U.S. patent application number 11/359241 was filed with the patent office on 2006-08-24 for reusable container.
Invention is credited to Russell G. Hall, William J. Skilliter, Kenneth R. Stojak.
Application Number | 20060186118 11/359241 |
Document ID | / |
Family ID | 36911579 |
Filed Date | 2006-08-24 |
United States Patent
Application |
20060186118 |
Kind Code |
A1 |
Stojak; Kenneth R. ; et
al. |
August 24, 2006 |
Reusable container
Abstract
A reusable container comprises a base comprising a pair of frame
members, a pair of end pieces and a center section, wherein the
base is provided with a plurality of tab slots, a lid provided with
a plurality of tab slots, and at least one wall comprising a
plurality of locking tabs formed as unitary extensions of the wall,
wherein the plurality of locking tabs engage the plurality of tab
slots, securing the to the base and to the lid. A back brace
carrier having at least one rib formed as a unitary extension of
the back brace carrier cooperates with a rib on the lid to
removably captivate a back brace. The back brace provides support
for the product. The walls may have a length and define a first
plane, and have unitary exterior ribs running along the length. The
walls also have unitary corner flanges formed at a right angle to
the first plane.
Inventors: |
Stojak; Kenneth R.; (Maumee,
OH) ; Hall; Russell G.; (Sylvania, OH) ;
Skilliter; William J.; (Curtice, OH) |
Correspondence
Address: |
Miller, Canfield, Paddock and Stone P.L.C.;c/o Robert Kelley Roth
Suite 2500
150 West Jefferson Ave
Detroit
MI
48226
US
|
Family ID: |
36911579 |
Appl. No.: |
11/359241 |
Filed: |
February 22, 2006 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60655942 |
Feb 24, 2005 |
|
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|
Current U.S.
Class: |
220/4.28 |
Current CPC
Class: |
B65D 2519/00029
20130101; B65D 2519/00661 20130101; B65D 2519/00497 20130101; B65D
2519/00562 20130101; B65D 2519/00203 20130101; B65D 2519/00422
20130101; B65D 2519/00711 20130101; B65D 9/12 20130101; Y02W 30/807
20150501; B65D 2519/00333 20130101; B65D 2519/00169 20130101; B65D
2519/00293 20130101; Y02W 30/80 20150501; B65D 2519/00064 20130101;
B65D 2519/00323 20130101; B65D 2519/00273 20130101; B65D 19/16
20130101; B65D 2519/00582 20130101; B65D 2519/00985 20130101 |
Class at
Publication: |
220/004.28 |
International
Class: |
B65D 6/16 20060101
B65D006/16 |
Claims
1. A reusable container for transporting a product comprising, in
combination: a base comprising a pair of frame members, a pair of
end pieces and a center section; a lid, comprising at least one lid
wall; and at least one wall having vertical ends, operatively
connecting the base to the lid, mounted generally perpendicular to
the base and to the lid in a first plane, the at least one wall
comprising at least one unitary exterior rib offset from the first
plane, and at least one unitary corner flange formed at about a
right angle to the first plane at one of the vertical ends.
2. The reusable container of claim 1 further comprising locking
tabs formed as unitary extensions of the at least one wall, and tab
slots formed in the base and in the lid, wherein the locking tabs
engage corresponding tab slots.
3. The reusable container of claim 2 wherein the tab slots are
formed on the end pieces and on the center section.
4. The reusable container of claim 1 wherein the base, lid and at
least one wall comprise a molded wood composite.
5. The reusable container of claim 1 comprising at least two walls,
both mounted to the base and to the lid, wherein the walls are
separate from one another.
6. The reusable container of claim 1 further comprising a plurality
of clips and corresponding clip slots positioned on the base, at
least one lid wall and at least one wall, wherein the clips
operatively engage the clip slots, connecting the lid wall to the
at least one wall and the base to the at least one wall.
7. The reusable container of claim 6 wherein the clip is formed
with an acute angle of about 87 degrees.
8. The reusable container of claim 1 wherein the center section has
a center pocket and unitary alignment flanges which cooperate to
align the center section over the frame members.
9. The reusable container of claim 1 wherein the end pieces each
have a trough defining an alignment flange which cooperates with a
unitary alignment flange to align the end pieces over the frame
members.
10. The reusable container of claim 1 further comprising two lid
walls, each having a channel adapted to be wide enough to receive a
corresponding frame member.
