U.S. patent application number 12/575775 was filed with the patent office on 2010-01-28 for collapsible containers.
This patent application is currently assigned to You Crate LLC. Invention is credited to Jeff Banion, Greg Bronner, Dave Cox, Ralph L. Roberts, II, Roby L. Roberts, Ralph L. Roberts, SR..
Application Number | 20100018966 12/575775 |
Document ID | / |
Family ID | 41567709 |
Filed Date | 2010-01-28 |
United States Patent
Application |
20100018966 |
Kind Code |
A1 |
Roberts, SR.; Ralph L. ; et
al. |
January 28, 2010 |
Collapsible Containers
Abstract
Collapsible containers dimensioned to integrate into motor
carrier operations are provided. The container may include a base,
a pair of first and second opposing walls, each first and second
opposing wall including a top edge, two side edges and a bottom
edge. The container further includes a top panel removably attached
to the top edge of the pairs of first and second opposing walls and
a plurality of engaging devices positioned along the perimeter of
the top panel and base and along the two side edges and top and
bottom edges of the pairs of first and second opposing walls. The
plurality of engaging devices are configured to removably connect
the pair of first opposing walls to the pair of second opposing
walls and to removably connect the pairs of first and second
opposing walls to the top panel and base.
Inventors: |
Roberts, SR.; Ralph L.;
(Reddick, FL) ; Roberts, II; Ralph L.;
(Wilmington, OH) ; Roberts; Roby L.; (Captiva,
FL) ; Banion; Jeff; (South Charleston, OH) ;
Cox; Dave; (Wilmington, OH) ; Bronner; Greg;
(Sabina, OH) |
Correspondence
Address: |
DINSMORE & SHOHL LLP
1900 CHEMED CENTER, 255 EAST FIFTH STREET
CINCINNATI
OH
45202
US
|
Assignee: |
You Crate LLC
Wilmington
OH
|
Family ID: |
41567709 |
Appl. No.: |
12/575775 |
Filed: |
October 8, 2009 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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12136401 |
Jun 10, 2008 |
|
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12575775 |
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Current U.S.
Class: |
220/4.31 |
Current CPC
Class: |
B65D 2519/00293
20130101; B65D 2519/00338 20130101; B65D 2519/00273 20130101; B65D
2519/00288 20130101; B65D 2519/00597 20130101; B65D 2519/00208
20130101; B65D 2519/00069 20130101; B65D 2519/00174 20130101; B65D
2519/00567 20130101; B65D 19/18 20130101; B65D 2519/00791 20130101;
B65D 2519/0099 20130101; B65D 2519/00497 20130101; B65D 2519/00711
20130101; B65D 2519/00034 20130101 |
Class at
Publication: |
220/4.31 |
International
Class: |
B65D 6/00 20060101
B65D006/00 |
Claims
1. A collapsible container comprising: a base; a pair of first
opposing walls, each first opposing wall comprising a top edge, two
side edges and a bottom edge; a pair of second opposing walls, each
second opposing wall comprising a top edge, two side edges and a
bottom edge; a top panel removably attached to the top edge of the
pairs of first and second opposing walls; and a plurality of
engaging devices positioned along the perimeter of the base and top
panel and along the two side edges and top and bottom edges of the
pairs of first and second opposing walls; wherein: the plurality of
engaging devices are configured to removably connect the pair of
first opposing walls to the pair of second opposing walls and to
removably connect the pairs of first and second opposing walls to
the base and to the top panel.
2. A collapsible container as claimed in claim 1, wherein the
collapsible container is dimensioned to integrate into less than
truck load operations.
3. A collapsible container as claimed in claim 1, wherein the
plurality of engaging devices comprise a plurality of male
fastening components and a plurality of female fastening
components, the plurality of female fastening components configured
to accept the plurality of male fastening components.
4. A collapsible container as claimed in claim 1, wherein the
plurality of engaging devices comprise a plurality of engaging tabs
and a plurality of slots configured to accept the engaging
tabs.
5. A collapsible container as claimed in claim 1, wherein the
plurality of engaging devices comprise: a plurality of engaging
hooks positioned outwardly along the two side edges of the pair of
first opposing walls; a plurality of engaging tabs positioned
outwardly along the top and bottom edges of the pairs of first and
second opposing walls; and a plurality of slots positioned along
the two side edges of the pair of second opposing walls and the
perimeter of the base and top panel, the slots configured to accept
the engaging hooks and the engaging tabs.
6. A collapsible container as claimed in claim 1, wherein the base
further comprises a plurality of support blocks spaced along the
underside of the base such that a forklift may be used to lift the
collapsible container.
7. A collapsible container as claimed in claim 1, wherein the base
is configured to secure to at least one of the pairs of the first
and second opposing walls.
8. A collapsible container as claimed in claim 7, wherein the base
is secured to at least one of the pairs of the first and second
opposing walls utilizing a latching mechanism.
