Abstract:
A reusable, sanitary and folding container includes a base, two folding sidewalls, two folding end walls and latches and hinges. The base includes slots that receive the hinge pins that allow the sidewalls and end walls to fold up and down. These hinge slots are open and provide for water or spray through them to improve the cleaning process of a container after it has been used. The container is formed of a resilient, but light polyurethane/fiber composite material.

Description:
[0001]    This application claims the benefit of U.S. Provisional Patent Application No. 61/850,289, filed on Feb. 13, 2013, which is incorporated by reference herein in its entirety. 
     
    
       [0002]    The field of the present invention is lightweight, heavy-duty, bulk shipping containers. These containers are widely used in the movement of food products. Specifically, the present invention is directed to a folding, reusable container that can be reliably cleaned for reuse. 
       BACKGROUND 
       [0003]    At present, the food industry uses large shipping containers to move a broad range of food products across the country and around the world. These containers are large enough to hold hundreds and even thousands of pounds. The most common type of food shipping container is a single-use corrugated paper container that is moved around on a heavy wooden pallet. These containers and pallets are relatively heavy, and they are expensive and inefficient in that they may only be used a single time before disposal is required. The corrugated paper structure of these containers is not heavy-duty enough for reuse. Furthermore, the corrugated material cannot be reused for hygienic reasons because the container cannot be thoroughly washed and cleaned for reuse. Furthermore, they put a greater burden on landfills because contaminated corrugated boxes are very difficult to recycle (no one wants them because they have bacteria,  E. coli, salmonella, campylobacter , etc. and they smell bad). The amount of contaminated corrugated boxes could be as high as 20% of the total volume used. 
         [0004]    Reusable, plastic containers are known for use. However, existing containers may be too heavy for commercially economical reuse. Also, existing plastic containers have nooks and crevices and other engineering details that make them very difficult, if not virtually impossible, to reliably clean and inspect for cleanliness. Additionally, most existing plastic boxes are made of inexpensive polypropylene or polyethylene and therefore periodically plastic parts break off during use and contaminate the food product. 
       SUMMARY 
       [0005]    Accordingly, it is an object of the present to provide a folding, lightweight, hygienic and heavy-duty shipping container. The container is engineered to be able to be reliably cleaned for reuse in the industry. 
         [0006]    In one example, a reusable, sanitary and folding container includes a base, two folding sidewalls, two folding end walls and latches and hinges. The base includes a rectangular platform having four corner portions fixed at each of the four corners of the base platform respectively. Each corner portion has a raised, two-wall, V-shape that defines the corner of the platform. Further, each of the corner walls of the V-shaped corner portion comprises a vertical slot that is an open slot through the thickness of the corner wall. 
         [0007]    The two folding sidewalls are rectangular surfaces, each sidewall comprising two hinge pins that extend outwardly from two corners along a bottom side of each rectangular sidewall. The hinge pins are received in two of the vertical slots of the adjacent corner portions so that the bottom sides of the sidewalls are hingedly connected to the base. The sidewalls are mounted on opposite sides of the base. Each sidewall comprises a C-shaped channel attached to opposite side edges that are each perpendicular to the bottom sides of the sidewalls. The C-shaped channel includes a latch pin fixed across the channel and proximate a top side of the sidewalls and the end of the C-shaped channel opposite the bottom side of the sidewalls. 
         [0008]    The two folding end walls are rectangular surfaces, each end wall comprising two hinge pins that extend outwardly from two corners along a bottom side of each rectangular end wall. The hinge pins are received in two of the vertical slots of adjacent corner portions so that the bottom sides of the end walls are hingedly connected to the base. The end walls are mounted on opposite sides of the base. Each end wall comprises a latch that extends outwardly from the end wall on opposite side edges perpendicular to the bottom sides of the end walls. The latch comprises a slot for engaging the latch pin of an adjacent sidewall when the sidewall and end wall are rotated in the up position substantially normal to the plane of the bottom of the box. 
         [0009]    The latch on each side of each end wall may comprise a flange having a latch groove therein adapted to receive and engage the latch pin of the adjacent sidewall. Alternatively, the latch on each side of each end wall comprises an L-shaped finger adapted to hook over and engage the latch pin of the adjacent sidewall. 
         [0010]    The base, two folding sidewalls and two folding end walls may be comprised of plastic, in one example a polyurethane and fiberglass composite. 
         [0011]    The container may also include a plurality of feet attached thereto on the opposite side of the platform from the corner portions, wherein the feet are substantially monolithic and include essentially no exposed crevices therein. The feet may be comprised of polyurethane. 