11. The reusable container of claim 1 further comprising four
walls, wherein the walls are essentially identical.
12. The reusable container of claim 1 wherein the at least one wall
has a length and the unitary exterior rib runs the length of the at
least one wall.
13. The reusable container of claim 12 wherein the at least one
wall further comprises a channel running less than the length of
the at least one wall.
14. A reusable container for transporting a product comprising, in
combination: a base comprising a pair of frame members, a pair of
end pieces and a center section, wherein the base is provided with
a plurality of tab slots; a lid provided with a plurality of tab
slots and comprising at least one lid wall; and at least one wall
comprising a plurality of locking tabs formed as unitary extensions
of the wall, wherein the plurality of locking tabs engage the
plurality of tab slots, securing the at least one wall to the base
and to the lid.
15. The reusable container of claim 14 further comprising a
plurality of clips and corresponding clip slots positioned on the
base, at least one lid wall and at least one wall, wherein the
clips operatively engage the clip slots, connecting the lid wall to
the at least one wall and the base to the at least one wall.
16. A reusable container for transporting a product comprising, in
combination: a base comprising a pair of frame members, a pair of
end pieces and a center section; a lid comprising a pair of lid
walls, each lid wall comprising at least one rib formed as a
unitary extension of the corresponding lid wall; four walls
operatively connecting the base and the lid; a back brace carrier
having at least one rib formed as a unitary extension of the back
brace carrier a back brace, adapted to be removably captivated
between the at least one rib on the lid and the at least one rib on
the back brace carrier and to provide a support for the
product.
17. The reusable container of claim 16 wherein the back brace
carrier and back brace comprise a molded wood composite.
18. The reusable container of claim 16 wherein the back brace
carrier is formed separate from the base.
19. The reusable container of claim 18 wherein the center section
defines a center pocket and the back brace carrier has a pocket
which nests in the center pocket.
20. The reusable container of claim 16 further comprising banding
holes formed in the wall, the back brace, back brace carrier and
center section adapted to receive banding to secure the product
against the back brace.
Description
RELATED APPLICATION
[0001] This application claims priority benefit of U.S. provisional
patent application No. 60/655,942 filed on Feb. 24, 2005.
FIELD OF THE INVENTION
[0002] This invention relates to improvements in packaging and
shipping containers, and more particularly to improved returnable
and reusable containers.
BACKGROUND OF THE INVENTION
[0003] Containers can be made of a wide variety of materials,
depending upon the design requirements of the container. For
example, containers made only of wood are relatively durable and
are capable of carrying relatively heavy loads. However, the cost
of the wood material and the labor for initial assembly may be
quite high. Multiple re-uses of wood containers are possible, but
such known containers are not easily collapsible for return
transport. Thus, relatively large amounts of space are required for
return transport of such containers.
[0004] It is known to manufacture containers of corrugated
material, e.g., corrugated cardboard or a combination of corrugated
materials and wood. For example, U.S. Pat. No. 5,174,448 discloses
a wood pallet with recyclable cardboard side walls. Such containers
are limited in strength and in carrying capacity. Further, where
re-use of containers is desired, as is the case with returnable
packaging, known containers will withstand only limited re-use.
Also, while some known containers may be collapsed to allow for
compact return transportation, much work is needed to reconstruct
the container for re-use.
[0005] It would be desirable to provide a reusable container for
transporting heavy, yet fragile materials which is structurally
robust yet relatively low in cost, and easy to assemble and
disassemble.
SUMMARY OF THE INVENTION
[0006] In accordance with a first aspect, a reusable container
comprises a base comprising a pair of frame members, a pair of end
pieces and a center section, wherein the base is provided with a
plurality of tab slots, a lid provided with a plurality of tab
slots, and at least one wall comprising a plurality of locking tabs
formed as unitary extensions of the wall, wherein the plurality of
locking tabs engage the plurality of tab slots, securing the to the
base and to the lid. In accordance with another aspect, a back
brace carrier having at least one rib formed as a unitary extension
of the back brace carrier cooperates with a rib on the lid to
removably captivate a back brace. The back brace provides support
for the product. In accordance with another aspect, the walls may
have a length and define a first plane, and have unitary exterior
ribs running along the length. The walls also have unitary corner
flanges formed at a right angle to the first plane.