9. A collapsible container as claimed in claim 7, wherein the base
is secured to at least one of the pairs of the first and second
opposing walls utilizing a tie-down mechanism.
10. A collapsible container as claimed in claim 7, wherein the base
is secured to at least one of the pairs of the first and second
opposing walls utilizing a pin and clevis mechanism.
11. A collapsible container as claimed in claim 6, wherein at least
one support block is configured to allow a pin to be inserted into
the support block and wherein at least one of the engaging devices
along the bottom edges of the pairs of the first and second
opposing walls is configured to allow the pin to be inserted
through the engaging device.
12. A collapsible container as claimed in claim 1, wherein at least
one of the pairs of first and second opposing walls comprise an
access point.
13. A collapsible container as claimed in claim 12, wherein the
access point comprises a door.
14. A collapsible container as claimed in claim 13, wherein the
access point comprises an overhead roll-up door.
15. A collapsible container as claimed in claim 12, wherein the
access point is transparent or semi-transparent.
16. A collapsible container as claimed in claim 12, wherein the
access point comprises a window.
17. A collapsible container as claimed in claim 12, wherein the
access point is configured to allow a user to load/unload items
from the collapsible container.
18. A collapsible container as claimed in claim 1, wherein the
collapsible container is dimensioned to fit in curtain side
linehaul trailers and trailers with overhead roll-up doors.
19. A collapsible container as claimed in claim 1, wherein the
base, the pairs of first and second opposing walls and the top
panel are made of a plastic material.
20. A collapsible container as claimed in claim 1, wherein the
collapsible container further comprises a tarp.
21. A collapsible container as claimed in claim 1, wherein the
collapsible container further comprises at least one freight
securing mechanism configured to secure items within the
collapsible container to the base.
22. A collapsible container as claimed in claim 21, wherein the
freight securing mechanism comprises a tie down positioned on an
interior face of the base.
23. A collapsible container as claimed in claim 21, wherein the
freight securing mechanism comprises a latch positioned on an
interior face of the base.
24. A collapsible container as claimed in claim 1, wherein the
base, the pairs of first and second opposing walls, and the top
panel are configured to be disassembled and stacked to minimize
storage space of the collapsible container.
25. A collapsible container as claimed in claim 1, wherein the top
panel further comprises at least one vertical lip along the
perimeter of an interior face of the top panel.
26. A collapsible container as claimed in claim 25, wherein the top
panel further comprises a first section, a second section and a
third section.
27. A collapsible container as claimed in claim 1, further
comprising one or more stability bars, wherein the one or more
stability bars are configured to extend between at least one pair
of the first and/or second opposing walls, and wherein the
stability bars are configured to secure to an interior of the at
least one pair of the first and/or second opposing walls.
28. A collapsible container as claimed in claim 27, wherein the
interior side of the at least one pair of the first and/or second
opposing walls comprises one or more sockets configured to engage
the one or more stability bars.
29. A collapsible container comprising: a pair of first opposing
walls, each first opposing wall comprising: a top edge comprising a
plurality of top male fastening components; a bottom edge
comprising a plurality of bottom male fastening components; and two
side edges comprising a plurality of side male fastening
components; a pair of second opposing walls, each second opposing
wall comprising: a top edge comprising a plurality of top male
fastening components; a bottom edge comprising a plurality of
bottom male fastening components; and two side edges comprising a
plurality of side female fastening components configured to accept
the plurality of side male fastening components; a base comprising
a plurality of base female fastening components along a perimeter
of the base, the plurality of base female fastening components
configured to accept the plurality of bottom male fastening
components of the pairs of first and second opposing walls; and a
top panel comprising a plurality of top female fastening components
along a perimeter of the top panel, the plurality of top female
fastening components configured to accept the plurality of top male
fastening components of the pairs of first and second opposing
walls.
30. A collapsible container as claimed in claim 29, wherein when
the collapsible container is in an erected position, the
collapsible container is a receptacle dimensioned to integrate into
less than truck load operations.
31. A collapsible container as claimed in claim 29, wherein the
base, the pairs of first and second opposing walls, and the top
panel are configured to be stacked when the collapsible container
is in a collapsed position.
32. A collapsible container comprising: a pair of first opposing
walls, each first opposing wall comprising: a plurality of engaging
hooks positioned outwardly along two opposing edges; a plurality of
first engaging tabs positioned outwardly along two edges adjacent
to the two opposing edges; and an exterior face comprising a
graphic; a pair of second opposing walls, each second opposing wall
comprising: a plurality of slots positioned along two opposing
edges configured to accept the plurality of engaging hooks of the
pair of first opposing walls; a plurality of second engaging tabs
positioned outwardly along two edges adjacent to the two opposing
edges; and an exterior face comprising a graphic; a base comprising
a plurality of base slots that are sized and positioned to accept
the first and second engaging tabs of the respective pairs of first
and second opposing walls to form a receptacle; and a top panel
comprising a plurality of top slots that are sized and positioned
to accept the first and second engaging tabs of the respective
pairs of first and second opposing walls.
