FIELD OF THE INVENTION
This invention relates to an improved collapsible sidewall structure which cooperates with upper and lower supports, such as pallets, to define a stackable storage bin.
BACKGROUND OF THE INVENTION
U.S. Pat. No. 4,700,862, as owned by the Assignee hereof, illustrates therein a stackable bin which has met with significant commercial success, and which has proven highly desirable for permitting storage of product therein in such a fashion as to permit shipment between locations, and storage at a selected location. This type of stackable bin, as illustrated in FIG. 1, employs an upright hollow wall structure, normally a four-sided wall structure, which is removably positioned between upper and lower pallet-like supports to define an enclosed compartment for the goods being transported. The upper and lower pallet-like supports typically have a structure which defines an opening or recess of a rectangular profile around the outer edge portion of the pallet so as to sidewardly confine the edge of the wall structure to maintain same in its non-collapsed position. The wall structure, which is illustrated in FIG. 2, is provided with four corner folds, and is also provided with two intermediate folds to facilitate collapsing of the sidewall structure.
After transportation and removal of the goods, the empty storage bin is folded down into a compact unit that facilitates return shipment of the empty bin while occupying only minimal space. In order to fold down a traditional bin, such as that described above, the upper and lower pallet-like supports are first removed from the four-sided wall structure. The four-sided wall structure is then folded down into a compact unit as shown in FIG. 2. This results in three relatively compact pieces, including the upper and lower pallet-like supports and the folded down wall structure.
To further reduce the amount of space taken up by three separate pieces of a collapsed bin of the above type, another type of storage bin includes box-shaped upper and lower pallets, wherein the collapsed wall structure can be placed inside one of the pallet-like supports. The remaining pallet-like support is then placed on top of the other support, thereby forming a relatively compact container made up of the two pallet-like supports and containing the collapsed wall structure. However, this specific stacking arrangement including the above three separate pieces is not always carried out by the person or persons responsible for collapsing the bin and getting same ready for return shipment. As such, the collapsed bin may take up more room than is actually necessary due to improper disassembly. Furthermore, as the pallet-like supports are removable from the four-sided wall structure, there is always the possibility that one of the pallet-like supports will be separated from the arrangement or lost. Lastly, upon setting up the bin for its reuse as a storage container, the removable wall structure must first be appropriately positioned with respect to the lower pallet-like support before loading of the storage bin can commence. Yet, positioning the removable wall structure relative to the lower pallet-like support can be difficult for an individual person to accomplish due to the relatively large and awkward size of the wall structure and pallet-like supports.
In addition to the issues presented above, traditional collapsible storage bins are also frequently subject to damage due to their use of top and bottom pallet-like supports of differing dimensions. Specifically, one pallet-like support is often made larger than the other so that when the storage bin is placed in a collapsed state, one pallet-like support will fit or nest inside the other when stacked. However, when the collapsible bin is expanded so that it may be used for the storage and transport of goods, the larger of the pallet-like supports tends to extend outwardly a significant distance beyond the boundaries of the rest of the storage bin (i.e. the opposite pallet-like support and upright wall structure) and subsequently be subject to damage by the equipment used to transport the storage bins. In response, the Applicant has developed a new and improved collapsible bin that addresses the problems raised above.
The present invention relates to an improved collapsible bin for the storage and transport of goods. The collapsible storage bin comprises a collapsible sidewall structure and upper and lower pallet-like supports. Further included is a securing structure that secures the sidewall structure to one of the pallet-like supports while permitting the sidewall structure to be placed in either a collapsed or non-collapsed state.
Further, the upper and lower pallet-like supports each include a base and a border or lip that projects transversely from the base and extends along an edge thereof. A portion of the border located at each corner of the respective base is notched out, allowing the opposed pallet-like supports to cooperate with and nest within each other when the storage bin is placed in a collapsed state.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 depicts a perspective view of a traditional collapsible storage bin having removable upper and lower pallet-like supports.
FIG. 2 depicts a perspective view of a traditional sidewall structure in a partially collapsed state.
FIG. 3 depicts a vertical cross-sectional view of a traditional storage bin having box-like upper and lower pallet-like supports.