[0007] From the foregoing disclosure and the following more
detailed description of various preferred embodiments it will be
apparent to those skilled in the art that the present invention
provides a significant advance in the technology of returnable
containers. Particularly significant in this regard is the
potential the invention affords for providing a high quality, low
cost returnable container. Additional features and advantages of
various preferred embodiments will be better understood in view of
the detailed description provided below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a perspective view of a container suitable for
re-use in accordance with a preferred embodiment containing
windshields.
[0009] FIG. 2 is an exploded perspective view showing the base, end
pieces, central section and of the preferred embodiment of FIG.
1.
[0010] FIG. 3 is an isolated perspective view of the back brace in
accordance with a preferred embodiment.
[0011] FIG. 4 is an isolated perspective view of a clip in
accordance with a preferred embodiment.
[0012] FIG. 5 is an isolated perspective view of an end wall in
accordance with a preferred embodiment.
[0013] FIG. 6 is an isolated perspective view of a side wall in
accordance with a preferred embodiment.
[0014] FIGS. 7-8 are isolated perspective top and underside views,
respectively, of a pair of lid walls in accordance with a preferred
embodiment.
[0015] FIG. 9 is a side view of the end wall to end piece
connection, showing an optional end cap covering an opening to a
pallet trough.
[0016] FIG. 10 is a close up perspective view of the side wall to
lid connection.
[0017] It should be understood that the appended drawings are not
necessarily to scale, presenting a somewhat simplified
representation of various preferred features illustrative of the
basic principles of the invention. The specific design features of
the returnable container as disclosed here will be determined in
part by the particular intended application and use environment.
Certain features of the illustrated embodiments have been enlarged
or distorted relative to others to enhance visualization and clear
understanding. In particular, thin features may be thickened, for
example, for clarity of illustration. All references to direction
and position, unless otherwise indicated, refer to the orientation
illustrated in the drawings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0018] It will be apparent to those skilled in the art, that is, to
those who have knowledge or experience in this area of technology,
that many uses and design variations are possible for the reusable
container disclosed here. The following detailed discussion of
various alternative and preferred features and embodiments will
illustrate the general principles of the invention with reference
to a reusable container particularly suitable for use with window
fixtures, such as windshields, rear windows and other glass sheets.
Other embodiments suitable for other applications will be apparent
to those skilled in the art given the benefit of this
disclosure.
[0019] Referring now to the drawings, FIG. 1 shows a perspective,
assembled view of a reusable container or crate 10 suitable for
carrying a product such as windshields 54. The container 10 has a
base or pallet 20, side walls 90, 91, end walls, 80, 81 mounted
generally perpendicular to the base, and a lid comprising lid walls
100, 101 mounted generally perpendicular to the side walls and end
walls. A back brace 70 supports the product and extends between the
lid walls and the pallet 20 directly. Alternatively, as shown in
the Figs., the back brace 70 is mounted on a back brace carrier 60
sitting on the pallet center section 30. Banding 52 wraps around
the product 54 and is threaded through openings 95 in the side
walls 90, 91, and down through the back brace carrier 60 and pallet
20. The banding 52 is used to hold the product in place during
transport. Clips 50 secure the base to each of the side walls 90,
91 and end walls 80, 81, and secure the lid walls 100, 101 to the
side walls and end walls. The base 20 is preferably provided with
side channels 26, 27 for receiving a forklift.
[0020] Preferably the base 20, walls 80, 81, 90, 91, back brace 70,
back brace carrier and lid walls 100, 101 all comprise a wood
composite material formed by a molding process. This is highly
advantageous as it allows for reinforcing ribs 96, columns 97,
flanges 84, 85 and similar structural features to be incorporated
as unitary (one-piece) extensions of the components, greatly
enhancing the strength, column loading, and durability of the
container 10. "Wood composite" material, as the term is used
herein, may be described as being made from wood materials,
primarily in the form of particles, flakes and/or fibers, combined
with a resin, typically a thermoset resin, and bonded at an
elevated temperature and elevated pressure, typically in a heated
pressing device. Wood composite products advantageously use waste
products from other processes, thus creating an environmental
benefit. Wood composite materials are also resistant to insect
infestation. Recent concern with international shipment of goods in
containers made of materials which may harbor insects makes use of
materials such as wood composite material particularly desirable.
The wood used in the some known current packaging must be heat
treated and is not accepted by some countries. Wood composite
materials may be as strong, or stronger than wood, are in most
cases, cost competitive with wood and may also be more
dimensionally stable and moisture resistant than wood. The wood
composite crate shown should have four to five times the life of
known conventional corrugated board crate designs used for
returnable packaging.