33. A collapsible container as claimed in claim 32, wherein the
collapsible container is dimensioned to integrate into less than
truck load operations.
34. A collapsible container as claimed in claim 32, wherein in the
length of the first engaging tabs is different than the length of
the second engaging tabs.
35. A collapsible container as claimed in claim 32, wherein the
collapsible container further comprises a plurality of freight
securing mechanisms.
36. A collapsible container as claimed in claim 35, wherein the
plurality of freight securing mechanisms comprise tie downs
positioned on an interior face of the base, the pairs of first and
second opposing walls and the top panel.
37. A collapsible container as claimed in claim 35, wherein the
plurality of freight securing mechanisms comprise latches
positioned on an interior face of the base, the first and second
pair of opposing walls and the top panel.
38. A collapsible container comprising: a base; a pair of first
opposing walls, each first opposing wall comprising a top edge, two
side edges and a bottom edge; a pair of second opposing walls, each
second opposing wall comprising a top edge, two side edges and a
bottom edge; a top panel removably attached to the top edge of the
pairs of first and second opposing walls; and a plurality of
engaging devices positioned along the perimeter of the base and
along the two side edges and bottom edge of the pairs of first and
second opposing walls; wherein: the plurality of engaging devices
are configured to removably connect the pair of first opposing
walls to the pair of second opposing walls and to removably connect
the pairs of first and second opposing walls to the base; wherein
the base further comprises a plurality of support blocks spaced
along the underside of the base such that a forklift may be used to
lift the collapsible container; and wherein the top panel further
comprises one or more support block lips configured to minimize
movement of a second container stacked on top of the container and
wherein the support block lips are dimensioned to engage
corresponding support blocks of a second container.
Description
RELATED APPLICATIONS
[0001] This present application is a continuation-in-part of
co-pending U.S. patent application Ser. No. 12/136,401 filed Jun.
10, 2008. The aforementioned application is incorporated herein by
reference in its entirety.
TECHNICAL FIELD
[0002] The present invention relates generally to shipping and
storage containers and methods, and in particular, embodiments
relate to collapsible containers that may be integrated into a
motor carrier's current operations without any additional equipment
or disruption of service.
BACKGROUND
[0003] Containers are utilized by industry and consumers to ship
freight from one location to another. Containers are also commonly
used to store items for a length of time. Conventional containers,
although effective when full of freight, become a source of lost
revenue for a motor carrier when the container is empty because the
space taken up by the empty container could be used by a full
container or other freight. Similarly, in the case of residential
or commercial use, an empty container undesirably takes up a great
deal of space in a residential or commercial user's basement,
attic, storage space, warehouse or other similar location. A user
may desire to keep an empty container in his or her possession for
future use but for the undesirable space the empty container
requires.
[0004] Conventional containers are also difficult for a commercial
or residential user to load and unload. The top-loading of a
shipping container can be a harrowing experience, especially when
the item to be shipped or stored is being loaded into a tall
container. For example, the article may be accidentally dropped
while it is being loaded into the container from the top.
Additionally, articles positioned at the bottom of a full
top-loaded container may be difficult, if not impossible, to locate
or remove if the need arises.
[0005] Additionally, conventional containers are not easily
integrated into a motor carrier's current less than load ("LTL")
operations. LTL freight, unlike full truckload freight, is
collected from various shippers and consolidated onto a trailer.
Non-uniformity of conventional container dimensions create
inefficiencies in LTL linehaul operations by causing large gaps of
dead space in between freight and containers. Similarly,
conventional shipping containers are not dimensioned to fit in
trailers with overhead, roll-up doors.
[0006] Accordingly, a shipping and storing container that takes up
minimum space when empty, is easily loaded and unloaded, and
integrates into a motor carrier's operations is desired.
SUMMARY
[0007] According to one embodiment, a collapsible container is
provided. The collapsible container includes a base, a pair of
first opposing walls, each first opposing wall comprising a top
edge, two side edges and a bottom edge, a pair of second opposing
walls, each second opposing wall comprising a top edge, two side
edges and a bottom edge, a top panel removably attached to the top
edge of the pairs of first and second opposing walls and a
plurality of engaging devices positioned along the perimeter of the
base and the top panel and along the two side edges and top and
bottom edges of the pairs of first and second opposing walls. The
plurality of engaging devices are configured to removably connect
the pair of first opposing walls to the pair of second opposing
walls and to removably connect the pairs of first and second
opposing walls to the base and top panel.
