1. Field of the Invention
The present invention relates to storage containers, and particularly to composite storage containers made using reinforcement structures, designed for adding strength and rigidity thereto. More particularly, the present invention relates to a relatively large, foldable reinforced storage container assembly formed by connecting two or more foldable storage containers in an end-to-end relationship, to connecting hardware for use in making such a composite storage container, and to methods of making such a composite storage container. The inventive composite storage container is made using specialized reinforcement structures adapted to reinforce and strengthen side walls of the large storage container assembly, for reliable use over a relatively long period.
2. Background Art
Storage containers, including reusable containers, are widely used in industrial settings. In particular, reusable industrial storage containers are commonly used in shipping parts for use on an assembly line or the like, in warehousing inventory, etc. A commonly used type of large, reusable plastic storage containers, which are foldably collapsible to approximately ⅓ of its normal size when not in use, are commercially available from the Ropak Corporation, and are described for example in the U.S. Pat. Nos. 4,923,079 and 6,145,682, the entire disclosures of which are hereby incorporated by reference. The collapsible nature of the storage containers is extremely desirable for reducing the space required to store and transport the containers when empty.
Many other types of storage containers are commercially available, including metal containers.
Further, there are situations where a particular, mass produced storage container does not have adequate capacity for a specific application thereof, and a user may wish to combine-connect two or more standard size storage containers together to form a larger capacity storage container assembly to meet a specific size requirement. Methods and apparatus previously proposed by applicant for connecting storage containers together, such as the reusable, collapsible Ropak containers, are discussed in U.S. Pat. Nos. 6,145,682 and 6,210,069, the entire disclosures of which are incorporated herein by reference.
For connecting the containers in the manners as previously proposed, an end wall of each container is removed, and then the open ends are joined together with appropriate fastening hardware such that the resulting large container has a single open space therein. Once connected, the side walls of the larger-capacity container assembly span typically twice the distance of the original side wall of a single container. As such, they may lack sufficient stiffness and strength to resist bowing outwardly when the container is filled with storage contents, particularly heavy and bulky materials, to be reliably folded and unfolded, etc., and therefore, these relatively unstable walls may hinder the purpose of creating larger capacity storage containers.
The applicant has previously implemented reinforcement measures, to strengthen a foldable storage container formed by connecting end-to-end two storage containers, which mainly included stiffening rails and brace members installed on side walls, and reinforcing braces installed on portions of inside corners of the container.
Another embodiment of the applicant's previously reinforced storage container assembly disclosed in U.S. Pat. No. 6,210,069, is shown in
Although applicant's previously proposed, reinforced, combined container assemblies discussed above and in greater detail in U.S. Pat. Nos. 6,145,682 and 6,210,069 function appropriately for their intended purposes, a need still exists in the art for improved reinforcement of the combined storage containers, especially as the overall size thereof increases. For example, applicant has determined that over an extended period of use, the lengthy side walls of the combined container assembly may become warped or damaged, particularly when the empty container is being collapsed/folded even with the known reinforcing structures. Factory workers tend to quickly fold the side walls of an empty container by simply kicking the side walls flat, after connecting pins at opposite ends thereof have been retracted.
Although the known reinforcing structures have relatively high strength and rigidity, these structures my become warped or displaced by such rough handling over time, especially along the joined interfaces of the connected containers, where stress tends to be concentrated. Further, in storage containers having a side wall height of more than 36 inches, the problem tends to be greater.
The present invention has been developed to fulfill the discussed need, and to correspondingly overcome limitations of the known structures. In a first embodiment thereof, the present invention provides a reinforced storage container assembly formed by connecting two or more storage containers end-to-end, where the assembly includes a first storage container, a second storage container, connecting hardware for connecting the two containers, and at least one reinforcement structure.
The reinforcement structures used for reinforcing both collapsibly foldable and non-collapsible storage containers include inner and outer reinforcing members, stiffening rails, modified stiffening rails and reinforcing channels. A first illustrative embodiment of the present invention provides a reinforced composite storage container assembly having outer reinforcing members disposed on outer portions of side walls thereof, and used in combination with at least one stiffening member, modified stiffening member or reinforcing brace for reinforcing the side walls of the storage container.
