The entire disclosure of U.S. Provisional Application No. 61,612,700, filed Mar. 19, 2012, is incorporated herein by reference.
The present invention is generally related to collapsible shipping containers and, more specifically, to collapsible shipping totes.
It is known for shipping containers to be used in shipping components to manufacturers, and then for the shipping containers to be collapsed and returned to be reused in shipping additional components. Preferably 100% of the containers are returned for reuse, but it is common for return ratios to be less than 100% for a wide variety of reasons.
Whereas a variety of shipping containers are known, there is always a desire for improved shipping containers that are efficient to make and use, durable, lightweight, and seek to provide high return ratios.
One aspect of this disclosure is the provision of a collapsible shipping tote. Very generally described, the tote may have a generally tubular body for extending around an interior space of the tote while the body is in an erected configuration. The body may have body panels that are respectively foldably connected to one another, so that the body can be reconfigured between the erected configuration and a collapsed configuration.
In one embodiment of this disclosure, the shipping tote has end assemblies that each have an end panel and one or more flaps foldably connected to respective edges of the end panel. Each of the end assemblies may be configured for being moved between open and closed configurations. In its closed configuration, each of the end assemblies at least partially closes a front and rear end of the erected body. In contrast, while each of the end assemblies is in its open configuration, the respective end of the erected body is at least partially open.
Fastener parts may be respectively mounted to the flaps and corresponding portions of the body for releasably securing the flaps to the body so that the end assemblies releasably securing the body in the erected configuration. For example, the fasteners may be hook-and-loop fasteners, such that the fastener parts are strips of textile material respectively comprising hooks and loops. These strips of textile material may be respectively sewn to the body and flaps.
Optionally, at least one divider panel may be positioned in the interior space of the tote and foldably connected to the tubular body for dividing the interior space into cells that are open at both of the opposite front and rear ends of the erected body while the end assemblies are open. In one embodiment, each of the panels comprises at least one piece of textile material and a stiffening panel that are at least partially secured to one another by way of one or more sewn seams. For example, a stiffening panel may be contained within a pocket formed by sewing textile material and/or a stiffening panel and textile material may be sewn directly together. Similarly, connections between the body panels, and between the divider panel(s) and the body, may be provided by one or more sewn seams. Optionally, one of the flaps of each end assembly may be sewn to the body.
The erected totes may be used, for example, in shipping components to manufacturers, and then the totes may be collapsed and returned to be reused in shipping additional components. For example, the components may be loaded and unloaded through front ends of the totes. As a result, the totes may be conveniently used, for example, in association with flow through supply racks on assembly lines. The totes may be used in any other suitable manner.
In one aspect, a substantial portion of each shipping tote is constructed of sewn textile material, so the totes may be lightweight, and their designs may be easily customized to accommodate different components to be shipped.
The foregoing presents a simplified summary of some aspects of this disclosure in order to provide a basic understanding. The foregoing summary is not extensive and is not intended to identify key or critical elements of the invention or to delineate the scope of the invention. The purpose of the foregoing summary is to present some concepts of this disclosure in a simplified form as a prelude to the more detailed description that is presented later. For example, other aspects will become apparent from the following.
Having described some aspects of this disclosure in general terms, reference will now be made to the accompanying drawings, which are schematic and not necessarily drawn to scale. The drawings are exemplary only, and should not be construed as limiting the invention.
Exemplary embodiments of this disclosure are described below and illustrated in the accompanying figures, in which like numerals refer to like parts throughout the several views.
The embodiments described provide examples and should not be interpreted as limiting the scope of the invention. Other embodiments, and modifications and improvements of the described embodiments, will occur to those skilled in the art and all such other embodiments, modifications and improvements are within the scope of the present invention. For example, it will be apparent to those skilled in the art that features illustrated or described as part of one embodiment may be used in another embodiment to yield a further embodiment, and that these further embodiments are within the scope of the present invention.
The tote 20 includes a generally tubular body 22 that extends around an interior space of the tote while the body/tote is erect. The body 22 includes top, bottom, right and left body panels 24, 26, 28, 30 that are respectively foldably connected to one another, as will be discussed in greater detail below.
