1. Field of the Disclosure
The disclosure is generally related to a storage product and, more particularly, to a storage product comprising a rigid storage body and at least one flexible covering surface, wherein the rigid storage body is capable of being nestably stacked in a volume-efficient manner with another rigid storage body.
2. Brief Description of Related Technology
Traditionally, boxes designed to store and/or transport school supplies have been manufactured using rigid, substantially vertical walls. Such boxes have utility for the consumer in that they are durable, yet lightweight, being typically formed from plastic, wood, light metals, etc. Thus, when filled, they may be easily transported by the user without risking damage to or escape of the contents.
However, traditional school boxes have inherent limitations that are disadvantageous to the consumer. Specifically, it is difficult to provide the consumer with a variety of aesthetic designs on the box surface because of the manufacturing costs associated with printing designs on three-dimensional product surfaces. The result is that less expensive school boxes do not offer different design options other than, perhaps, a variable color thermoplastic used for the school box body.
Additionally, because the empty boxes have such a large void volume and substantially vertical sidewalls, their display on the shelves of retail stores is relatively volume-inefficient. Shipment to distibutors and retailers of these conventional empty boxes is also inefficient due to the cumulative empty space of the stacked boxes. Often, multiple units are simply stacked in horizontal rows or vertical columns, and much shelf space or shipping container space is wasted. This further limits the consumer's aesthetic options because, even if the manufacturer were willing to produce a large variety of designs, shelf-space constraints in the retail outlet limit the total number of units that can be displayed and successfully marketed.
Attempts at remedying the inefficient retail display and shipping of products have been made with respect to non-school products using the concept of nestability. When designed to be nestable, products that ordinarily displace a significant amount of volume as a single unit may be stacked such that the body of one product fits within the void volume defined by the body of a second product, thereby permitting efficient use of retail outlet shelves by increasing the shelf packing density on a per-product-unit basis.
Exemplary products with the trait of nestability include laundry baskets, waste baskets, and home organizational bins. Such products are typically open, one-piece products that do not securely contain their contents during extended transport, such as would be typical of a filled school box being transported from place to place in, for example, a backpack.
A food storage box with a lid is an example of a two-piece, nestable product that is capable of securely transporting its contents. In such a product, a group of food storage boxes may be nestably stacked. The lids, which are typically rigid and flat, do not pack inefficiently and may thus be simply stacked. However, there is some wasted volume in the retail packaging of a group of boxes and lids. Because the boxes and lids are necessarily used in a 1:1 ratio, they are sold as such. Therefore, there is typically some external packaging structure that holds the nestably-stacked boxes and the simply-stacked lids. This creates additional inefficient volume overhead in the retail packaging.
The school boxes of the present disclosure utilize a rigid storage body in connection with at least one flexible covering surface in order to create storage products that can securely hold their contained items, with school supplies being exemplary contents. The rigid storage body is comprised of at least one rigid storage frame. As illustrated in one embodiment of the following disclosure, the rigid storage frames are designed to permit efficient, nestable stacking arrangements of the rigid storage body, thereby facilitating volume-efficient packing of the rigid storage body either while on display in a retail store or while in transit during distribution. In another embodiment, the rigid storage frame is designed with open regions to promote material savings, while the flexible covering surface is used to contain the items in the storage product.
The flexible covering surface can serve as a way of incorporating various aesthetic designs into the storage product. Additionally (or optionally), the flexible covering surface can be used to seal the storage product in connection with the rigid storage body. Because the flexible covering surface is substantially flat in its natural state, various designs may be more easily imparted to the surface (as compared to the three-dimensional rigid surface of a conventional school box). This makes it less expensive for the manufacturer of the storage product to provide the consumer with a variety of aesthetic designs without having to vary the manufacture of the underlying rigid storage frame. Furthermore, in embodiments of the storage product that accept more than one flexible covering surface, the consumer is free to mix and match flexible covering surfaces with differing designs to suit personal tastes. Finally, because a consumer is encouraged to customize his or her own storage product by choosing from a selection of flexible covering surfaces and/or rigid storage bodies, there is no need for additional packaging, such as shrink wrap or twist ties, to group two or more associated elements into appropriate sets. The flexible covering can also serve to provide a soft exterior to the storage product.
Exemplary aspects and features of a storage product in accordance with the present disclosure are described and explained in greater detail below with the aid of the drawing figures in which:
One embodiment of the disclosure provides a rigid storage body and a single flexible covering surface, wherein the rigid storage body further comprises a single rigid storage frame. In this embodiment, the rigid storage frame is a solid body and the affixation of the flexible covering surface to the rigid storage frame creates a sealed storage product that can protect its contents either during stationary storage or during transport.