[0008] According to another embodiment, a collapsible container is
provided. The collapsible container includes a pair of first
opposing walls, each first opposing wall including a top edge
comprising a plurality of top male fastening components and a
bottom edge comprising a plurality of bottom male fastening
components, and two side edges including a plurality of side male
fastening components. The collapsible container also includes a
pair of second opposing walls, each second opposing wall including
a top edge comprising a plurality of top male fastening components,
a bottom edge comprising a plurality of bottom male fastening
components, and two side edges comprising a plurality of side
female fastening components configured to accept the plurality of
side male fastening components. A base including a plurality of
base female fastening components along a perimeter of the base, the
plurality of base female fastening components configured to accept
the plurality of bottom male fastening components of the pairs of
first and second opposing walls. A top panel including a plurality
of top panel female fastening components along a perimeter of the
top panel, the plurality of top panel female fastening components
configured to accept the plurality of top male fastening components
of the pairs of first and second opposing walls.
[0009] According to yet another embodiment, a collapsible container
includes a pair of first opposing walls, each first opposing wall
including a plurality of engaging hooks positioned outwardly along
two opposing edges, a plurality of first engaging tabs positioned
outwardly along the edges adjacent to the two opposing edges and an
exterior face comprising a graphic. The collapsible container also
includes a pair of second opposing walls, each second opposing wall
including a plurality of slots positioned along two opposing edges
configured to accept the plurality of engaging hooks of the pair of
first opposing walls, a plurality of second engaging tabs
positioned outwardly along the edges adjacent to the two opposing
edges, and an exterior face comprising a graphic. The collapsible
container also includes a base comprising a plurality of base slots
that are sized and positioned to accept the first and second
engaging tabs of the respective pairs of first and second opposing
walls to form a receptacle and a top panel comprising a plurality
of top slots that are sized and positioned to accept the first and
second engaging tabs of the respective pairs of first and second
opposing walls to form a receptacle.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The following detailed description will be more fully
understood in view of the drawings in which:
[0011] FIG. 1 is a perspective view of a collapsible container with
one side removed according to one or more embodiments of the
present invention.
[0012] FIG. 2 is an exploded view of a collapsible container
according to one or more embodiments of the present invention.
[0013] FIG. 3 is a perspective view of a collapsible container with
one side removed according to one or more embodiments of the
present invention.
[0014] FIG. 4 is a perspective view of a collapsible container with
one side removed according to one or more embodiments of the
present invention.
[0015] FIG. 5 is a perspective view of a first opposing wall being
inserted into a base of a collapsible container according to one or
more embodiments of the present invention.
[0016] FIG. 6A is a front view of a first and second opposing wall
of a collapsible container according to one or more embodiments of
the present invention.
[0017] FIG. 6B is a top view of a base and a bottom view of a top
panel of a collapsible container according to one or more
embodiments of the present invention.
[0018] FIG. 7A is a front view of a first and second opposing wall
of a collapsible container according to one or more embodiments of
the present invention.
[0019] FIG. 7B is a top view of a base of a collapsible container
according to one or more embodiments of the present invention.
[0020] FIG. 7C is a bottom view of a top panel of a collapsible
container according to one or more embodiments of the present
invention.
[0021] FIG. 7D is a side view of a top panel of a collapsible
container according to one or more embodiments of the present
invention.
[0022] FIG. 8 is a perspective view of an access point on a side
wall of a collapsible container according to one or more
embodiments of the present invention.
[0023] FIG. 9A is a perspective view of a first opposing wall being
inserted into a base of a collapsible container according to one or
more embodiments of the present invention.
[0024] FIG. 9B is a perspective view of a second opposing wall
being inserted into a base of a collapsible container according to
one or more embodiments of the present invention.
[0025] FIG. 9C is a close up perspective view of a collapsible
container according to one or more embodiments of the present
invention.
[0026] FIG. 9D is a front view of a collapsible container covered
with a tarp according to one or more embodiments of the present
invention.
[0027] FIG. 10 is an exploded view of a collapsible container
according to one or more embodiments of the present invention.
[0028] FIG. 11 is a perspective view of a collapsible container
with one side removed according to one or more embodiments of the
present invention.
[0029] The embodiments set forth in the drawings are illustrative
in nature and are not intended to be limiting of the invention
defined by the claims. Moreover, individual features of the
drawings and the invention will be more fully apparent and
understood in view of the detailed description.
DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS
[0030] In one embodiment, a collapsible storage and shipping
container is provided. According to the embodiment, the container
may be used for both commercial and residential shipping and
storing applications. The container, which may be made of a wood,
composite and/or plastic material such as natural HDPE, for
example, is designed and dimensioned to allow a motor carrier to
integrate pickup and delivery of the container into the motor
carrier's current operations without any additional equipment or
disruption of service. One exemplary embodiment of such operations
is less than load (LTL) operations. For example, according to some
embodiments, the container may be loaded and unloaded at a dock or
with a liftgate on the trailer so the user or carrier is not
required to provide equipment such as a forklift, pallet-jack or
flatbed trailer. As described herein below, embodiments are
dimensioned such that they are easily integrated current LTL
operations. Dimensioning of the containers ensures that space is
not wasted within the trailer by minimizing gaps caused by
oddly-dimensioned freight and containers. According to some
embodiments, the container will fit in all linehaul trailers,
including, as an example and not a limitation, curtain side
linehaul trailers, trailers with overhead roll-up doors and other
types of linehaul trailers. Embodiments are also dimensioned to
allow the shipping and storage of oversized items, such as couches,
other large furniture, machines or equipment. The container may be
custom-sized to suit the user's shipping and storage needs.
[0031] The container is fully collapsible to provide efficient
storage and/or transport of the container when the container is
empty, as well as provide increased loading and unloading
flexibility for the user. According to some embodiments, engaging
tabs and hooks are configured to be inserted into mating slots for
easy assembly and collapsibility of the container. The container of
this embodiment may be assembled and disassembled without the use
of, or need for, tools. Because the container is collapsible, it
may be collapsed during transport when the container is empty,
thereby decreasing the required volume of the container within the
linehaul trailer. This significantly increases the load capacity of
the trailer, which frees up the motor carrier to load the trailer
with more freight. Likewise, the user may collapse the container
when he or she is not presently using the container, thereby taking
up less space within the storage area. The collapsibility also
allows for increased loading and unloading flexibility. As an
example, the freight to be loaded into the container for shipping
and/or storage may be placed on the base of the container before
the attachment of the sides and top panel. A user may choose to
remove just the top panel of the container when unloading an item
from the container, or he or she may additionally remove one or
more sides to unload items that are difficult to access from the
container.
[0032] Embodiments may also comprise additional features. Freight
securing mechanisms may be provided on the interior surface of the
base according to some embodiments. The freight securing mechanisms
allow freight to be tied down or secured to the base of the
container, thus preventing damage to the freight during transport.
Other embodiments may also include a tarp that covers the container
for all-weather protection when the container is subject to the
elements. Because conventional containers may be unsightly,
residential and commercial users may be reluctant to store items in
a container in the exterior of their home or place of business
where the container may be seen from the road, sidewalk or other
public vantage point. However, exterior storage may be desirable
where the user does not have adequate interior storage space, does
not wish the store the item indoors, or for other reasons.
Therefore, according to some embodiments, the exterior of the
container may comprise an aesthetically pleasing design. As an
example and not a limitation, the design may include a playhouse,
club house, fence, landscape scene, or any other pleasing design to
disguise the container. In a further embodiment, one or more of the
sidewalls may comprise a window. Exemplary windows could be
comprised of glass, plastic or other transparent/semi-transparent
materials. In one embodiment, the window is configured to allow a
user to visually inspect one or more contents in the collapsible
container.
[0033] As shown in the illustrated embodiment of FIGS. 1 and 2, a
collapsible shipping and storage container 10 is provided. The
embodiment illustrated in FIGS. 1 and 2 is of a square geometry
(e.g., 48''.times.48''.times.48'' among others). As described and
illustrated herein, other geometries and sizes that integrate into
motor carrier operations are also provided. The container comprises
a base 16, a pair of first opposing walls 12, a pair of second
opposing walls 14 and a top panel 18 that are configured to easily
attach to one another to form the collapsible container 10 without
the use of tools. The base 16, top panel 18 and the opposing walls
12, 14 comprise engaging devices that are configured to interlock
the base 16 and the opposing walls 12, 14 to each other.
[0034] According to the embodiment of FIGS. 1 and 2, the engaging
devices comprise a plurality of male fastening components (e.g.,
20, 24 and 26) and a plurality of female fastening components
(e.g., 21, 25 and 27). More particularly, the male fastening
components may include a plurality of engaging hooks 20 (e.g.,
three on each side of the first opposing walls 12 in this
embodiment) and engaging tabs 24, 26, and the female fastening
components may comprise a plurality of slots 21, 25, 27. The
engaging hooks 20 of the illustrated embodiment are located along
two opposing sides of the pair of first opposing walls 12. It is
contemplated that the engaging hooks 20 may also be provided along
two sides of the pair of second opposing walls 14. The engaging
hooks 20 are configured to be inserted and secured to matching
slots 21 provided along two opposing sides of the pair of second
opposing walls 14. Other engaging device configurations are also
possible. More specifically, rather than an fastening hook, an
engaging tab with a hole or a notch configured for the insertion of
a locking pin to fasten the walls together may also be
employed.
