provided between and mechanically fastened to the deckboards 118, 120 and stringer boards 122. Mechanical fasteners such as nails, screws, pins, bolts, rivets, ties, or the like can be used for the mechanical attachments of the base 112. Furthermore, other joining methods of assembling the base 112 can also be used.

As with the first embodiment, other embodiments of the structural base 112 are possible, including different configurations of the slats than that shown herein. While a customized base 112 for shipping a motorcycle is shown herein, the base on which the corners posts 114 are mounted can be any type of base. For example, in one embodiment, the structural base 112 can be a pallet. Furthermore, the corner post assemblies 114 are adapted to be transferred between different types of bases, as described in further detail below. Also, while it is preferred that the structural base 112 be manufactured from a low-cost material such as wood, in other embodiments of the crate 110, the structural base 112 can be manufactured using a variety of materials including wood, plastic, composite, metal, fiberglass, wood-plastic composite, or some combination of these materials. In some applications of the crate 110, it is preferred that the structural base 112 be constructed of a material that is lower cost than the material used for the corner post assemblies 114.

FIG. 20 is an exploded view of a corner portion of the crate 110 of FIG. 17, and shows one of the corner post assemblies 114 exploded from a corner of the structural base 112. The collapsible corner post assemblies 114 are upright supports configured to provide lateral protection to the payload, and are adapted to allow multiple crates to be stacked when assembled or when collapsed as shown in FIGS. 18-19. The corner post assemblies 114 can include a post 126 and a post mount 128 configured to couple the post 126 to the structural base 112.

The various components of the corner post assembly 114 can be attached using mechanical fasteners; alternatively, some of the various components can be welded, or otherwise attached. While the corner post assemblies 114 can be preferably fabricated from metal, and more particularly from steel, in other embodiments, the corner post assemblies 114 can be manufactured using a variety of materials including metal, plastic, composite, wood, fiberglass, wood-plastic composite, or some combination of these materials. In some applications of the crate 110, it is preferred that the corner post assemblies 114 be constructed of a material that is more robust than the material used for the structural base 112, so that the corner post assemblies 114 can withstand the repeating stacking and collapsing required of the collapsible, stackable, and returnable crate 110.

In the illustrated embodiment, the post 126 is a single post having a fixed length; in other embodiments of the crate 110, the post 126 can be a telescoping post having an adjustable length, such as shown for the corner post assembly 14 of the first embodiment.

The post 126 includes an elongated tubular body 138 defining an at least partially hollow interior and having an open upper end 140 and an open lower end 142 which couples with the post mount 128. Slots 144, only one of which is visible in FIG. 20, are formed near the lower end 142 of the tubular body 138 in opposing sides of the post 126, and maybe angled in order to guide the post 126 between an upright position and a collapsed position while also clearing the post mount 128. In the embodiment shown herein, the slots 144 have a dogleg shape, with a generally vertically-extending upper slot portion 146 and a lower slot portion 148 which extends at an angle to the upper slot portion 146 but is otherwise continuous with the upper slot portion 146.

FIG. 21 is a close-up view of the top the corner post assembly 114. The upper end 140 includes at least one toothed upper edge 150. The toothed upper edge 150 is adapted to grip the bottom of the base 112 of another crate 110 for securely stacking the crates 110 (see, for example, FIG. 18). As illustrated, the post 126 is rectilinear in shape, and includes two toothed edges 150 on opposing sides of the upper end 140, and two untoothed edges 152 joining the toothed edges 150 Alternative configurations of the upper end 140 are possible as long as the crates 110 can be securely stacked, such as, but not limited to the entire upper edge of the post 126 having teeth, or a non-toothed configuration, such as the locator pin 70 shown in the first embodiment.

FIG. 22 is a close-up view of an interface between the stacked crates 110 shown in FIG. 18, in particular the interface between one corner post assembly 114 of the lower crate 110 and the base 112 of the upper crate 110. The toothed edges 150 of the corner post assemblies 114 of the lower crate 110 grip the base 112 of the upper crate 110 for secure stacking of the crates 110. In one embodiment where the post 126 is metal, such as steel, and the base 112 is wood, the toothed edges 150 of the lower post 126 can dig into the wood of the base 112.

