U.S. patent application number 11/032617 was filed with the patent office on 2005-07-14 for collapsible storage bin with attached lower pallet-like support.
Invention is credited to Carter, Alan T..
Application Number | 20050150812 11/032617 |
Document ID | / |
Family ID | 34742504 |
Filed Date | 2005-07-14 |
United States Patent
Application |
20050150812 |
Kind Code |
A1 |
Carter, Alan T. |
July 14, 2005 |
Collapsible storage bin with attached lower pallet-like support
Abstract
A collapsible bin for the storage and transport of goods, which
includes a collapsible sidewall structure and upper and lower
pallet-like supports. A securing structure secures the sidewall
structure to the lower pallet-like support while permitting the
sidewall structure to be placed in either a collapsed or
non-collapsed state. The first and second pallet-like supports each
include a base and a border that projects out from and runs along
an edge of the respective base. A portion of the border located at
each corner of the base of each pallet-like support is notched out,
allowing the first and second pallet-like supports to cooperate
with and nest within each other when the storage bin is placed in a
collapsed state.
Inventors: |
Carter, Alan T.; (Sturgis,
MI) |
Correspondence
Address: |
FLYNN THIEL BOUTELL & TANIS, P.C.
2026 RAMBLING ROAD
KALAMAZOO
MI
49008-1699
US
|
Family ID: |
34742504 |
Appl. No.: |
11/032617 |
Filed: |
January 10, 2005 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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60534868 |
Jan 8, 2004 |
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Current U.S.
Class: |
206/600 |
Current CPC
Class: |
B65D 11/1893 20130101;
B65D 11/1846 20130101 |
Class at
Publication: |
206/600 |
International
Class: |
B65D 019/00 |
Claims
What is claimed is:
1. A storage bin comprising: a sidewall structure including a pair
of sheet-like sidewalls joined together by a pair of sheet-like end
walls, said end and sidewalls having vertical edges joined together
along a fold which permits relative horizontal swinging movement
between the adjacent end and sidewalls to permit collapsing of said
sidewall structure, said sidewall structure when in a non-collapsed
condition defining a vertically extending opening therethrough; a
top pallet-like member removably engaged with an upper edge of said
sidewall structure to close off an upper end of said opening; a
bottom pallet-like member engaged with a lower edge of said
sidewall structure to close off a lower portion of said opening,
said bottom member having a base portion and a flange which is
joined to and extends upwardly from a peripheral edge portion of
said base portion in transverse relation thereto, said base and
said flange together defining an opening within said bottom member
which opens upwardly; and a securing member fixedly securing said
sidewall structure to said bottom member to prevent detachment
therefrom, said securing member being configured to permit
collapsing of said sidewall structure and folding of said collapsed
sidewall structure into said bottom member such that said sidewall
structure is disposed within said opening of said bottom member and
surrounded by said flange thereof.
2. The storage bin of claim 1, wherein said top member has a base
portion and a flange which is joined to and extends downwardly from
a peripheral edge portion of said base portion in transverse
relation thereto, said flanges of said top and bottom members being
configured to nest with one another with said collapsed sidewall
structure disposed therebetween.
3. The storage bin of claim 1, wherein said securing member
includes a first generally planar portion which is fixed to one of
said sidewalls in superimposed relation therewith, and a second
generally planar portion which is fixed to said bottom member in
superimposed relation therewith.
4. The storage bin of claim 3, wherein said securing structure
includes a third portion disposed between said first and second
portions and joined thereto by respective parallel fold lines which
define respective hinges of said securing member.
5. The storage bin of claim 4, wherein said first portion is fixed
to and superimposed upon an inner surface of said one sidewall, and
said second portion is fixed to and superimposed upon an upper
surface of said base portion of said bottom member.