FIG. 4 is a top view of a traditional six-fold sidewall structure of a collapsible storage bin.
FIG. 5 depicts an end view of the sidewall structure of FIG. 4 in a collapsed state.
FIG. 6 is a vertical cross-sectional view of the sidewall structure of FIG. 5, illustrating the box-like pallet-like supports in a nested configuration and the sidewall structure in a collapsed state therein.
FIG. 7 depicts a perspective view of the storage bin according to the invention in a use configuration.
FIG. 8 depicts a top view of the securing structure in isolation.
FIG. 9 depicts a vertical cross-sectional view of the storage bin.
FIG. 10 depicts a perspective view in vertical cross-section taken generally perpendicularly through the two sidewalls, wherein the sidewall structure is partially folded or collapsed.
FIG. 11 depicts a perspective view similar to FIG. 10 showing the storage bin after the sidewall structure has been completely folded in, but prior to being collapsed horizontally onto the bottom pallet-like support.
FIG. 12 is an enlarged fragmentary vertical cross-sectional view of the storage bin after the sidewall structure has been collapsed onto the bottom pallet-like support.
FIG. 13 depicts a perspective view of one of the pallet-like supports in isolation.
FIG. 14 depicts an enlarged, fragmentary perspective view of one corner of the storage bin in a fully collapsed state.
FIG. 15 is an enlarged fragmentary end view of the storage bin in a collapsed state.
FIG. 16 depicts a top view of a sidewall structure illustrating a preferred hinge arrangement.
FIG. 17 depicts a perspective view of a storage bin according to a preferred embodiment.
Certain terminology will be used in the following description for convenience and reference only, and will not be limiting. For example, the words “upwardly”, “downwardly”, “rightwardly”, and “leftwardly” will refer to directions in the drawings to which reference is made. The words “inwardly”, “outwardly” will refer to directions toward and away from, respectively, the geometric center of the structure and designated parts thereof. Said terminology will include the words specifically mentioned, derivatives thereof, and words of similar import.
DETAILED DESCRIPTION
Illustrated in FIG. 3 is a cross-sectional view of a collapsible bin 10 which is diagrammatically typical of many such bins conventionally in use. This bin 10 includes removable bottom and top pallets 11 and 12, respectively. These pallets 11 and 12 can be, for example, formed of a plastics material. The pallets are designed to cooperate with a collapsible sidewall structure 13, the latter when open having a tube-like configuration defining a vertical opening therethrough, the ends of this opening being closed by the pallets 11 and 12. This collapsible sidewall structure 13, when in an open condition, cooperates with the pallets to define an interior storage compartment 14. The pallets 11 and 12 are typically configured to have a structure that resembles the lid of a box. Specifically, each pallet 11 and 12 has a planar base 11A and 12A, respectively of substantially the same shape as the terminal free edge of the sidewall structure 13 in a non-collapsed state. Projecting out from the edge of the planar base 11A and 12A of each pallet is a lip or border 11B and 12B, respectively. When the bottom pallet 11 and top pallet 12 are placed under and on top, respectively, of the sidewall structure 13, the pallet lip 11B acts to sidewardly confine the edge of the sidewall structure 13, so as to assist in maintaining the sidewall structure 13 in its open or non-collapsed state.
The collapsible sidewall structure 13, one example of which is depicted in FIG. 4 for illustrative purposes only, includes substantially parallel sidewalls 21 which are joined together by end walls 22, the latter being substantially parallel and extending substantially perpendicularly between the sidewalls 21 when the sidewall structure 13 is in its open and vertically-oriented condition as illustrated by FIGS. 3 and 4. The adjacent edges of the side and end walls 21 and 22, in the illustrated sidewall structure, are joined together by a hinge-type corner structure 23. A further hinge 24 extends vertically along each end wall 22 substantially midway between the respective sidewalls 21. This hinge 24 causes the respective end wall 22 to be of a bi-fold construction having a pair of wall portions 26 and 27 which project outwardly from opposite sides of the hinge 24. The corner hinge structures 23 and center hinges 24 permit the end walls 22 to fold inwardly so that the wall portions 26 and 27 directly overlie one another, and hence enable the sidewall arrangement 13 to be stored in a collapsed position or configuration as diagrammatically illustrated by FIG. 5. In traditional collapsible bins, the sidewall structure 13 is separate and removable from both the bottom and top pallets.