Referring back to FIG. 20, the post mount 128 includes a corner bracket 170 having a vertical mounting plate 172 and a horizontal mounting plate 174 coupled with a post receiver 176 configured to receive the post 126. The mounting plates 172, 174 are configured to mount to the structural base 112, thereby mounting the post 126 to the structural base 112. Specifically, the vertical mounting plate 172 is coupled to one of the stringer boards 122 and one of the adjacent blocks 124, and the horizontal mounting plate 174 is mounted to one of the top deckboards 120, though in other configurations of the base 112, the plates 172, 174 may mount to other portions of the base 112.

Each plate 172, 174 includes at least one hole 178 configured to receive a mechanical fastener, illustrated herein as a carriage bolt 180, used to secure the plates 172, 174 to the structural base 112. Other mechanical fasteners are possible, as long as the mechanical fastener can temporarily join the mounting plates 172, 174 to the base 112 to allow the post mount 128 to be removed from the structural base 112 as needed. As illustrated, each plate 172, 174 includes two holes 178 that are spaced and offset from each other. Offsetting the holes 178 distributes the forces from the payload over a greater area within the base 112. In general, the holes 178 can be aligned vertically, aligned horizontally, and/or offset depending on the application and constraints. Also, in the illustrated embodiment, two holes 178 are provided in each plate 172, 174, though the number can vary in other embodiments of the corner post assembly 114.

The post mount 128 can be configured as a universal mount, such that the corner post assemblies 114 can be attached to any base, not just the structural base 112 illustrated herein. The corner bracket 170 can be sized to accommodate attaching the corner post assembly 114 to a base 112 having boards or slats in a range of sizes. The mounting plates 172, 174 and post receiver 176 can be fabricated from one flat plate that is stamped to define the corners of the post receiver 176 and the corner between the post receiver 176 and the horizontal mounting plate 174. Alternatively, the plates 172, 174 and post receiver 176 can be fabricated separately and welded or otherwise attached to form the post mount 128.

The post receiver 176 includes a U-shaped body defining an at least partially hollow interior and having an open upper end 184 which receives with the lower end 142 of the post 126, and an open lower end 186 configured to meet the base 112, alongside the horizontal mounting plate 174. The U-shaped body is further open at a side that extends between the upper and lower ends 184, 186,

At least one pair of holes 188 is formed along the same opposing sides of the post receiver 176 as the slots 144. The holes 188 are used for the connection between the post 126 and post mount 128. In the illustrated embodiment, the bodies of the post 126 and post receiver 176 can be rectilinear in shape, and the body of the post 126 can nest within the post receiver 176. Also, while the bodies are shown as having a rectilinear cross-section, other cross-sectional shapes are possible.

The tubular body 138 can be slidingly received in the post receiver 176 to couple the post 126 with the post mount 128 and also selectively allow the post 126 to collapse, as described in further detail below. To fix the post 126 on the post receiver 176, a mechanical fastener such as a bolt 190 and a nut 192 which can be threaded onto the bolt 190 can be used; optionally, a washer 194 can also be provided. In the present embodiment, the bolt 190 is received by the holes 188 in the post receiver 176 and the slots 144 in the post 126. The bolt 190 and slots 144 form a pin-in-slot joint between the telescoping post 126 and the post mount 128, which has two degrees of freedom such that the slots 144 can slide relative to and pivot about the bolt 190, and therefore the post 26 can slide and pivot relative to the post mount 128. Other joints permitting translational and rotating movement between the post 126 and post mount 128 can also be used. Other mechanical fasteners are possible, as long as the mechanical fastener can join the post 126 and post receiver 176 in a manner that allows the post 126 to collapse.

FIGS. 17-18 show the crate 110 with the corner post assemblies 114 in an upright position. In the upright position, the corner post assemblies 114 can be fully extended from structural base 112, i.e. the posts 126 can extend vertically upwardly from the corners of the structural base 112. FIG. 19 shows the crate 110 with the corner post assemblies 114 in a collapsed position. In the collapsed position, the corner post assemblies 114 can be collapsed to lie substantially horizontally, with the posts 126 extending laterally from the post mounts 128 rather than longitudinally. When collapsed, the corner post assemblies 114 can remain attached to the structural base 112. FIG. 19 shows stacked crates 110 in which the corner post assemblies 114 are collapsed, and remain attached to the structural base 112 via the post mounts 128.