The tote 20 further includes front and rear end assemblies 32 for opening and closing (e.g., at least partially or substantially closing) the front and rear ends of the tote. When closed, the end assemblies 32 cooperatively provide, or serve as, structure for holding the tote 20 in its erected configuration. Each end assembly 32 has an end panel 34 and flaps 36 foldably connected to the edges of the end panel, as will be discussed in greater detail below. Each of the end assemblies 32 is configured for being moved between open and closed configurations. In its closed configuration, each of the end assemblies 32 at least partially closes a respective end of the erected body 22. In contrast, while each of the end assemblies 32 is in its open configuration, the respective end of the erected body 22 is at least partially open. In the first exemplary embodiment, the empty erected body will collapse under its own weight as soon as/in response to both of the end assemblies 32 being opened, and the tote 20 is shown in its collapsed configuration in
In the exemplary embodiment, fastener parts are respectively mounted to the flaps 36 and corresponding portions of the body 22 for releasably securing the flaps to the body and, thus, releasably securing the body in the erected configuration. For example, the fasteners may be hook-and-loop fasteners, such that the fastener parts are fastener strips 38 of textile material respectively comprising hooks and loops. The fastener strips 38 of textile material in and of themselves are conventional, and as an example such fasteners are available as Velcro® hook and loop fasteners. For reasons of convenience, in this disclosure the reference number 38 is used for designating both fastener strips comprising hooks and fastener strips comprising loops.
Notwithstanding, those of ordinary skill in the art will understand that when a pair of fastener strips 38 forms a fastener, typically one of the fastener strips comprises hooks and the other of the fastener strips comprises loops. The fastener strips 38 may be respectively sewn to the body 22 and flaps 36, as will be discussed in greater detail below. Other types of fasteners may be used, such as, but not limited to, conventional snaps, conventional buttons, or any other suitable fasteners. In addition, the flaps 36 may be characterized as being portions of the fastener mechanisms, and the flaps may be omitted if the selected fasteners do not require the flaps for operability.
Referring to
The length of the tote 20 may be longer or shorter than its width. Irrespective, a longitudinal direction may be characterized as extending from the front to the rear end of the body 22, or vice versa, so that the opposite front and rear ends of the body are spaced apart from one another in a longitudinal direction. Accordingly, the divider panels 40 each extend in the longitudinal direction and in a direction crosswise to the longitudinal direction. As shown in
Referring generally to the representative panel schematically shown in
The foldable connections of the divider panels 40 to the body 22 and the body panels 24, 26, 28, 30 to one another are cooperatively configured so that, while the end assemblies 32 are open as shown in
In an example of a method of using the tote 20, erected totes may be used in shipping components to manufacturers, and then the totes may be collapsed and returned to be reused in shipping additional components. For example, the components may be loaded and unloaded through front ends of the totes 20 configured as shown in
An example of a suitable method for forming the tote 20 is described in the following, in accordance with the first exemplary embodiment, although the tote may be assembled in any other suitable manner. Very generally described, the tote 20 may be manufactured by cutting pieces of textile material to size, respectively sewing the fastener strips to the pieces of textile material, and then sewing the pieces of textile material together in a predetermined manner, wherein stiffening panels are incorporated into the process at a predetermined time, as will be discussed in greater detail below.
Referring more specifically to
In accordance with the first exemplary embodiment, each of the pieces 44, 46, 48 is a piece of textile material, or more specifically a material that comprises fabric. The outer and inner pieces 44, 46 of the body panels 24, 26, 28, 30 may each be a different type of textile material, with the outer piece 44 being selected with a relatively high emphasis on durability, and the inner piece 46 being selected with a relatively high emphasis on being non-abrasive for protecting the components being shipped in the tote 20.
In some of the drawings of this disclosure, the sewn seams are not shown, and where they are shown, they are shown schematically. For example, lateral sewn seams are schematically illustrated by dashed lines in
Generally described,
With continued reference to
Thereafter and as best understood with reference to
The longitudinal sewn seams 54 substantially close the opposite sides of the body pockets. The longitudinal sewn seams 54 preferably (e.g., optionally) extend for substantially the entire length of the body 22. However, the seams 54 may be configured differently without departing from the scope of this disclosure.