         [0012]    The container may further comprise a damage reduction insert that includes a rectangular box sized to fit inside the container. The box comprises a base, two sidewalls and two end walls. The box sidewalls and end walls have a height that is less than the height of the container sidewalls and end walls. The box further comprises a box flange on the top side of the box sidewalls and end walls and opposite the box base. The box flange is adapted to engage the top of the container sidewalls and end walls so that the box base is secured inside the container and above the container base. The box base may comprise a door that is retained on the box base edge but that is hingedly connected to the box base edge so that the flap rotates upwardly when the box base is inverted to an upside down position. 
         [0013]    The base, sidewalls and end walls may be each monolithic and contain no hollow portions therein. Further, the base, sidewalls and end walls may be coated with a polymer. The base, end walls and sidewalls comprise no crevices. The topography of the base, sidewalls and end walls may comprise no texture more than about one half of the thickness of the respective base, sidewall or end wall having an uneven surface. 
         [0014]    In another example, the flange with a latch groove of the sidewalls of the container may each comprise an aperture in the channel that is perpendicular to the sidewall and proximate a top side of the sidewalls and end of the flange with a latch groove channel opposite the bottom side of the sidewalls. The end walls may comprise a latch that extends outwardly from the end wall on opposite side edges perpendicular to the bottom sides of the end walls, the latch is adapted to engage the aperture in the channel of an adjacent sidewall when the sidewall and end wall are rotated in the up position substantially normal to the plane of the bottom of the box. In another example, the latch may comprise a clip that frictionally engages the sidewall aperture. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0015]      FIG. 1  is a perspective view of a shipping container as described herein. 
           [0016]      FIG. 2  is a perspective view of a shipping container as described herein with a sidewall and an end wall removed. 
           [0017]      FIG. 3  is an exploded, perspective view of the base of a container as described herein. 
           [0018]      FIG. 4  is a perspective view of a container where the sidewalls and end walls are shown in exploded view. 
           [0019]      FIGS. 5A-5E  are perspective views of a container as it is folded up or collapsed for storage and transport. 
           [0020]      FIG. 6  is a cutaway view of a corner of a container as described herein. 
           [0021]      FIGS. 7A-7C  demonstrate the latching mechanism of a container as described herein. 
           [0022]      FIG. 8  is a perspective cutaway view of the inside of a corner portion of the base of the container as described herein. 
           [0023]      FIGS. 9A-9D  are a series of drawings showing the action of the hinge pins in the slots in the corners of the base of the container as shown herein. 
           [0024]      FIG. 10  is a perspective view of the container further having a damage reduction insert therein. 
           [0025]      FIG. 11  is a perspective view of the container shown in  FIG. 10  with an end wall removed. 
           [0026]      FIGS. 12A-12C  demonstrate the operation of the doors in the base of the damage reduction insert. 
           [0027]      FIGS. 13A-13D  illustrate the latching mechanism of an alternative latch construction to that shown in FIGS.  6  and  7 A- 7 C. 
       
    
    
     DETAILED DESCRIPTION 
       [0028]    The container described herein is a rectangular box that may be used for transporting a wide variety of meats, produce and other goods. The container may be virtually any size depending on an industry need. The teachings apply to both larger and smaller scale versions of a box than described herein. An exemplary container is a container that is 48 inches wide by 40 inches long by 48 inches tall. An industry that uses these containers includes the protein industry shipping poultry and pork products, among others. 
         [0029]    With reference now to the Figures, the container  10  is made up of a base  20 , sidewalls  50 , and end walls  80 . Each of these components shall be addressed in more detail. It should be noted that the components named sidewalls  50  and end walls  80  are given these arbitrary names. It is only important that the sidewalls  50  and end walls  80  are opposite walls. They could be referred to in vice versa terminology in the drawings. Still further alternatively, a container may have a square base such that the sidewalls and end walls would be the same size. 
         [0030]    The base  20  includes a top surface platform  22  and a bottom surface  24  on the opposite side of the planar surface platform. Attached to the bottom surface  24  of the base  20  are feet  26 . As shown, the feet  26  are attached to the corners  28  of the base  20 . There may be additional feet  26  attached at a midpoint of the sides of the base  20  and at structurally important locations on the bottom surface  24  of the base  20 . For instance, a container that is intended for very heavy weights and rough use may have more feet than a container that is intended for use to transport lightweight products. The feet  26  may be integral with the base  20  in that they are all molded as a single piece together with the base  20 . Alternatively, the feet  26  are separately molded and attached to the corners  28  of the base  20 . Specifically with reference to  FIG. 3 , the feet  26  are bolted onto the bottom surface  24  of the base  20  using bolts  42  and nuts  43 . Importantly, it is preferred that the material that is used to form the feet  26  is rugged but also pliant enough that when tightened against the bottom surface  24  of the base  20 , the feet  26  will compress and seal thereto and not form any crevices between the feet  26  and the bottom surface  24 . 