The outer reinforcing members may be T-shaped in cross section, and may be made of metal, such as steel plate. In the first embodiment, the outer reinforcing member includes a V-shaped stem formed of angle iron having a first end portion and a second end portion, and a flat plate attached by means of welding to the first end portion of the stem such that a triangular cross section is formed at the first end portion, where the flat plate is attached to the V-shaped stem. In the depicted embodiment, the flat plates are rectangular in shape. The flat plate includes a plurality of attachment holes formed therethrough for attaching the outer reinforcing member to the side wall of a storage container having corresponding holes formed therethrough.
As described earlier, a reinforced storage container assembly is formed by connecting two or more storage containers end-to-end, with intermediate walls thereof removed. Such connection of two storage containers into a large storage container may form a V-shaped groove between abutted side walls, on outer portions of the side walls. In order to create a reinforced storage container assembly, the V-shaped stem of the outer reinforcing member is disposed in the V-shaped groove formed between abutted walls of the storage container. A second end portion of the V-shaped stem of the outer reinforcing member is secured on the upper portion of the side wall of the container, using at least one stiffening member, modified stiffening member or reinforcing channel. The first end portion of the V-shaped stem, having the flat plate attached thereto, where the flat plate has a plurality of attachment holes formed therein, is secured on the lower portion of the side wall of the storage container using suitable fasteners, which may be a plurality of nuts and bolts.
The provided reinforced storage container assembly can either be collapsibly foldable or may be formed from non-collapsible storage containers. In collapsibly foldable reinforced storage containers having a folding line, the outer reinforcing members are installed on the outer portion of the side walls above the folding line. In non-collapsible reinforced storage containers, the outer reinforcing members may be installed at any level.
In one aspect of the invention, a reinforced storage container assembly formed by connecting two storage containers end-to-end, with intermediate walls thereof removed, includes the outer reinforcing members used in combination with the stiffening rails. The outer reinforcing members are disposed along the height on outer portions of abutted side walls, with a second end portion of the stem attached to very top edge of the side walls and the first end portion having the flat plate attached to the container above the folding line of the side walls. The stiffening member is attached to abutted side walls for reinforcing and interconnecting the storage containers together. The stiffening member, being substantially U-shaped in cross section, is adapted to securely receive the upper edge portions of the side walls, and the second end portion of the stem of the outer reinforcing member therein.
In another aspect of the invention, the reinforced storage container assembly includes outer reinforcing members used in combination with modified substantially U-shaped stiffening rails. The modified stiffening member includes elongated elements for receiving the second end portion of the stem of outer reinforcing member which is not extended up to very top edge of the side wall. In other words, the second end portion of the stem may placed below the very top edge of the side wall and, such placement of the second end portion is received by the elongated elements of the modified stiffening rails. Alternatively, the second end portion may be extended up to the very top edge of side wall. The attachment of the outer reinforcing member to the modified stiffening member generally includes disposing a portion of the second end portion of the stem between the elongated element of the modified member and the side wall.
In yet another aspect of the invention, the reinforced storage container assembly includes an outer reinforcing members used in combination with reinforcing channels mounted along substantial length portions of side walls. The reinforcing channel includes a longitudinal channel that may be made of metal. The reinforcing channel is designed for reinforcing side walls and also for securing the second end portion of the stem of outer reinforcing member therein. The second end portion of the stem is not required to be extended up to very top edge of the side wall of the storage container. Alternatively, as the second end portion is placed beneath the reinforcing channel thereby allowing the second portion of the stem to be extended up to very top edge of the side wall.
In another aspect of the invention, a reinforced storage container assembly includes inner reinforcement panels mounted on portions of container floor and inside side walls, and outer reinforcing members mounted on outer portions of side walls. The outer reinforcing members are used in combination with at least on of the stiffening member, modified stiffening member, and the reinforcing channel. Alternatively, the reinforced storage container assembly may only include inner reinforcement panels.
The inner reinforcement panels may have a generally L-shaped cross section, and may also be made of metal. Each inner reinforcement panel includes a vertical portion, a horizontal portion attached to the vertical portion at one end, and a plurality of attachment holes formed therethrough the vertical portion for fastening the inner reinforcement panel to the side walls of the storage container. The inner reinforcement panels are designed to receive portions of container floor and inner side walls. The inner reinforcement panel is disposed on inside of collapsibly foldable storage container at a seam between two containers at the very bottom of side wall below a folding line. Generally, one inner reinforcement panel is used for each junction of side walls at the seam between two containers. Also, the inner reinforcement panel may be used at a seam between two non-collapsible storage containers. Additionally, inner reinforcement panels may be used for reinforcing side walls or end walls of a storage container.