Another embodiment of the disclosure comprises a rigid storage body and two flexible covering surfaces, wherein the rigid storage body further comprises two rigid storage frames. In this embodiment, the rigid storage frames may be either solid bodies or partially-open frames. When the rigid storage frames are partially open, the affixation of the flexible covering surfaces to the rigid storage frames not only serves a decorative purpose, but also creates a sealed storage product that can protect its contents either during stationary storage or during transport by covering any open portions of the rigid storage frame. When the rigid storage frames are solid bodies, the flexible covering surfaces are not required to create a sealed storage product, but still serve aesthetic functions.
Another embodiment of the disclosure comprises a rigid storage body and two flexible covering surfaces, wherein the rigid storage body further comprises two rigid storage frames. However, this embodiment illustrates an alternate rigid body frame structure that provides an alternate means of affixation for the flexible covering surface.
Yet another embodiment of the disclosure comprises a rigid storage body and two flexible covering surfaces, wherein the rigid storage body further comprises a single rigid storage frame. In this embodiment, the rigid storage frame has a plurality of open regions that are covered by the first flexible covering surface. The affixation of the second flexible covering surface to the rigid storage frame creates a sealed storage product that can protect its contents either during stationary storage or during transport.
The embodiments disclosed herein thus satisfy a need for a versatile storage product that securely holds its contents while simultaneously providing manufacturing and merchandising advantages to both the producer and the consumer. In each of the disclosed embodiments, the sidewalls of the rigid storage frames which form the rigid storage body are slanted, arced, or bowed away from opposing sidewalls, instead of being vertical. As a result, a plurality of the disclosed rigid storage frames are nestable with one another. The rigid storage frames may be nested as connected pairs of open storage frames, each pair of storage frames forming a rigid storage body of a storage product. Alternately, the rigid storage frames may be nested individually, as explained further below.
A representative embodiment of the disclosed storage product is shown in FIGS. 1 to 5.
A plurality of catches 134 is disposed circumferentially on the outer surfaces of sidewalls 126 and 128.
The flexible covering surface 140 comprises a wrap 142, the outer edge of which defines a wrap edge 146. A plurality of loops 144 is disposed circumferentially on the wrap edge 146. As shown in
In an alternate embodiment (not shown), the base 124, instead of comprising a solid surface (as shown in
A representative second embodiment of the disclosed storage product is shown in FIGS. 6 to 9.
The rigid storage frame 222 is generally defined by a base 224 from which longitudinal sidewalls 226 and lateral sidewalls 228 upwardly extend. In the illustrated embodiment, the base comprises a plurality of base elements 223 that define open regions 227 in the base 224. This structure provides rigidity and shape while simultaneously reducing the weight and material consumption of the rigid storage body 200. However, an alternate embodiment (not shown) could use a solid base without open regions (analogous to base 124 in the first embodiment).
The upper edges of the sidewalls 226 and 228 define a continuous upper sidewall edge 230, which further defines a nesting surface 232. The upwardly projected area of the base 224 defines a projected base surface 225. The nesting surface 232 circumscribes the projected base surface 225, thus allowing multiple rigid storage bodies 220 to be nestably stacked.
A plurality of catches 234 is disposed on the inner surfaces of longitudinal sidewalls 226.
In this embodiment, the two flexible covering surfaces 240 and 260 are identical; therefore, only the detailed structure with respect to the flexible covering surface 240 is described. However, the two may be separately designed to accommodate different designs, coverage areas, attachment means, etc. The flexible covering surface 240 comprises a wrap 242, the outer edge of which defines a wrap edge 246. The wrap 242 comprises three regions corresponding to the particular element of the rigid storage frame 222 that they contact when attached: a base region 248, an outer sidewall region 250, and an inner sidewall region 252. A plurality of holes 244 is disposed on the inner sidewall region 252 of the wrap 242. The holes 244 may be reinforced with grommets or the like (not shown) to extend the life of the flexible covering surface 240. The number of holes 244 need not be fixed at two per inner sidewall region 252 (as illustrated in
A third embodiment of the disclosed storage product is shown in
A plurality of catches 344 is disposed circumferentially on the upper sidewall edge 330 of the first rigid storage frame 322. Each catch 344 is defined by a pair of grooves 335 in the sidewalls 326 and 328 projecting downward from the upper sidewall edge 330, as shown in
The flexible covering surface 340 comprises a wrap 342, the outer edge of which defines a wrap edge 346. The wrap 342 comprises three regions corresponding to the particular element of the first rigid storage frame 322 that they contact when attached: a base region 348, an outer sidewall region 350, and a corner region 252. A plurality of holes 344 is disposed on the comer region 352 of the wrap 342. The number of holes 344 is generally selected to correspond to the number of catches 334 disposed on the first rigid structure frame 322.