6. The storage bin of claim 1, wherein said top member has a base
portion and a flange which is joined to and extends downwardly from
a peripheral edge portion of said base portion in transverse
relation thereto, said top and bottom members being generally
rectangular in shape and said flanges of said top and bottom
members each defining a plurality of corner regions, said corner
regions of said top member being disposed in vertical alignment
with the respective corner regions of said bottom member, each said
corner region defining a notch therein which opens outwardly
towards a free edge of the respective flange, said notches of the
respective flanges permitting nesting of said top and bottom
members with one another in a storage configuration of said storage
bin when said sidewall structure is collapsed and folded onto said
bottom member.
7. The storage bin of claim 1, wherein said securing member is a
separate component from said sidewall structure.
8. The storage bin of claim 6, wherein said top and bottom members
each have a width and a length dimension, said width dimension
being defined between a first pair of opposed parallel portions of
the corresponding said flange and said length dimension being
defined between a second pair of opposed parallel portions of the
corresponding said flange, said width and length dimensions of said
top member being identical to the respective width and length
dimensions of said bottom member.
9. A collapsible storage bin comprising: top and bottom pallet
members each having a generally planar and rectangular base portion
and a lip which extends transversely with respect to said base
portion about a peripheral edge thereof and terminates in a free
edge, said base portion and said lip of each said pallet member
together defining a compartment which opens outwardly towards the
other said pallet member; a collapsible and generally tubular and
open-ended sidewall member disposed between said top and bottom
pallet members inwardly of said lips thereof, said sidewall member
being defined by a pair of generally parallel and laterally spaced
sidewalls and a pair of generally parallel and laterally spaced end
walls which extend transversely between and interconnect the
respective sidewalls to one another, said end walls each having a
pair of vertical edges which are hingedly joined to respective
vertical edges of said sidewalls, each said end wall defining
therein a vertical hinge disposed between said vertical edges of
said end wall to permit folding of said end walls inwardly and into
superimposed relation with the respective sidewalls to define a
collapsed and generally flat configuration of said sidewall member
which is dimensioned to fit entirely within said compartment of
said bottom pallet member; and a securing element hingedly joined
to one of said sidewalls and hingedly joined to said base member of
said bottom pallet member to prevent detachment of said sidewall
member from said bottom pallet member while allowing collapsing of
said sidewall member; said lips of said top and bottom pallets
defining notches therein which open through said free edges thereof
adjacent corners of the respective top and bottom pallets, said
notches permitting nesting of said top and bottom pallets with one
another in a collapsed configuration of said storage bin wherein
said sidewall member is enclosed between said top and bottom
pallets.
10. The collapsible storage bin of claim 9, wherein said base
portion of said top pallet has width and length dimensions which
are identical to respective width and length dimensions of said
base portion of said bottom pallet.
11. A collapsible storage bin comprising: a collapsible sidewall
structure which, when in a non-collapsed state, is of a generally
rectangular shape and defines a generally vertically extending
opening therethrough, said sidewall structure including a pair of
substantially parallel and sheet-like sidewalls joined together by
a pair of substantially parallel sheet-like end walls, said end and
sidewalls having adjacent vertical edges joined together along a
fold which permits relative horizontal swinging movement between
the adjacent end and sidewalls to permit collapsing of said
sidewall structure; a first pallet-like member engaged with an
upper terminal edge of said sidewall structure, said first member
including a generally rectangular base and a border which projects
transversely outwardly from and extends along a peripheral edge of
said base, a portion of said border disposed adjacent each corner
of said base being recessed inwardly to define a notch; and a
second pallet-like member engaged with a lower edge of said
sidewall structure, said second member including a generally
rectangular base and a border which projects transversely outwardly
from and extends along a peripheral edge of said base, a portion of
said border of said second member disposed adjacent each corner of
said base of said second member being recessed inwardly to define a
notch, said notches of said first and second members allowing
cooperative nesting of said first and second supports with one
another while containing therein the collapsed sidewall
structure.