Turning now to the instant invention, FIG. 7 illustrates a storage bin according to the invention. Components which are similar or identical to components of conventional storage bins as discussed above are represented by the same reference number plus a “-1”. The storage bin 10-1 includes upper and lower pallet-like supports or pallets 28 and 29 which-cooperate with a collapsible sidewall structure 13-1. The collapsible storage bin 10-1 of the present invention additionally includes a securing structure 30 that secures the sidewall structure 13-1 to the bottom pallet 29, in contrast to the conventional bin structure discussed above. According to one embodiment, and as shown in FIG. 8, the securing structure 30 comprises a strip or piece of material that is divided into first and second flanges or portions 32 and 34, respectively, by at least one hinge. In the illustrated embodiment, the first flange 32 and the second flange 34 are separated by two neighboring hinges 36A and 36B, respectively, each of which extends across the entire width of the securing structure 30. Placement of the securing structure 30 is illustrated in FIG. 9, which is a vertical cross-sectional depiction of the sidewall structure 13-1 in a non-collapsed state and positioned upon the bottom pallet 29 within the boundaries of bottom pallet lips 29A. One flange 32 of the securing structure 30 is fixed to the interior-facing surface of one of the sidewalls 21-1, while the flange 34 of the securing structure 30 is fixed to the upwardly facing surface of base 29B of the bottom pallet 29. The flanges 32 and 34 of securing structure 30 may be fixed to sidewall 21 and base 29B with adhesive, or other suitable fastening arrangements.
The securing device 30 is also illustrated in FIG. 10, which is a fragmentary, partial vertical cross-sectional perspective view, wherein one of the end walls 22-1 of the sidewall structure 13-1 is removed for purposes of illustration. However, unlike FIG. 9, FIG. 10 depicts the sidewall structure 13-1 in a partially inwardly collapsed state. As illustrated in FIG. 10, the end wall 22-1 has begun to collapse inwardly along the vertically-extending hinge 24-1 located in the end wall 22-1 substantially midway between the two sidewalls 21-1. This folding in of the end wall 22-1 results in the two sidewalls 21-1 being drawn inwardly towards one another. However, one sidewall 21-1 is prevented from moving laterally within the bottom pallet 29 due to the securing structure 30. Accordingly, as the sidewall structure 13-1 collapses, the sidewall 21-1 attached to the securing structure 30 remains in place, while the opposite sidewall 21-1 and end walls 22-1 are drawn across the pallet 29 and inwardly towards the sidewall 21-1 that is fixed in place.
Upon the end walls 22-1 completely folding in, the sidewall structure 13-1 is considered to be in its collapsed or flat state. As illustrated in the cross-sectional perspective view of FIG. 11, the sidewall structure 13-1 can be folded down onto the bottom pallet 29 subsequent to being placed in its collapsed state. During the above process, the securing structure 30 remains attached to the sidewall 21-1 and the bottom pallet 29, thereby assuring that the collapsed sidewall structure 13-1 folds down into the same position every time.
Illustrated in FIG. 12 is one end of the sidewall structure 13-1 after it has been collapsed and folded down onto the bottom pallet 29. From the perspective of FIG. 12, the collapsed sidewall structure 13-1 is seen to comprise four layers, the four layers being defined by the first sidewall 21-1 resting against the bottom pallet 29, two end wall layers 26-1 and 27-1 representing the two halves of the end wall 22-1 folded about hinge 24-1, and the second sidewall 21-1. The first flange 32 of the securing structure 30 remains attached to the second sidewall 21-1, while the second flange 34 remains attached to the base 29B of the bottom pallet 29. The portion of the securing structure 30 that spans between the two hinges 36A and 36B is superimposed over the ends of the first sidewall 21-1 and end wall halves 26-1 and 27-1.