A fourth embodiment of the disclosed storage product is shown in
The upper edges of the sidewalls 426 and 428 define a continuous upper sidewall edge 430, which further defines a surface 432. The upwardly projected area of the base 424 defines a projected base surface 425. In the illustrated embodiment of
A plurality of catches 434 that allows attachment of a first flexible covering surface 440 to the rigid storage frame 422 is disposed on the inner surfaces of longitudinal sidewalls 426. The structure and manner of attachment of the first flexible covering surface 440 are analogous to those described above in relation to
A plurality of catches 468 that allows attachment of a second flexible covering surface 460 to the rigid storage frame 422 is also disposed circumferentially on the outer surfaces of sidewalls 426 and 428. The structure and manner of attachment of the second flexible covering surface 460 are analogous to those described above in relation to
The embodiments shown in
Multiple Storage Products in a Nested Configuration
The efficient packing of a plurality of the disclosed storage products is shown in
Each rigid storage frame 622, 636 also may have a corresponding hinge element 638a, 638b. The hinge elements 638a, 638b may be releasably attached to form a single hinge (not shown) similar to hinge 238. This allows a consumer to design and assemble a customized storage product by individually selecting rigid storage frame components (e.g., where the top and bottom may be of the same or different structure) and flexible covering surfaces (e.g., where the top and bottom may be of the same or different decorative design and/or material).
The volume displacement of a single rigid storage body 220 or a rigid storage frame 622, 636 is proportional to its height h. The volume displacement of each additional rigid storage body 220 or rigid storage frame 622, 636 in a nested stack 610, 620, 630 is proportional to its incremental height Δh. The volume efficiency, defined as the actual volume displaced by the nested stack 610, 620, 630 relative to the volume which would otherwise be occupied by an un-stacked group of storage bodies, approaches Δh/h as the number of storage bodies in the nested stacks 610, 620, 630 increases. The value of Δh/h in typical applications is about 1/20 to ⅓, but may be larger or smaller depending on a variety of geometric factors, such as (by way of example only) the clearance height required by hinges, latches, and lips; the thickness of the sidewalls; and the slope of the sidewalls, etc.
The volume efficiency of the nested stacks 610, 620, 630 allows retailers to display approximately 3 to 20 times more product on a fixed amount of retail shelf space. This results in the retailer being able to present the consumer with more product choices, both in terms of the size, shape, and material of the rigid product body, as well as the design and material of the flexible covering surface. Similarly, manufacturers and distributors may transport more product in a fixed volume.
Storage Product Material Composition
The rigid storage frame may be fabricated from any material that is strong enough to impart rigidity and shape to the storage product and that is also durable enough to withstand continuous transport and use. It is also desirable for the rigid storage frame to be lightweight. Typically, an injection-molded thermoplastic resin is used for the rigid storage frame, as it satisfies all of these desired qualities. Additionally, the use of a thermoplastic facilitates other design choices, such as the inclusion of open areas in the rigid storage frame to reduce the storage product weight. Other suitable materials for the rigid storage frame include, for example, wood, metal, mesh, glass, and wire.
The flexible covering surface should meet the functional object of securely attaching to the rigid storage frame and sealing (where appropriate) the storage product. It should also meet the aesthetic object of being able to accommodate various different designs. Typically, the wrap of the flexible covering surface is made from fabric, which may or may not have some inherent elasticity. Other materials for the wrap are possible, including, for example, rubber and plastic. The materials may be used alone or in combination. For instance, a two-layer wrap may have a bottom layer of rubber to provide secure frictional gripping to the rigid storage frame and may have a fabric outer layer to impart visual and textural designs to the storage product. The wrap designs may be printed, embroidered, or may be inherent to the wrap itself (e.g., a patchwork of multi-colored fabric, knits or wovens comprising multicolored yarns, etc.). When the flexible covering surface includes loops or draw strings, these may be made from elastic material (e.g., rubber) or relatively inelastic material (e.g., string, nylon, plastic, etc.) and serve as a way to enhance the attachment force of the flexible covering surface to the rigid storage frame.
Other means of attaching the flexible covering surface to the rigid storage frame are possible. For instance, buttons, snaps, zippers, glue, hook-and-loop type fasteners, other synthetic fastening material having complementary parts which adhere to each other when pressed together, etc., may all be used within the scope of the present disclosure. Additionally, these alternate means may be used in connection with the flexible covering surface and/or the rigid storage frame.
Although numerous different embodiments of storage products in various configurations using rigid and flexible components are disclosed herein, the detailed description is to be construed as exemplary only, and does not describe every possible embodiment in accordance with the disclosure. Thus, it should be recognized that variations may be made that are within the scope of the appended claims.
This application claims priority benefit from U.S. Provisional Application No. 60/736,092, filed on Nov. 10, 2005, the entirety of which is hereby incorporated by reference herein.
Number | Date | Country | |
---|---|---|---|
60736092 | Nov 2005 | US |