The present invention provides a reinforced storage container assembly formed by connecting two or more storage containers end-to-end with one or more reinforcing structures which are durable and easy to install.
For a more complete understanding of the present invention, the reader is referred to the following detailed description section, which should be read in accordance with the accompanying drawings. Throughout the following description, like numbers refer to like parts.
Referring now to
The reinforced storage container assembly 100, formed by connecting two or more storage containers end-to-end, includes a first storage container 102, a second storage container 104, a connector, and one or more reinforcement structures, to be described in further detail herein.
The reinforced storage container assembly 100 includes a floor 116, a first end wall 118 pivotally attached to the floor 116 via a first hinge pivot pin (not shown), forming a folding line 119 for the first end wall 118, and disposed at a first height above the floor 116. The reinforced storage container assembly 100 also includes a second end wall 117 pivotally attached to the floor 116 opposite the first end wall 118. The second end wall 117 is pivotally foldable into the container 100, as shown by the two-headed arrow in
The reinforced container also includes a first side wall 112 pivotally attached to the floor 116 via a second hinge pivot pin (not shown) and disposed at a second height above the floor 116, where the second height is above the first height of the first hinge pivot pin. The connection between the first side wall 112 and the floor 116 forms a folding line, adjacent the second hinge pivot pin, to allow the side wall 112 to fold down on top of the already collapsed end walls 117, 118. The reinforced container 100 further includes a second side wall 114, pivotally attached to the floor 116 opposite the first side wall 112. The second side wall 114 is joined to the floor 116 via a third hinge pivot pin (not shown) forming a folding line 115 which is disposed at substantially the same height as the second pivot pin.
As discussed earlier, a reinforced collapsibly foldable storage container assembly 100 is generally made up of two storage containers 102, 104 joined end-to-end, with the intermediate walls thereof removed, to define a larger capacity container. When using these commercially available ROPAK brand containers, the end-to-end joining of two containers 102, 104 forms an inwardly extending V-shaped groove 122 facing outwardly at the seam between the containers 102, 104, located substantially in the middle of the assembly, along the height of the container on an outside portion of the side walls 112, 114 thereof.
The reinforced storage container assembly 100, in accordance with the first embodiment of the present invention, also includes a pair of outer reinforcing members 124, 126 (
The outer reinforcing members 124, 126 shown generally in
The cross-sectionally V-shaped stem portion 132 of the outer reinforcing member 124126 is disposed outside of the corresponding side wall 112, 114 in the V-shaped groove 122 which, as previously noted, is formed on an outside portion of the wall when the two storage containers are joined together. The free second end 138 of the V-shaped stem portion 132 is arranged close to the top edge of the corresponding side wall 112, 114, and the tip of the second end 138 is covered by a central area of a corresponding stiffening member 128 or 130, as shown.
Each outer reinforcing member 124, 126 is attached to its corresponding side wall 112, 114 above the folding line 113, 115 of the side wall, using fasteners such as nuts and bolts, which extend through holes (not shown) drilled in the side wall, and also through the holes 140 formed in the anchor plate.
Referring now to
Optionally, the reinforced storage container assembly 100 may include reinforcing braces 125, 127 (
The outer reinforcing members 124, 126 are particularly advantageous for reinforcing tall storage containers, e.g., containers having a height of 36 inches and above. It may be noted that the storage containers come in various sizes. The outer reinforcing member 124, 126 can be made in various lengths, as needed, according to the height and length of the containers needing reinforcement. The reinforcing of the side walls 112, 114 using outer reinforcing members 124, 126 to add strength and rigidity to the side walls 112, 114 is very important, particularly when the side walls 112, 114 are foldably collapsed (when container is empty) for returning the empty containers 100.