In the above embodiment of the present invention, flange 32 of the securing structure 30 is attached to the interior-facing surface of one of the sidewalls 21-1. However, according to an alternative embodiment, the flange 32 may be attached to the exterior-facing surface of the same sidewall 21-1. Accordingly, when the sidewall structure 13-1 is collapsed and folded down, the ends of both sidewalls 21-1 and end wall layers 26-1 and 27-1 will be covered by the securing structure 30.
In the exemplary embodiment discussed above, and in the associated illustrations, two hinges 36A and 36B are defined on the securing structure 30. However, according to a further embodiment of the present invention, securing structure 30 may possess more than two hinges. For example, in one embodiment (not depicted), the securing structure has three hinges lying between the first and second flanges 32 and 34, thereby providing it with greater flexibility during handling.
Illustrated in FIG. 6 is a cross-sectional view of a traditional collapsed sidewall structure 13 that has been folded down into a traditional bottom pallet 11 and then covered by a traditional top pallet 12. As illustrated, the two pallets are not of the same dimensions. Instead, the top pallet 12 is designed to have a greater length and width than the bottom pallet 11 so that the entire downward extending lip 12B of the top pallet 12 is superimposed over or overlaps the upward-extending lip 11B of the bottom pallet 11. In this manner, the collapsed sidewall structure 13 and pallets 11 and 12 are configured to take up the smallest amount of volume or space as is possible when the storage bin is collapsed.
Upon expanding the collapsible bin illustrated in FIG. 6 so that it may be used for the transport of goods, it becomes apparent that the top pallet 12 does not fit the sidewall structure 13 as closely as does the bottom pallet 11. FIG. 3 better illustrates this size discrepancy, depicting a cross-sectional view of the storage bin of FIG. 6 in an expanded state. The sidewall structure 13 sits on bottom pallet 11 having a length X, and is covered by top pallet 12 having a length Y, where Y>X. Consequently, the edges of the top pallet 12 extend outwardly a significant distance past the sidewall structure 13 when the collapsible bin is being used to store and transport goods as shown in FIG. 3. This frequently results in damage to the collapsible bin whenever it has to be moved while in an expanded state. Specifically, the expanded storage bin is typically moved from a first location to a second location by means of large clamps that press up against opposite sides of the storage bin. This clamping action can deform the top pallet 12, since the top pallet 12 extends outwardly past the edges of the sidewall structure 13 a significant distance. This deformation of the top pallet 12 can significantly reduce the effective life of the collapsible bin.
To prevent or at least minimize the damage described above, the top and bottom pallets 28 and 29 of the storage bin 10-1 according to the invention have substantially equal dimensions, but allow the storage bin to continue to be collapsed into the smallest amount of space as is possible. In this regard, the storage bin 10-1 utilizes two substantially identical pallets 28 and 29 for enclosing both the top and bottom openings of sidewall structure 13-1. Since pallets 28 and 29 are substantially identical to one another, only one of same will be described herein. Pallet 28, as illustrated in FIG. 13, as discussed above, resembles a traditional lid of a box, having base 28B and border or lip 28A that extends transversely outwardly from the base 28B. However, unlike previous pallet designs, the pallet lip 28A is notched at all four corners of the pallet 28. Furthermore, this notch 40 is of substantially equal size and shape in each one of the four corners of the pallet 28. The presence of the notch 40 in each of the four corners of the pallet lip 28A allows for the use of top and bottom pallets 28, 29 of substantially equal dimensions, thereby eliminating the possibility of an oversized pallet becoming deformed by a pair of moving clamps pressing up against the sides of the storage container during movement of same. Furthermore, the presence of the notches 40 allow for two notched pallets 28, 29 to nest within one another, thereby permitting the storage bin 10-1 to collapse into a very compact form.