FIGS. 23-24 are close-up views showing the movement of the corner post assembly 114 from the upright position to the collapsed position. Initially, when in the upright position, the post 126 is received with the lower end 142 within the post receiver 176 and engaging the base 112, and the slots 144 receiving the connecting bolt 190. When the post 126 is upright and the bolt 190 is at the top of the slots 144, the back of the post receiver 176 locks the post 126 vertically.

To collapse the corner post assembly 114, the post 126 is moved or pulled upwardly away from the post receiver 176. As the post 126 moves, the bolt 190 slides within the aligned slots 144 on the lower end 142 of the post 126, which limits the distance the post 126 can travel away from the post receiver 176 and ensures that the post 126 is not fully separated from the post receiver 176. The bolt 190 can optionally be loosened before moving the post 126 to permit the post 126 to slide a little easier. As the post 126 is lifted upwardly, the bolt 190 passing through the angled slots 144 forces the post 126 forward, spacing the lower end 142 of the post 126 away from the back of the post receiver 176 and eventually allowing the post 126 to clear the back of the post receiver as it is rotated about the bolt 190 to lie in a generally lateral or horizontal orientation, as shown in FIG. 24.

The crate 110 can be initially assembled and collapsed in accordance with the following methods. The sequence of steps discussed is for illustrative purposes only and is not meant to limit the method in any way as it is understood that the steps may proceed in a different logical order, additional or intervening steps may be included, or described steps may be divided into multiple steps, without detracting from the invention.

To initially assemble the crate 110, holes for the post mount 128 can be pre-drilled into each corner of the structural base 112. The corner post assemblies 114 are connected to each corner of the structural base 112 using the carriage bolts 180. The assembled crate 110 is shown in FIG. 17.

When the crates 110 are assembled with the corner post assemblies 114 attached to the base 112, the crates 110 are stackable by placing the base 112 of one crate 110 on the upper ends 140 of the corner post assemblies 114 of another crate 110, as shown in FIG. 18. Also when assembled, the corners posts 114 of the crate 110 are collapsible when still attached to the structural base 112, as shown in FIGS. 19 and 24. Collapsing the corner post assemblies 114 allows them to lay essentially flat, and provides the ability to stack multiple collapsed crates 110 on top of one another. To collapse an assembled crate 110, the post 126 is folded toward the base 112 according to the steps described above with reference to FIGS. 23-24.

FIGS. 25-27 show a corner post assembly 214 for a crate according to a third embodiment of the invention. A crate comprising the corner post assembly 214 can include the same three primary component groups, including a structural base, multiple corner post assemblies 214, and various mechanical fasteners, as described for any of the embodiments of crates discussed herein. It is understood that the corner post assembly 214 can, for example, be used for the crate 10 or crate 110 of the first or second embodiments in place of the corner post assemblies 14, 114 discussed for those embodiments. Furthermore, the corner post assembly 214 can be adapted to be transferred between different types of bases for different types of crates.

The corner post assembly 214 is an upright support configured to provide lateral protection to a payload, and is further adapted to allow multiple crates to be stacked when assembled or when collapsed, as shown in FIGS. 25 and 26-27, respectively. The corner post assembly 214 can include a post 226 and a post mount 228 configured to couple the post 228 to the structural base of a crate. In FIGS. 25-27, break lines are used to shorten the post 226 in order to allow an enlarged view of the corner post assembly 214 to be shown.

The various components of the corner post assembly 214 can be attached using mechanical fasteners; alternatively, some of the various components can be welded, or otherwise attached. While the corner post assembly 214 can be preferably fabricated from metal, and more particularly from steel, in other embodiments, the corner post assembly 214 can be manufactured using a variety of materials including metal, plastic, composite, wood, fiberglass, wood-plastic composite, or some combination of these materials. In some applications, it is preferred that the corner post assembly 214 be constructed of a material that is more robust than the material used for the structural base, so that the corner post assembly 214 can withstand the repeating stacking and collapsing required of a collapsible, stackable, and returnable crate.