Referring now to
The composite storage container assembly 150 is formed by joining two storage containers end-to-end with the intermediate walls thereof removed, and includes a first storage container, a second storage container, a connector, and outer reinforcing members 124, 126 used in combination with the modified stiffening rails 158, 160. The modified stiffening members 158, 160 are designed to receive and securely restrain the second end 138 of the V-shaped stem portion 132 of the outer reinforcing member 124, 126, as shown in
The modified stiffening rails 158, 160 are substantially U-shaped in cross section, similar to that of the stiffening rails 128, 130 of the first embodiment. However, the modified stiffening member 158, 160 further include elongated side sections 162, 164 designed for securely holding the second end portion 138 of the V-shaped stem portion 132 of the outer reinforcing member 124, 126 beneath the elongated element as shown in
Additionally, the reinforced container may include reinforcing brace members 125, 127 installed on inner corner portions along the height of the container, similar to those shown in
As shown in
The V-shaped stem portion 132 of the outer reinforcing member 124, 126 is disposed on outer portions of the side walls 112, 114 in the V-shaped groove 122 between side walls, formed by joining two storage containers. The second end 138 of the stem portion 132 is secured by the reinforcing bar 168, 170 disposed on the outer portion of the side wall 112, 114. The first end 136, of the stem portion 132 of the outer reinforcement member, having a flat plate 134 attached thereto, is secured on the vertically intermediate portion above the folding line 115 of the side walls 112, 114 in a similar manner as discussed above in connection with the first embodiment.
Each reinforcing bar 168, 170 includes a longitudinal rod, which may be made of metal. The length and the shape of the reinforcing channels may be varied according to the container size and strengthening requirements. The reinforcing bar 168, 170 is generally fixed on to the outside portion of a side wall along a substantial length portion of a side walls 112, 114 at a vertically intermediate portion thereof, and disposed in a recessed channel formed on the side wall of the storage container 100 between integral reinforcing ribs of the wall. The reinforcing bars 168, 170 may be disposed at any vertically intermediate portion of the side walls above the folding line such that it does not interfere with the folding of side walls of collapsible storage container 100. The reinforcing bars 168, 170 are designed to reinforce their respective associated side walls, and to securely restrain a portion of the second end portion 138 of the V-shaped stem portion 132 of the outer reinforcing members 124, 126 installed on outer portion of the side walls.
In the embodiment of
In another aspect of the third embodiment, the reinforced storage container includes only reinforcing channels attached to the side walls of the storage container below and above the folding line of the respective side walls, and does not include outer reinforcing members.
Now referring to
Similar to that of the first and second embodiments, the outer reinforcing member 124, 126 is disposed in the V-shaped groove 122, formed between side walls on outside portion by joining two storage containers 102, 104 above the folding line 15 of side walls. The V-shaped stem having a second end portion 138 of 132 is secured by at least one of the stiffening rails 128, 130, modified stiffening member 158, 160, and reinforcing bars 168, 170, and the stem further includes a first end portion having flat attached thereto is further attached to the side walls 112, 114 using fastening hardware including nuts and bolts. When stiffening member 128, 130 are used to receive the second end portion of the stem therein, second end portion of the stem must be extended up to the very top edge of the side wall. When either modified stiffening member 158, 160 or reinforcing bars 168, 170 are used for receiving and securing the second end portion 138 of the stem portion 132 may be placed below the very top edge of the side wall 112, 114.
The inner reinforcement panels 174, 176 used for reinforcing side walls 112, 114 are generally disposed inside the storage container at an intermediate position below the folding line 115 and are flushed against portions of side walls 112, 114 and container floor 116 as generally shown in the
The inner reinforcement panels 174, 176 as seen in
The inner reinforcement panels 174, 176 are designed to receive portions of container floor 116 and portions of inner side walls 112, 114. It desirable to flush the inner reinforcement panel 174, 176 with the portions of side wall 112, 114 on the container floor 116 so that when folding the container it allows easy collapsing of the side walls 112, 114. Attachment bolts are placed through the plurality of the attachment holes 182 formed on vertical surface 178 of the inner reinforcement panel 174, 176 and then through the receiving holes formed therethrough side walls 112, 114. The attachment bolts extend beyond the outer surface of side wall for tightening the nuts for flushing the inner reinforcement panels against inside portions of side walls 112, 114 and container floor 116. The inner reinforcement panels 174, 176 may also include recesses concentrically formed about each attachment hole 182, thereby permitting head of the attachment bolts to be recessed flush with or beyond the vertical surface 178 of the corresponding inner reinforcement panel 174, 176. Alternatively, the inner reinforcement panel 174, 176 may not have any recesses formed thereon.
Although the present invention has been described herein with respect to specific embodiments thereof, the foregoing description is intended to be illustrative, and not restrictive. Many modifications may be made to the described embodiments without departing from the scope hereof. All such modifications, which fall within the scope of the appended claims, are intended to be within the scope and spirit of the present invention.
The present application claims priority under 35 U.S.C. 119(e) based on U.S. provisional patent application No. 60/705,852, filed Aug. 5, 2005.
Number | Date | Country | |
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60705852 | Aug 2005 | US |