         [0031]    The top surface platform  22  has corner portions  30  situated at each of the corners  28  of the rectangular surface platform  22 . The corner portions  30  include corner walls  32  having a V-shape and standing up perpendicular to the plane of the top surface platform  22 . Each of the corner walls  32  of the corner portions  30  has slots  34  and  36  therein that each extend through the entire thickness of each of the corner walls. The corner portions slots  34  and  36  have a vertical length that allows a hinge pin to slide up and down in that slot. Functionally, the length of the corner portions slots  34  and  36  enables the movement of the hinge pins up and down during the latching process and also during the fold-up storage process of the container  10 . Accordingly, the slot length must be at least greater than the thickness of the respective sidewalk and end walls having hinge pins mounted within the corner portions slots  34  and  36 . Similarly, the with of the corner portions slots  34  and  36  is greater than the diameter of the hinge pins that will rotate and slide therein. Additionally, the slot width is large enough to enable washing water and spray to pass freely through the open slots. 
         [0032]    The base  20  also includes retaining flanges  38  along one or more of the four walls of the base  20 . In the Figures, there are two retaining flanges  38  that will support the sidewalls  50 . The retaining flanges  38  are perpendicular to the top surface platform  22 . The retaining flanges  38  may preferably be integral or formed with the base  20 . Alternatively, the retaining flanges  38  may be attached to the base  20 . These retaining flanges  38  are optional only, if the product being shipped is lightweight, then they might not be necessary. In one example, the retaining flanges  38  are approximately two inches tall and extend along substantially the entire length of the sides of the base  20  in between the corner portions  30 . The composition of the retaining flanges  38  is typically the same as the composition of the rest of the base  20 . However, the composition could be different depending on the duty requirements of the container. 
         [0033]    Rub rails  40  are formed integrally with the base  20  and are protective strips that mitigate or prevent damage to the container  10  during handling. 
         [0034]    The base  20 , and the top surface platform  22  of the base especially must be formed from a tough composition, because the base is a load bearing component of the container  10 . The container  10  may bear loads of 500 to 3,000 pounds during service. An example composition of the base  20  is a polyurethane/fiber composite having dimensions of 48 inches by 40 inches and a thickness of 1/16 to ¼ of an inch. The thickness of the base  20  may be more or less consistent with the motivation that the entire container  10  should be relatively lightweight for purposes of shipping product. 
         [0035]    The sidewalls  50  have a top side  52 , bottom side  54  and sides  62  that define a rectangular wall panel. The sidewalls  50  include bottom corners  56  from which protrude outwardly hinge pins  58 . The hinge pins  58  are received in corner portion slots  34 . The sidewalls  50  further include a deflector  60  that is a small ridge along the outside surface  68  of the sidewalls  50 . The deflector  60  serves to prevent any inadvertent, unwanted foreign material from sliding down the wall and into the container in the gap at the bottom of the sidewall  50  when mounted on the base  20 . The deflector  60  runs substantially the full length of the sidewalls  50 . 
         [0036]    A C-channel  64  is configured along the opposite sides  62  of the sidewalls  50  with the open C-portion facing inwardly. In  FIGS. 13A-13D , the C-channel  64  is best shown with the C-shape. In FIGS.  6  and  7 A- 7 C, the channel  64  has an L-shape, but functionally serves a similar latch receiving purpose. In either example, the channel  64  is an example of a flange that receives a latch. The C-channel  64  will receive and support the sides of neighboring end walls  80  when in the up position. The C-channel  64  extends along a portion of the length of the side  62  of the sidewalls  50 . Alternatively, the C-channel  64  may extend along substantially the full length of the side  62  of the sidewalls  50 . Still further alternatively, a C-channel  64  may have segments along the sides  62  of the sidewalls  50 . The C-channel  64  may be molded into the sidewall  50 . The C-channel  64  may be integral with the sidewall  50  and therefore seamless therein. Still further alternatively, the C-channel  64  can be fastened onto each side  62  of the sidewalls  50 . Preferably, the sidewall  50  is a monolithic piece of molded plastic. There are no hollow sections of the sidewalls  50 , preferably. The hinge pins  58  may be molded in with the sidewalls  50 , or alternatively they may be part of the plastic mold. Similarly, the C-channel  64  may be molded in or, alternatively, a part of the plastic mold. 