The post 226 includes at least one elongated tubular body 238 defining an at least partially hollow interior and having an upper end 240 and a lower end 242 which couples with the post mount 228. The upper end 240 may have a locator pin as described for the first embodiment, a toothed upper edge as described for the second embodiment, or neither, as shown herein. The post 226 can be a single post having a fixed length; alternatively, the post 226 can be a telescoping post having an adjustable length, such as shown for the corner post assembly 14 of the first embodiment.

The post mount 228 includes a corner bracket 270 configured to be attached to the corner of a structural base, thereby mounting the post 226 to the structural base. The bracket 270 can have a first U-shaped receiver 272 and a second U-shaped receiver 274 joined in an L-shape and coupled with a post receiver 276 configured to receive the post 226. The bracket 270 can be attached to a crate base by one or more mechanical fasteners or another joining method.

The U-shaped receivers 272, 274 are configured to hold stringer boards that create a frame for the structural base. This allows for a structural base without bottom deck boards, which makes the use of a pallet jack much easier. The U-shaped receivers 272, 274 can optionally further comprise a tooth system to attach the corner post assembly 214 to the base. As shown in the illustrated embodiment, the U-shaped receivers 272, 274 have triangular or tooth-shaped cutouts 278 that are pushed in so when the stringer boards for the base are forced into the U-shaped receivers 272, 274, the or tooth-shaped cutouts 278 bite into the stringer boards and lock them into place, eliminating the need for additional mechanical fasteners.

The post receiver 276 includes a U-shaped body defining an at least partially hollow interior and has an open side 282 and an open upper end 284 which receives with the lower end 242 of the post 226. In the illustrated embodiment, the bodies of the post 226 and post receiver 276 can be rectilinear in shape, and the body of the post 226 can nest within the post receiver 276. Also, while the bodies are shown as having a rectilinear cross-section, other cross-sectional shapes are possible.

The post 226 can be connected with the post mount 228 by a pin-in-slot joint, whereby the tubular body 238 can be slidingly received in the post receiver 276 in an upright or assembled position as shown in FIG. 25, and also selectively allow the post 226 to collapse, as described in further detail below, as shown in FIGS. 26-27. Other joints permitting translational and rotating movement between the post 226 and post mount 228 can also be used.

First slots 286 are formed in opposing sides of the post receiver 276. A second slot 288 is formed in the first U-shaped receiver 272, and is at least partially coextensive with the first slots 288. The slots 286, 288 can be elongated generally in the lengthwise or vertical direction of the post 226.

To fix the post 226 on the post receiver 276, a mechanical fastener or pin 290, such as a bolt and a nut which can be threaded onto the bolt, can be used, and extends through the post 226 and through the slots 286, 288. The pin 190 and slots 286, 288 form the pin-in-slot joint, which has two degrees of freedom such that the post 226 can slide and pivot relative to the post mount 228. The first slots 286 are closed at the upper and lower ends thereof to prevent the post 226 from being entirely separated from the post receiver 276 as the post 226 is moved relative to the post mount 228, while the second slot 288 is open at an upper end thereof, which allows the pin 290 to drop below the upper edge of the bracket 270.

The post mount 228 further comprises a post pocket 292 configured to nest with another corner post assembly 214 on another crate for securing stacking the crates. As illustrated, the post pocket 292 is flared outwardly and has a wide base 294. For example, the base 294 can be wider than the upper portion of the pocket 292 and the post receiver 276. The flared shape of the pocket 292 can help guide an upper crate in the stack into proper alignment on top of a lower crate. Crates are stackable by placing the pockets 292 of one crate on the upper ends 240 of the posts 226 of another crate. The wide base 294 of the pockets 292 also eases stacking crates when the corner post assemblies 214 are collapsed. When collapsed, crates are stackable by resting the wide base 294 of the pockets 292 of one crate on top of the post mounts 228 of another crate. Alternative configurations of the post pocket 292 are possible, as long as the crates can be stacked when assembled or collapsed.