[0035] The slots 25, 27 located on the base 16 and top panel 18 are
configured to accept the corresponding engaging tabs 24, 26 of the
pairs of first and second of opposing walls 12, 14 (i.e., slot 25
is configured to accept engaging tab 24 and slot 27 is configured
to accept engaging tab 26). In one exemplary embodiment, the slots
25, 27 and engaging tabs 24, 26 are dimensioned such that the pairs
of first and second opposing walls 12, 14 may only be inserted in
the correct position on the base and/or top panel. For example,
slot 25 and engaging tab 24 may be of a length that is longer than
slot 27 and engaging tab 26 or visa versa. Similarly, slot 25 and
engaging tab 24 may be of a width that is wider than slot 27 and
engaging tab 26 or visa versa. As is shown in FIG. 9A, the base 16
comprises support blocks 30 that provide additional support for the
container, as well as depth for the slots 25, 27 to accept the
engaging tabs 24, 26. The depth of the slots 25, 27 increases the
strength and rigidity of the container. In one exemplary
embodiment, illustrated in FIG. 5, the support block 30 is
configured to provide an opening 150 to allow a pin 160 to be
inserted through the support block 30, wherein the opening 150 is
positioned corresponding to the slot 25 on the base 16. In one
exemplary embodiment, the engaging tabs 24, 26 have a corresponding
hole 152 such that a pin 160 may be inserted into the opening 150
of the support block 30 and through the hole 152 of the engaging
tab, thus securing the side wall 12, 14 to the base 16.
[0036] Referring again to FIGS. 1 and 2, the base 16 may contain
support blocks 30 as described above. The support blocks 30 form
gaps within the base 16 in which a forklift, pallet-jack or other
transporting device may be inserted to move the container 10 to a
specific location. The support blocks 30 also ensure that the
container 10 is sufficiently raised from the ground to prevent
water from entering the container 10. According to some
embodiments, freight securing mechanisms 28 may be provided
throughout the floor of the base 16. In FIG. 2, the exemplary
freight securing mechanisms 28 are positioned along the perimeter
of the floor of the base 16. The freight securing mechanisms 28 may
be used to secure freight to the base and therefore container 10 by
running a strap, bungee cord, rope, twine or other similar device
under the latch or ring of the freight securing mechanisms 28 and
around the freight (FIG. 9A). Many other freight securing mechanism
configurations are possible.
[0037] Additional embodiments may comprise handles 22 that are
located on each wall of the container 22. These handles 22 may be
attached to the opposing walls 12, 14. Or, according to other
embodiments and as illustrated in FIGS. 1 and 2, the handles 22 may
be recesses that are formed into the one or more of the opposing
walls during the molding or formation of the opposing walls 12, 14.
The handles 22 may be used to lift and carry the container 10 from
one location or another. The handles 22 also aid in erecting and
collapsing the container 10, as well as assist in carrying and
moving the opposing walls 12, 14.
[0038] In another exemplary embodiment, at least one of the sides
and the base are configured to be secured to each other. For
example, as illustrated in FIG. 3, a strap 210 with a ratcheting
mechanism (alternatively an elastic element) might be utilized and
looped through an opening or ring 212 on the side 12 and the base
16 and the strap 210 tightened to secure one or more of the sides
12 to the base 16 to minimize the chance of the side walls
disengaging from the base. In another example, a spring clamp can
be utilized. Alternatively, a cam-door lock or similar device could
be utilized. In yet another example, illustrated in FIG. 5, a pin
and clevis arrangement could be utilized, wherein the base and the
side walls are configured to allow a pin 160 to be inserted an
opening 150 on the base 16 or alternatively on the support block 30
and through a corresponding opening 152 in the engaging tab 24 of
the side wall 12, thereby minimizing the ability of the side wall
12 to become disengaged from the base 16. In another exemplary
embodiment, the top panel may also be configured with one or more
securing mechanisms to secure the top panel to the side walls. In
addition to minimizing the ability of the side walls to become
disengaged from the base and/or top panel, the securing mechanisms
also provide the ability to create a secure container for shipment
needs which require such security (such as high value items,
pharmaceuticals or confidential materials).
[0039] In another exemplary embodiment, the top panel comprises one
or more slots configured to engage one or more corresponding tabs
of the side walls. In one further embodiment, illustrated in FIG.
4, the tabs 24, 26 of the side walls 12, 14 pass through the slots
25, 27 of the top panel when the top panel 18 is placed onto the
side walls. The tabs 24, 26 can then be secured to the top panel
through a variety of securing mechanisms such as pin and clevis,
straps, latch or clamps and the like in a similar manner as
illustrated in FIGS. 3 and 5 and as discussed above. In yet a
further embodiment, the support blocks 30 are configured to allow a
second container to be stacked on a first container. The tabs of
the side walls are positioned such that the support block of a
second container can be placed on top of the first container. In
one embodiment, the underneath portion of the support block has a
corresponding slot to accept the engaging tab that extends through
the slot of the top panel of the first container. This embodiment
can also help prevent the second container from sliding or slipping
off the first container. In yet a further embodiment, the tabs of
the first container's side walls can be secured to the support
block utilizing a similar opening and securing mechanism as
illustrated in FIGS. 3 and 5.