[0021] FIG. 2 shows the various components of the pallet/base 20,
along with back brace carrier 60 in accordance with the preferred
embodiment of FIG. 1. Two generally elongate frame members 23, 24
are shown, each defining a respective trough 21, 22 and each having
corresponding channels 26, 27 for receiving a forklift. Mounted at
ends of the frame members are end pieces 40, 41. Each end piece has
a trough 44 forming alignment flanges 43 which cooperate with
alignment flanges 42 to position the end pieces over the frame
members 23, 24. Clip slots 34 are provided to receive clips
connecting the end walls 80, 81 to the pallet, and tab slots 32 are
provided to receive unitary tabs 92 extending from the end walls.
The end walls may be bonded to the frame members with an
adhesive.
[0022] Also bonded to the frame members 23, 24 is a center section
30. Center section 30 has a central pocket 37 and downwardly
extending flanges 39 which cooperate to align the center section
over the frame members 23, 24 in much the same way as trough 44 and
flanges 42 cooperate to align the end pieces 40, 41 over the frame
members. Center section 30 is also provided with a plurality of
openings and slots: tab slots 32 adapted to receive tabs 92 on side
walls 90, 91; clip slots 34 adapted to receive clips 50 connecting
side walls 90, 91 to base 20; and banding holes 35, 36 adapted to
receive banding 52 to wrap around the product.
[0023] In the preferred embodiment shown in FIG. 2, the pallet 20
is formed from the frame members 23, 24, end pieces, 40, 41, and
center section 30. During assembly and disassembly, these
components, having been glued together, would preferably stay
together as one piece. Positioned on top of the center section is
the back brace carrier 60. Back brace carrier 60 is preferably
removable during disassembly. Carrier 60 has a pocket 65 which
snugly nests in central pocket 37 of the center section 30, and has
a series of ribs 64 which cooperate with ribs 109 of the lid, shown
in FIG. 8 to support the back brace 70, shown in FIG. 3. Banding 52
is threaded through banding holes and notches 66, 67, which are
aligned with banding holes 35, 36, respectively, in the center
section 30. The product is typically positioned on runners 62,
which may optionally be provided with foam padding or other
cushioning material to help reduce the likelihood of damage to the
product as it is shipped.
[0024] The back brace 70, shown in FIG. 3, is designed to provide a
wall to rest the product against. Back brace 70 preferably has a
pair of reinforcing ribs 72 running along its length, and banding
holes 36 to receive banding. A second pair of banding holes 36 can
be provided. Even though banding would normally only be routed
through one pair of holes, a symmetrical design allows for easier
assembly.
[0025] In accordance with a highly advantageous feature, clips 50
are used to connect the pallet 20 to the side walls 90, 91 and end
walls 80, 81, and to connect the side walls and end walls to the
lid walls 100, 101. The clips 50 are simple to install, greatly
reduce assembly and disassembly times, and remove the need for
exterior banding, nails, or other difficult to remove fasteners.
The clips 50 are inserted into clip slots 34, one each on two
different components to secure the components together. FIG. 4
shows a preferred fastener (clip 50) which secures the position of
each of the walls 80, 81, 90, 91 to the base 20 and secures the lid
walls 100, 101 of the crate 10 to the walls 80, 81, 90, 91. Clips
50 are preferably made of a flexible metal material having certain
spring-like qualities to allow such fasteners to lock into slots 34
formed into the wood composite material. Preferably, the clips 50
are formed as shown having an L-shaped clip-type fastener of a
heavy gauge metal wire. Most preferably the angle .alpha. formed by
the clip is slightly acute, e.g., about 87 degrees, so that some
resilient force is brought to bear on the two components which are
fastened together.
[0026] FIG. 5 shows an end wall 81 and FIG. 6 shows a side wall 90.
Preferably both walls are mounted in a plane 96 generally
perpendicular to the base 20 and to the lid walls 100, 101.