For each of the upper two longitudinal sewn seams 54 at each of the ends of the body 22, the fastener strips 38 of the upper flaps 36 may be respectively attached to the outer fastener strips 38 of the top body panel 24 when the upper two longitudinal sewn seams 54 are formed, so that the upper two longitudinal sewn seams 54 securely connect the upper flaps 36, and thus the end assemblies 32, to the opposite ends of the top body panel 24. For example,
Referring to
Immediately after the body and divider pockets are formed and substantially closed as discussed above, and before the stiffening panels 42 are respectively inserted in the pockets, the front opening of each of these pockets may remain substantially closed by the mated interaction of the inner fastener strips 38 of the pocket. As a general example, see the end of the divider panel being held closed by fastener strips 38 in
In the first exemplary embodiment, each of the pockets is substantially filled with a single one of the stiffening panels 42, although more than one of the stiffening panels may be included in each of the pockets, and in some situations one or more of the stiffening panels may be omitted. After inserting the stiffening panels 42, typically the front opening of each of the pockets is closed by causing mated interaction between the inner fastener strips 38 of the pocket. That is, the stiffening panels 42 are retained in the respective pockets by at least partially closing the front opening of the pockets.
In the first exemplary embodiment, the inner fastener strips 38 of each pocket extend for the entire width of the pocket, although they may extend to a lesser extent, and the stiffening panels 42 may be retained in their respective pockets in any other suitable manner. For example, alternatively the front openings of the pockets may be at least partially closed with sewn stitches or any other suitable fastening mechanisms.
In an alternative embodiment, the stiffening panel 58 may be positioned in a pocket of the end panel 34, wherein the pocket may be defined by the textile material of the end assembly 32 and one or more appropriately configured sewn seams, or the like. Alternatively and similarly to the end assemblies 32, one or more of the stiffening panels 42 may be sewn to their adjacent textile material, such that rather than forming pockets and including the stiffening panels 42 in the pockets, the stiffening panels 42 may be sewn to the textile material of the respective panel.
In the first exemplary embodiment, for each of the end assemblies 32, the stiffening panel 58 is the outermost layer of the end assembly 32, the periphery of the stiffening panel 58 is about the same size as the periphery of the respective end opening of the body 22, and the stiffening panel 58 is sufficiently rigid for operating in conjunction with, for example, the rigid stiffening panels 42 to hold the tote 20 in the erected, open configuration shown in
The stiffening panels 42, 58 may be any suitable, generally rigid, plate-like pieces of materials. For example, in the first exemplary embodiment the stiffening panels 42, 58 are extruded corrugated sheets of polymeric (e.g., plastic) material, although they may be pieces of cardboard, sheet metal, or any other suitable material. The above-discussed pieces of textile material (e.g., fabric) may be any suitable types of textile material, such as, but not limited to, nonwoven or woven textile materials, and the textile materials may be coated with suitable coatings and/or may have suitable films or other suitable layers laminated thereto. In addition, each of the pieces of textile material may consist of a single layer of textile material or multiple layers of textile material optionally in combination with any other suitable layers.
As an example that is not shown in the drawings, the bottom body panel 26 may further include a durable outermost layer that is sewn or otherwise attached to the outer piece 44 of the bottom body panel 26 for reinforcement. This outermost layer may comprise textile material, polymeric film, extruded sheet, any other suitable material and/or any suitable combination thereof. Likewise, the other panels 24, 26, 28, 30, 40 and features of the tote 20 may be modified. For example and alternatively, in some situations the tote 20 may be made predominately of paperboard, cardboard and/or any other suitable materials.
Other variations are also within the scope of this disclosure. For example, the number of flaps 36 can be reduced, the number of divider panels 40 may be increased and/or the divider panels may be configured differently. For example,
The above examples are in no way intended to limit the scope of the present invention. It will be understood by those skilled in the art that while the present disclosure has been discussed above with reference to exemplary embodiments, various additions, modifications and changes can be made thereto without departing from the spirit and scope of the invention as set forth in the claims.
This application claims the benefit of U.S. Provisional Application No. 61,612,700, filed Mar. 19, 2012.
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