[0040] As described above, the container 10 may be designed and
dimensioned in a number of sizes that allow the container 10 to be
integrated into motor carrier operations. For example, in one
exemplary embodiment, LTL operations. FIGS. 6A and 6B illustrate an
embodiment that is dimensioned as a rectangular container that is
taller than the square embodiment of FIGS. 1 and 2 (e.g.,
48''.times.48''.times.75''). As an example, this embodiment may be
useful for storing and/or transporting a refrigerator or other tall
items. According to the embodiment of FIGS. 6A and 6B, the opposing
side walls 12, 14 have four engaging hooks 20 and slots 21 along
each side. FIGS. 7A-7C illustrate an embodiment in which the
container 10 has a geometry suitable for storing and transporting
large, oversized items (e.g., 48''.times.90''.times.55''). For
example, this embodiment may be utilized to transport bicycles,
four-wheelers, dressers, and other relatively long items. The
engaging tabs 24a (FIG. 7A) and slots 25a are relatively longer
than the engaging tabs 24 and slots 25 provided in the embodiments
illustrated in FIGS. 1 and 2 and FIGS. 6A and 6B. The increased
length of the engaging tabs 24a and slots 25a increase the
stability of the container 10. Referring to FIG. 7C, the top of the
container 10 is composed of three top panel sections 18a, 18b, and
18c. The top panel sections comprise engaging slots 25a and 27. The
three section embodiment allows for easy access to the container 10
as only a small section needs to be removed to access items within
the container 10. Additionally, the three sections 18a-18c are easy
for a single person to install and remove as the pieces are smaller
and lighter than one large top panel. According to one exemplary
embodiment, the top panel(s) may further comprise an interior
engaging lip 29b along portions of the three sections 18a-18c to
increase the stability of the container 10. Some embodiments
comprising the three top sections 18a-18c may employ a notch fit to
assemble the top 18 onto the top of the container 10. As
illustrated in FIG. 7D, 18b may comprise notch 52 which is
configured to rest upon corresponding notches 50 located on 18a and
18b. In this manner, all three sections 18a-18c may be securely
attached to first and second opposing walls 12, 14. In another
embodiment, top sections 18a-18c also comprise one or more
corresponding slots configured to engage the tabs of the side
walls.
[0041] In one exemplary embodiment, illustrated in FIG. 8, one or
more of the side walls comprise an access point 300 to allow visual
inspection and/or entry into the collapsible container when
assembled. For example, in one embodiment, the access point
comprises a door 300 configured to allow a visual inspection of one
or more items placed in the container. In another embodiment, the
access point comprises a larger door(s) which allows the ability to
load/unload items into/from the assembled container. The access
point in one exemplary embodiment comprises a roll-up door. The
access point may also comprise a securing mechanism which can
secure the access point from being opened. In another exemplary
embodiment, the access point is transparent or semi-transparent.
[00421 FIGS. 9A-9D illustrate a method of erecting a collapsible
container 10 according to one embodiment. Referring initially to
FIG. 9A, the base 16 is placed on level surface. Freight may be
placed on the base 16 at this time, or any other time in the
assembly process. Next, a first opposing wall 12 (i.e., a wall
having male engaging structures 20) may be lifted by the handles 22
(not shown) so that the engaging tabs 24 are aligned with the
engaging slots 25. The wall 12 and engaging tabs 24 are then pushed
down into the engaging slots 25. This is repeated for the other
second opposing wall 12.
[0042] Now referring to FIG. 9B, a second opposing wall 14 (i.e., a
wall having female engaging structures) may be lifted over the base
16 such that the engaging tabs 26 are aligned with the slots 27 on
the base 16, and the engaging hooks 20 of the pair of first
opposing walls 12 are aligned with the slots 21 of the second
opposing wall 14. After positioning the second opposing wall 14
into place, the wall 14 is then pushed down so that the engaging
tabs 26 enter the slots 27 and the engaging hooks 20 of wall 12
grip and secure the wall 14. This is repeated for the remaining
second opposing wall 14 having slots 21 such that all four opposing
walls 12, 14 are fitted and locked together to the base 16.
[0043] After the opposing walls 12, 14 are in place and the freight
has been loaded, the top panel 18 may be placed on the top portion
of the opposing walls 12, 14 and fit into place, as illustrated in
FIG. 9C. In one embodiment, the top panel 18 comprises one or more
corresponding slots 25, 27 configured to engage one or more tabs
24, 26 of the opposing walls. The container 10 is now fully
assembled and ready for storage and/or transport. According to some
embodiments, a tarp 40 may be fitted over the container to protect
the container 10 from the elements, including wind, rain, frost,
snow and sun, for example (FIG. 9D). The tarp 40 may be secured to
the container 10 by flaps 42. The flaps 42 may be secured by
attachments 44a, 44b which may be Velcro, or a loop in which a hook
or a clip may use to engage attachment 44a to attachment 44b, for
example. The container 10 may be collapsed by removing the top
panel 18, then removing the pair of second opposing walls 14 and
finally the pair of first opposing walls 12. The base 16, opposing
walls 12, 14 and top panel 18 may then be stacked into a compact
form for later use.