         [0037]    The sidewalls  50 , and specifically the C-channel  64 , further include a latch pin  66  across the C-channel  64  ( FIGS. 13A-13D ). Alternatively, the latch receiver may be one or more apertures  72  (FIGS.  6  and  7 A- 7 C) through the bottom of the C-channel  64 . Still further alternatively, the latch receiver may be multiple pins and/or multiple apertures along the length of the C-channel  64 . 
         [0038]    The topography of the outside surface  68  of the sidewalls  50  may include a molded pattern  70 . Importantly, this molded pattern  70  must be a topography that includes no 90° corners in order to facilitate the cleaning and sanitizing of the sidewalls  50 . Also, preferably, the topography of the outside surface  68  of the sidewalls  50  are shallow enough that they would not exceed 50%, or alternatively 25% of the depth or thickness of the sidewalls  50 . 
         [0039]    The end walls  80  are rectangular wall panels having a top side  82 , bottom side  84 , bottom corners  86  and hinge pins  88  that extend outwardly from the bottom corners of the end walls  80 . The hinge pins  88  are received in the corner portion slots  36  of the base  20 . Accordingly, the end walls  80  are allowed to rotate up and down on the hinges  88 . The two end walls  80  are mounted opposite each other on the base  20  and between the two sidewalls  50 . All of the end walls  80  and sidewalls  50  form the walls of the rectangular container  10  with the base  20 . 
         [0040]    The end walls  80  include a deflector  90  that, like the deflector  60  of the sidewalls, is intended to prevent foreign material from accidentally dropping down inside the container  10 . The sides  92  of the end walls  80  include integral latch hooks  94 . The latch hooks  94  may be a male hook protrusion  94  having an L-shape (e.g.  FIGS. 7A-7C ). Alternatively, the latch hooks  94  may be an integral groove within a flange  100  that is adapted to receive the latch pin  66  of the sidewall  50  (e.g.  FIGS. 13A-13D ). Multiple latch hooks  94  may correspond to multiple pins  66  or multiple apertures  72  in the flange  64  of the sidewalls  50 . The latch hooks  94  are proximate the sides  92  and near the top side  82  of the end wall  80 . The hooks or hook grooves may be spaced along the length of the sides  92  of the end walls  80 . 
         [0041]    Preferably, the end walls  80  are monolithic and solid so that there are no hollow portions therein. Preferably, the latch hooks  94  are integral with or may alternatively be molded integrally with the end walls  80  so that there are no crevices around them. 
         [0042]    The outside surface  96  of the end walls  80  may include some topographical design or molded pattern  98 . Preferably, this topography creates an unevenness that is no more than about 50%, or alternatively about 25% of the thickness of the end walls  80 . Importantly, the molded pattern  98  does not include any 90° corners that could harbor bacteria or unwanted pathogens. 
         [0043]      FIGS. 5A-5E  demonstrate the collapsibility of the container  10  for its commercial use. In use, the container  10  is loaded with product and shipped to its destination. At the destination, the container is collapsed so that it takes up less space where it is then transported for washing and sanitation, if necessary, and then further use. As demonstrated in  FIG. 5A , the container  10  is shown with all four walls,  50  and  80  up and latched. In  FIG. 5B , one of the end walls  80   a  is shown in its rotated down position. In  FIG. 5C , the second end wall  80   b  is rotated down and lays on top of the first end wall  80   a . These walls lay flat, because the hinge is allowed to move up and down in the slots  36  in the corner portions  30 . In this way, the second end wall  80   b  lays flat on top of the first end wall  80   a . In  FIG. 5D , a sidewall  50   a  is rotated down. In  FIG. 5E , the second sidewall  50   b  is rotated down so that the container  10  is now in its fully collapsed position for ready transportation. Depending on the relative positions of the corner portion slots  34  and  36 , the end wails  80  may be folded down first if assuming that those corner portion slots  36  are under or lower than the corner portion slots  34  for the sidewalls  50 . 
         [0044]    In another feature not shown, similar containers  10  may be stacked upon each other with the sidewalls  50  and end walls  80  protected by the corner portions  30  that interlock with the respective adjacent containers that are stacked thereon. 