FIG. 25 shows the corner post assembly 214 in an upright position. In the upright position, the corner post assembly 214 can be fully extended from structural base, i.e. the posts 226 can extend vertically upwardly from the corner of the structural base. The post 226 is received with the lower end 242 within the post receiver 276, and the pin 290 is at or closer to the bottom of the aligned slots 286, 288. The back of the post receiver 276 can lock the post 226 vertically.

FIGS. 26-27 show the corner post assembly 214 in a collapsed position. In the collapsed position, the corner post assembly 214 can be collapsed to lie substantially horizontally, with the post 226 extending laterally from the post mount 228 rather than longitudinally. When collapsed, the corner post assembly 214 can remain attached to the structural base. Further, crates can be stacked when the corner post assemblies 214 are collapsed, which can remain attached to the structural base via the post mounts 228.

To collapse the corner post assembly 214, the post 226 is moved or pulled upwardly away from the post receiver 276. As the post 226 moves, the pin 290 slides within the aligned slots 286, 288, which limit the distance the post 226 can travel away from the post receiver 276 and ensures that the post 226 is not fully separated from the post receiver 276. The pin 290 can optionally be loosened before moving the post 226 to permit the post 226 to slide a little easier. As the post 226 is lifted upwardly, the pin 290 eventually clears the slot 288 in the first U-shaped receiver 272, and the post 226 is rotated to lie in a generally lateral or horizontal orientation, as shown in FIG. 26.

As shown in FIGS. 26-27, when the corner post assembly 214 is collapsed, the upper edge 284 of the post receiver 276 can be substantially flush which the side of the tubular body 238 to enable crates to be stacked. Alternatively, the upper edge 284 of the post receiver 276 can be raised relative to the side of the tubular body 238 for nesting further into the post pocket 292 when collapsed crates are stacked.

It is noted that any of the crate embodiments disclosed herein can be provided as a complete crated solution, including a structural base, collapsible corner post assemblies, and various mechanical fasteners. Alternatively, the corner post assemblies 14, 114, 214 can be packaged as a universal kit which is attachable to any base or pallet. Still further, a rental system is contemplated in which a whole crate or just corner post assemblies are rented on a per use basis.

It is further noted that while various mechanical fasteners are discussed herein for joining particular components of the crate embodiments disclosed herein, it is understood that alternative mechanical fasteners such as screws, pins, bolts, rivets, ties, nails, or the like can be used for the mechanical attachments described, unless otherwise noted. Furthermore, other methods of joining the components of the crate embodiments disclosed herein can be used, including, but not limited to, crimping, welding, soldering, brazing, taping, gluing, cementing, or the use of other adhesives, unless otherwise noted.

It is further noted that while the crate embodiments disclosed herein may be described as being returnable, any of the crate embodiments disclosed herein can also be configured for one-way use. A returnable crate can, for example, be made from more heavy duty components than a one-way crate, such as having thicker steel for the post mounts, larger tube sizes for the posts, and/or bolting the corner post assemblies to the base with a nut and washer instead of simply screwing the corner post assemblies to the base with deck screws or lag screws.

The embodiments of the invention disclosed herein provide for a collapsible and stackable crate that improves over prior crate systems. The crate provides a strong, stackable system that can be folded flat for storage or shipping. The corner post assemblies provide the flexibility to be used with any size base or pallet configuration. The corner post assemblies are collapsible, which allows them to lay flat & provides the ability of stacking systems on top of one another. In some embodiments of the invention, the corner post assemblies further have an adjustable length to accommodate for differently-sized payloads and/or stacking heights. The crate is durable and at least some embodiments of the invention can offer a conveniently returnable system that can be reused many times. The crate can be preferably constructed from both wood and steel, which offers both affordability and strength.

While the invention has been specifically described in connection with certain specific embodiments thereof, it is to be understood that this is by way of illustration and not of limitation. Reasonable variation and modification are possible with the scope of the foregoing disclosure and drawings without departing from the spirit of the invention which, is defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise.

COLLAPSIBLE CRATE

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