FIG. 14 illustrates one corner of the storage bin 10-1 in a collapsed state, and, more specifically, depicts how identical notched pallets 28, 29, making up both the top and bottom of the collapsed storage bin 10-1, nest or fit inside one another while containing therein the collapsed sidewall structure 13-1. To achieve this compact state, the upper and lower pallets 28 and 29, respectively, nest within one another in such a manner that the opposing sides of the border of one pallet (e.g., border 28A of pallet 28) are offset from the corresponding border of the other pallet (e.g., border 29A of pallet 29). As a result of the offset that occurs when the upper and lower pallets 28 and 29, respectively, are nested, each pallet 28, 29 will have two adjacent sides of its border or lip 28A, 29A exposed to the exterior while the remaining two adjacent sides of the border or lip 28A, 29A are covered by the corresponding side of the opposing pallet border 28A, 29A. FIG. 15, which depicts an end view of a collapsed storage bin, further illustrates how the opposing pallets nest within one another. As demonstrated in FIG. 15, when in a collapsed or nested state, the lower pallet border 29A residing at one end of the collapsed storage bin covers over, or lies exterior to, the side of the opposing pallet border 28A.
The use and operation of the sidewall structure 13-1 of this invention, and in particular its use in association with the structure of the bin 10-1, is believed readily apparent from the description set forth above, particularly when taken in conjunction with FIGS. 1-6, so that further detailed description of the use of this structure is believed unnecessary.
While the conventional sidewall structure 13 illustrated in FIGS. 4 and 5 includes hinges 23 which interconnect the respective side and end walls 21 and 22, it will be appreciated that the sidewall structure according to the invention may include sidewalls which are integrally formed with (or formed as one-piece with) portions of the respective end walls. More specifically, as shown in FIG. 16, each sidewall 21-1 may be formed as one piece with the adjacent halves 26-1 of the respective end walls 22-1. Thus, each end wall 22-1 is separated into two halves 26-1 and 27-1, which halves are joined together by a hinge part 50. Each hinge part 50 is constructed as a planar, sheet-like member which in the illustrated embodiment extends along the entire vertical height of the end wall 22-1 and is fixed thereto. Hinge part 50 defines therein a fold line or hinge 24-1 which allows folding of the respective end wall 22-1 inwardly. Hinge part 50 is secured to the outer surfaces of the respective end wall halves 26-1, 27-1 by adhesive, or other suitable fastening arrangements.
According to an additional embodiment of the present invention (not depicted), any one or more of the sidewalls 21-1 and end walls 22-1 of the sidewall structure 13-1 can be provided with a removable or tear-away access panel so as to provide an access opening to allow double stacking of bins along an assembly line. This access panel can be formed by either cuts or score lines, and the panel can be replaceable such as by being taped in position. The panel and the access opening will be defined wholly within the borders of the respective end or sidewall.
A preferred embodiment of the storage bin according to the invention is illustrated in FIG. 17. The storage bin as shown is identical to the storage bin 10-1 of FIGS. 7-12, except for the corner configuration of the respective top and bottom pallets. Accordingly, components which are similar to or identical to components of storage bin 10-1 are identified with the same reference numbers plus a “-2”.
In this embodiment, the notches 40-2 of the respective top and bottom pallets 28-2 and 29-2, instead of having a pair of parallel vertical edges as defined by the respective neighboring lips 28A-2 (with respect to the notches 40-2 defined in top pallet 28-2) and 29A-2 (with respect to the notches 40-2 defined in bottom pallet 29-2), each have a pair of edges 53 which diverge from one another as same project towards the free edge of the respective lip 28A-2, 29A-2. Thus, the corner-shaped portions (shown in dotted lines as “55” in FIG. 7) of the respective adjacent pallet lips which define the outwardly opening end of each of the notches has been removed in the embodiment of FIG. 17. The removal of these corner-shaped portions prevents or at least minimizes the catching or snagging of the pallet lips on adjacent objects during use and/or handling of the storage bin.
In a preferred embodiment of the invention, each of the pallets 28, 29, sidewall structure 13-1 and securing structure 30 are extruded plastic members having parallel facing sheets joined together by a plurality of transversely extending ribs, this overall construction being often referred to as a “fluted” construction. Hinge part 50 discussed above may also have such a fluted construction.
Although a particular preferred embodiment of the invention has been disclosed in detail for illustrative purposes, it will be recognized that variation or modifications of the disclosed apparatus, including the rearrangement of parts, lie within the scope of the present invention.
Patent Application
20050150812