[0044] In one exemplary embodiment, illustrated in FIG. 10, the
container 10 further comprises one or more stability bars 85 which
are configured to minimize inward and outward movement of the side
walls 12, 14. The stability bars 85 are connected to the side walls
through a connection mechanism 88 on the interior side of the at
least one pair of opposing side walls 12, 14. As one skilled in the
art will appreciate, various locations and connection mechanisms
may be employed, including multiple stability bars in a container.
In a further embodiment, the stability bars 85 can be utilized to
secure and/or separate items within the container 10.
[0045] Another exemplary embodiment of the container 10 is
illustrated in FIG. 11. The container 10 comprises a base 16, a
pair of first opposing walls 12, a pair of second opposing walls 12
and a top panel 18 that are configured to easily attach to one
another to form the collapsible container 10 without the use of
tools. The base 16 and the opposing walls 12, 14 comprise engaging
devices that are configured to interlock the base 16 and the
opposing walls 12, 14 to each other. According to this particular
embodiment, the engaging devices comprise a plurality of male
fastening components (e.g., 20, 24 and 26) and a plurality of
female fastening components (e.g., 21, 25 and 27). More
particularly, the male fastening components may include a plurality
of engaging hooks 20 (e.g., three on each side of the first
opposing walls 12 in this embodiment) and engaging tabs 24, 26, and
the female fastening components may comprise a plurality of slots
21, 25, 27. The engaging hooks 20 of the illustrated embodiment are
located along two opposing sides of the pair of first opposing
walls 12. It is contemplated that the engaging hooks 20 may also be
provided along two sides of the pair of second opposing walls 14.
The engaging hooks 20 are configured to be inserted and secured to
matching slots 21 provided along two opposing sides of the pair of
second opposing walls 14. Other engaging device configurations are
also possible. More specifically, rather than an fastening hook, an
engaging tab with a hole or a notch configured for the insertion of
a locking pin to fasten the walls together may also be
employed.
[0046] In this particular embodiment, the slots 25, 27 located on
the base 16 are configured to accept the corresponding engaging
tabs 24, 26 of the pairs of first and second of opposing walls 12,
14 (i.e., slot 25 is configured to accept engaging tab 24 and slot
27 is configured to accept engaging tab 26). The slots 25, 27 and
engaging tabs 24, 26 are dimensioned such that the pairs of first
and second opposing walls 12, 14 may only be inserted in the
correct position on the base. For example, slot 25 and engaging tab
24 may be of a length that is longer than slot 27 and engaging tab
26 or visa versa. Similarly, slot 25 and engaging tab 24 may be of
a width that is wider than slot 27 and engaging tab 26 or visa
versa. The base 16 may contain support blocks 30 as described
above. The support blocks 30 form gaps within the base 16 in which
a forklift or other transporting device may be inserted to move the
container 10 to a specific location. The support blocks 30 also
ensure that the container 10 is sufficiently raised from the ground
to prevent water from entering the container 10. The top panel 18
of the container 10 is dimensioned such that there is an overhang
above each opposing wall 12, 14. Under each overhang (i.e., around
the perimeter of the underside of the top panel 18) is a vertical
lip 29 that enfolds the walls 12, 14 when the container 10 is
assembled, as may be viewed in the embodiment illustrated in FIG.
1. The vertical lip 29 therefore secures the top panel 18 to the
top portions of the walls 12, 14 and ultimately, the container 10.
The exterior side of the top panel further comprises one or more
support block lips 94 which are configured to minimize movement of
a second container stacked on top of a first container. The support
block lips 94 are configured to minimize and/or prevent movement of
the support blocks 30 of the second container. The support blocks
lips 94 can be an integral part of the top panel 18 or can be an
optional attachment that is secured to the top panel through known
attachment processes such as adhesives, screws, rivets, latches,
etc.
[0047] The foregoing description of the various embodiments of the
invention has been presented for the purposes of illustration and
description. It is not intended to be exhaustive or to limit the
invention to the precise steps and/or forms disclosed. Many
alternatives, modifications and variations will be apparent to
those skilled in the art of the above teaching. Moreover, although
multiple inventive aspects have been presented, such aspects need
not be utilized in combination, and various combinations of
inventive aspects are possible in light of the various embodiments
provided above. Accordingly, the above description is intended to
embrace all possible alternatives, modifications, combinations, and
variations that have been discussed or suggested herein, as well as
all others that fall with the principles, spirit and broad scope of
the inventions as defined by the claims.
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