12. The storage bin of claim 11, wherein said border of each said
first and second member includes a border portion defined between
each pair of adjacent notches, and at least one border portion of
each said first and second member is disposed exteriorly of and in
superimposed relation with an adjacent border portion of the
opposite member when said first and second members are nested with
one another.
13. The storage bin of claim 11, further including a sheet-like
securing member which interconnects said sidewall structure to said
second member to prevent detachment therefrom.
14. The storage bin of claim 11, wherein said borders of said first
and second members terminate in respective free edges, said notches
opening through said free edges.
15. The storage bin of claim 11, wherein said bases of the
respective first and second members have identical width and length
dimensions.
16. The storage bin of claim 16, wherein each said border includes
a border portion defined between two neighboring notches, two
adjacent border portions of said first member being disposed
exteriorly of and in superimposed relation with two adjacent border
portions of said second member in a nested configuration of said
first and second members.
17. The storage bin of claim 11, wherein each said end wall defines
a vertical hinge therein between said vertical edges thereof which
permits inward folding of the respective end walls to allow
collapsing of said sidewall member.
18. The storage bin of claim 13, wherein said securing member
includes a first generally planar portion which is fixedly secured
to an interior surface of one of said sidewalls and a second
generally planar portion which is fixedly secured to an upper
surface of said base of said second member.
19. The storage bin of claim 18, wherein said securing member
includes a third portion disposed between and interconnecting said
first and second portions, said third porting being joined to said
first and second portions through respective parallel fold lines
which define respective hinges of said securing member.
20. The storage bin of claim 19, wherein said securing member is a
separate component from said sidewall structure and is attached to
said one sidewall and said base by a fastening arrangement.
Description
CROSS-REFERENCE TO PRIOR APPLICATION
[0001] This application claims priority under 35 USC .sctn.119(e)
of copending provisional application Ser. No. 60/534,868 filed Jan.
8, 2004, the entire disclosure of which is herein incorporated by
reference.
FIELD OF THE INVENTION
[0002] 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
[0003] 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.
[0004] 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.
[0005] 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.
[0006] 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.
[0007] 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.
[0008] 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
[0009] FIG. 1 depicts a perspective view of a traditional
collapsible storage bin having removable upper and lower
pallet-like supports.
[0010] FIG. 2 depicts a perspective view of a traditional sidewall
structure in a partially collapsed state.
[0011] FIG. 3 depicts a vertical cross-sectional view of a
traditional storage bin having box-like upper and lower pallet-like
supports.
[0012] FIG. 4 is a top view of a traditional six-fold sidewall
structure of a collapsible storage bin.
[0013] FIG. 5 depicts an end view of the sidewall structure of FIG.
4 in a collapsed state.
[0014] 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.
[0015] FIG. 7 depicts a perspective view of the storage bin
according to the invention in a use configuration.
[0016] FIG. 8 depicts a top view of the securing structure in
isolation.
[0017] FIG. 9 depicts a vertical cross-sectional view of the
storage bin.
[0018] 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.
[0019] 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.
[0020] 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.
[0021] FIG. 13 depicts a perspective view of one of the pallet-like
supports in isolation.
[0022] FIG. 14 depicts an enlarged, fragmentary perspective view of
one corner of the storage bin in a fully collapsed state.
[0023] FIG. 15 is an enlarged fragmentary end view of the storage
bin in a collapsed state.
[0024] FIG. 16 depicts a top view of a sidewall structure
illustrating a preferred hinge arrangement.
[0025] FIG. 17 depicts a perspective view of a storage bin
according to a preferred embodiment.
[0026] 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
[0027] 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.
[0028] 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.
[0029] 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.
[0030] 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.
[0031] 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.
[0032] 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.
[0033] 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.
[0034] 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.
[0035] 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.
[0036] 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.
[0037] 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.
[0038] 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.
[0039] 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.
[0040] 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.
[0041] 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.
[0042] 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".
[0043] 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.
[0044] 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.
[0045] 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.
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