Receptacles – Sectional – Folding
Reexamination Certificate
1999-12-16
2001-01-09
Sewell, Paul T. (Department: 3728)
Receptacles
Sectional
Folding
C220S001500, C220S004310, C220S004330, C220S006000, C220S605000, C206S508000, C206S509000, C206S511000, C206S512000, C229S122240
Reexamination Certificate
active
06170689
ABSTRACT:
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention is directed to a collapsible container of the type that is maneuvered using a fork lift.
2. Related Art
Conventional storage and shipping containers consist of a wooden pallet upon which rests a corrugated cardboard box. Typically, the cardboard box component of such conventional containers is disposed of after a single use. This occurs for many reasons. First, if access to an item within such a box is required when the box is either stacked or stored on a shelf, the box is typically cut with a razor knife, which ruins the structural integrity of the box (and often ruins the item(s) within the box). Second, such cardboard boxes are not easily collapsed and are therefore inefficient to transport when empty. Further, even if they can be collapsed, when the cardboard boxes are large, as they typically are, they are awkward to handle in their collapsed position.
There have been various attempts to provide improved collapsible containers. However, the collapsible containers in the prior art are often difficult to collapse, and even more difficult to change from a collapsed position to all open (i.e., non-collapsed) position. Furthermore, the collapsible containers in the prior art typically include internal reinforcement structures that reduce the storage volume of the container. Additionally, the prior art collapsible containers often include removable parts that can be easily lost, rendering the containers useless. Other shortcomings of prior art collapsible containers are that they can be heavy, difficult and/or expensive to manufacture, and can include internal projections that can damage the item(s) stored within the containers.
What is needed is a collapsible container that is easy to collapse and easy to open from the collapsed position. The collapsible container should also be relatively easy and inexpensive to manufacture. Further, there is a need for a collapsible container that does not have removable components that can be lost. Additionally, the collapsible container should include no internal projections that can damage stored items. Still further, the collapsible container should be able to be easily and efficiently transported when collapsed.
SUMMARY OF THE INVENTION
The present invention is a collapsible container. The container includes a substantially rectangular plastic base, a first plastic wall coupled by a first hinge to a first edge of the base, and a second plastic wall coupled by a second hinge to a second edge of the base that is opposite the first edge of the base. The container also includes a first corrugated element folded to form a first corrugated floor portion and a first corrugated wall portion. The first corrugated floor portion is attached to the base so that the first corrugated wall portion is positioned between and adjacent to the first and second plastic walls. The first corrugated wall portion mates with a first lip of the first plastic wall and a first lip of the second plastic wall. A second corrugated element is folded to form a second corrugated floor portion and a second corrugated wall portion. The second corrugated floor portion is attached to the base such that the second corrugated wall portion is positioned between and adjacent to the first and second plastic walls and is opposite the first corrugated wall portion. The second corrugated wall portion mates with a second lip of the first plastic wall and a second lip of the second plastic wall.
When the container is in a collapsed position, the first and second corrugated wall portions are folded in towards the base, and the first and second plastic walls are folded in toward the base and over the folded-in first and second corrugated wall portions.
In one embodiment, the first corrugated element and the second corrugated element are formed from a single sheet of corrugated material, which can be made of, for example, plastic or cardboard. In such an embodiment, the first corrugated floor portion and the second corrugated floor portion are contiguous.
In an alternative embodiment, the first corrugated element and the second corrugated element are formed from separate sheets of corrugated material. The first corrugated floor portion in this embodiment is adjacent to the second corrugated floor portion. Further, in this embodiment, preferably the first corrugated element and the second corrugated element are substantially identical and thus interchangeable.
In one embodiment the first and second corrugated elements are attached to the plastic base by one or more plastic rivets.
In one embodiment, the plastic base, the first plastic wall, and the second plastic wall are manufactured from a single sheet of material. In this embodiment the first and second hinges are integrally formed, flexible, living hinges. Further, in this embodiment the plastic base and the first and second plastic walls are preferably thermoformed.
In a preferred embodiment, each of the first and second plastic walls includes a slot in each distal corner. A lever is pivotally attached to each distal corner of the corrugated wall portions, such that each lever can pivotally engage a corresponding slot in one of the plastic walls. When the levers engage the slots they secure the corrugated wall portions to that adjacent plastic walls.
The collapsible container preferably includes a removable lid that can rest along an outer peripheral edge of the opened container. The removable lid can also cover the container in the collapsed position. Importantly, if one or more lid covered containers in the collapsed position are stored outside, the lids keep the corrugated elements dry.
In one embodiment, where the lid includes ribs to increase its strength and rigidity, an outer rib can form a well on an upper surface of the lid. One or more drain holes can be formed in the well to allow rain water to drain out of the well in situations where the container is stored outside in the collapsed position. This will keep the corrugated elements from getting wet. In one embodiment, a surface of the well is slightly slanted to ensure that rain water drains through the drain hole(s).
In a preferred embodiment, the first plastic wall includes a first pair of bumps, one near each corner proximal to the first hinge, and the second plastic wall includes a second pair of bumps, one near each corner proximal to the second hinge. When the container is in the open position, the first and second pairs of bumps protrude in a direction outward from an interior of the container. When the container is in the collapsed position, the first pair of bumps and the second pair of bumps extend in a direction outward from an inner surface of the base. This allows four detents in an underside of a removable lid (the detents substantially align with the first and second pair of bumps) to rest, at least partially, over the first and second pair of bumps when the container is in the collapsed position. In this embodiment, the second pair of bumps preferably extend a greater distance from the second plastic wall than the first pair of bumps extend from the first plastic wall so that the second pair of bumps and the first pair of bumps are substantially planer when the container is in the closed position and the second plastic wall is folded in prior to the first plastic wall.
An advantage of the present invention is that the collapsible container is easy to collapse and easy to open from the collapsed position.
Another advantage of the present invention is that the collapsible container is easy and inexpensive to manufacture and can be manufactured from a minimal amount of materials.
Another advantage of the present invention is that the container can be made as strong, rigid and reusable as desired by increasing the thickness of the plastic base and walls and/or the corrugated elements.
A further advantage of the present invention is that the collapsible container has no (or minimal) removable components that can be lost.
Yet another advantage of the present invention is that the collapsible c
Barnes Kevin J.
Flesher Robert W.
Monteleone Michael
Apogee Designs, Ltd.
Arnold Troy
Sewell Paul T.
Sterne Kessler Goldstein & Fox P.L.L.C.
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