Optionally, the end walls and side walls may be essentially
identical. This helps simplify assembly and disassembly of the
container 10 and reduces the possibility for improper assembly. The
walls each have tabs 92 which are adapted to fit into tab slots 32
formed on the base (at end pieces 40, 41 and center section 30) and
on the lid walls 100, 101 (shown in FIGS. 7-8). Unitary tabs 92,
formed as a one-piece extension of the walls, hold the walls
together with the lid and base, allowing for the clips 50 to be
installed. The walls as shown also have unitary exterior ribs 96
running the length of the walls 81, 90, and also have unitary
exterior channels 97 which are shaped similar to the ribs except
that the channels do not run the entire length of the wall. Ribs 96
and channels 97 are offset from the rest of the wall such that they
are still perpendicular to the base, but are in a second plane 57
offset from a first plane 56 of the wall. These ribs 96 and
channels 97 advantageously cooperate to increase the strength of
the walls. The vertically ribbed configuration provides
substantially greater strength than a flat panel. The specific
dimensions of the ribs 96 are optimized prior to molding to provide
the desired bearing strength. The placement of, and the curved
shape of, the reinforcing channels 97 are designed to optimize the
strength of the base component to provide a desired load capacity
for the base component. It has been found that the curved shapes of
the reinforcing channels 97, rather than square or rectilinear
shapes, provide greater strength per unit area.
[0027] In the embodiment shown in the drawings, the walls are
generally planar, with each wall 81, 90 having a corresponding
width 181, 190, and a length 281, 290, respectively. However, the
ribs, channels and flanges define an irregular, non-planar cross
section. This is highly advantageous in that it increases the
strength and durability of the components of the container. For
example, unitary corner flanges 84, 85 are provided generally at a
right angle to the width of the corresponding wall at vertical ends
98, 99 of the walls. Such corner flanges help increase the stacking
strength of the walls. Known reusable packaging requires separate
reinforcing members to increase stacking strength.
[0028] Preferably the walls 80, 81, 90, 91 do not connect with each
other to close off the sides of the crate 10. This advantageously
allows the product to be visible, reducing the likelihood concealed
product damage. This is considered especially desirable where the
product is relatively fragile, as is the case with glass. Other
wall geometries will be readily apparent to those skilled in the
art, given the benefit of this disclosure. For example, instead of
four walls, a single cylindrical or semi-cylindrical shaped wall
can be used.
[0029] FIGS. 7 and 8 show the lid walls 100, 101. Preferably the
lid walls are essentially identical, as with the side walls and end
walls, again helping to make assembly and disassembly easier.
Providing lid walls 100, 101 having the same dimensions avoids the
problems of maintaining adequate supplies of different size panels
at locations where the containers are assembled or may be
re-assembled. Initial manufacturing costs may also be reduced. Each
wall 100, 101 is provided with a series of ribs 109 which cooperate
with ribs 64 on the back brace carrier 60 to mount the back brace
70. Tab slots 32 on the receive tabs 92 from the walls 80, 81, 90,
91 and clip slots 34 receive clips from the end walls. Banding
holes 36 are again provided, including redundant banding holes on
the lid wall not contacting the back brace.
[0030] In accordance with a highly advantageous feature, the
reusable containers may be stacked together. As discussed above,
the walls are sufficiently structurally robust to allow for
stacking. Elongate channels 108 on the lids are provided to receive
the bottom of frame members 23, 24 of a container immediately
above.
[0031] Advantageously, returnable and reusable containers or crates
10 disclosed herein "knock-down" into a relatively flat, compact
shape, allowing for more crates to be placed on, for example, a
truck or railroad car, for ease of return and storage. The crate 10
also significantly increases the amount of crates that can be
returned in a truck trailer, by as much as a 9 to 1 ratio over
current returnable containers packaging.
[0032] FIG. 9 shows a side view showing the connection of the clip
50 between the end wall 80 and the end piece 40. An end piece cover
45 covers trough 21 on frame member 23. A small opening 53 allows
the clip to extend to the clip slot on end piece 40 (not shown) and
the other end of the clip engages the end wall 80 at clip slot 34.
Trough 44 defines alignment flange 43, which cooperates with 42 to
align the end piece 40 with respect to the frame member 23. FIG. 10
shows a similar connection between the lid wall 101 and end wall
80. Clip 50 is preferably positioned generally adjacent corner
flange 84 and remote from vertical channel 97.
[0033] From the foregoing disclosure and detailed description of
certain preferred embodiments, it will be apparent that various
modifications, additions and other alternative embodiments are
possible without departing from the true scope and spirit of the
invention. The embodiments discussed were chosen and described to
provide the best illustration of the principles of the invention
and its practical application to thereby enable one of ordinary
skill in the art to use the invention in various embodiments and
with various modifications as are suited to the particular use
contemplated. All such modifications and variations are within the
scope of the invention as determined by the appended claims when
interpreted in accordance with the breadth to which they are
fairly, legally, and equitably entitled.
* * * * *