         [0045]      FIGS. 9A-9D  demonstrate the up and down motion of a sidewall  50  during the latching mechanism. Also demonstrated is the wall locking guide  45  which ensures that the hinge pin  58  on the sidewall  50  is moved to the lower horizontal section of the corner portion slot  34 . As shown in  FIG. 9A , the hinge pin  58  is in this lower portion of the corner portion slot  34  and prevents the sidewall  50  from moving up and down in the longer portion of the slot  34  while the container is being handled. As shown in  FIG. 9A , when the sidewall  50  is in the vertical, perpendicular upright position with respect to the container  10 , then the hinge pin  58  is not allowed to move outwardly or it will frictionally engage the locking guide  45 . However, in  FIG. 9B , when the sidewall  50  is rotated outwardly, then the hinge pin  58  is able to slide toward the outside and not bump into the locking guide  45 . As shown in  FIG. 9C , the hinge pin  58  in the sidewall  50  can then move upwardly along the vertical portion of the slot  34 . As demonstrated finally in  FIG. 9D , the sidewall  50  is allowed to then move freely up and down within the slot  34 . 
         [0046]    Turning now to  FIGS. 10-12C , there is shown a damage reduction insert  120 . This insert  120  is designed to protect product that is placed inside the container  10  that might otherwise be crushed or otherwise damaged by stacking too much of the product on it. For instance, meat products that are first placed into the container  10  may be crushed or damaged by the hundreds of pounds of meat product that is stacked on top of it. 
         [0047]    The damage reduction insert  120  includes sidewalls  122 , end walls  124  and a base  126 . The sidewalls  122  and end walls  124  of the insert  120  have a height less than the height of the sidewalls  50  and end walls  80  of the container  10 . The rectangular box shape of the insert  120  is sized to fit inside the container  10 . One or more inserts  120  may be mounted within a container  10 . In this example described herein, there is shown only one insert  120 . If there were more than one insert, then a stacking or other support construction would be employed, not a nesting design. 
         [0048]    The insert  120  has an outwardly-flaring flange  130  on the top side of the insert sidewalls  122  and end walls  124 . This flange  130  engages the top sides  52  and  82  of the sidewalls  50  and end walls  80  respectively. Accordingly, the weight of the products placed inside the insert  120  is supported by the container sidewalls  50  and end walls  80 . 
         [0049]    Alternatively, there may also be a support ridge  132  along the inside walls of the container  10  that alternatively or additionally support the base  126  of the insert  120 . Specifically, the base  126  includes a base perimeter edge  128 . This edge  128  would rest on the support ridge along the inside walls of the container. The insert  120  also includes base doors  134  that make up a part of the base  126 . The base doors  134  are connected by live hinges  136  to the base perimeter edge  128 . In this way, the doors  134  may rotate upwardly only but not downwardly below the insert  120 . In use, when the entire container  10  including insert  120  is rotated upwardly to an upside down position for dumping the contents, those contents will push the doors  134  of the insert  120  upwardly and open so that the food or product underneath the insert  120  can be easily dumped out by an industrial lift and dumping mechanism. There is shown two doors  134  in the Figures. Alternatively, there could be a single door that forms the base  126 . 
         [0050]    The composition of the base  20 , sidewalls  50  and end walls  80  is preferably solid with no hollow portions or sections. These container  10  components may be formed from metal, composite, or plastic materials or combinations thereof. In one example of the present container  10 , the container components are formed from a polyurethane/fiber composite that is both solid and strong. Importantly, the polyurethane material is also relatively lightweight. Also favorably, the polyurethane material is impermeable. In one example, a long fiber technology is used to create a polyurethane and fiberglass composite using a reaction injection molding process. The polyurethane polymer is light and durable, and the integral fiberglass fibers impart substantial reinforcement strength to the molded parts. 
         [0051]    The hinge pins  58  and  88  disclosed herein are traditionally metal rods molded into the sidewalls  50  and end walls  80  respectfully. Alternatively, the hinge pins  58  and  88  may also be made of the plastic composition and are a part of the molded product itself. Either way, the hinge pin is formed with the respective walls so that they are integral and have no crevices around their base where they extend into or out from those walls. 
         [0052]    The latches including the latch pins  66  or latch hooks  94  are similarly either molded in place in the sidewalls  50  and end walls  80 , or they are plastic and part of the mold itself. 
         [0053]    Still further, all or a part of the components of the container  10  may be over molded or otherwise coated for surface protection. This surface protection provides for UV protection, scratch protection, an antibacterial barrier and extra sealant. The type and amount of over mold or coating is determined based on the use of the container. 
         [0054]    As noted, the urethane material in the present example is especially favorable for its weight and strength characteristics. These containers are shipped multiple times. The less weight that is shipped, the less cost that is associated with the container. 
         [0055]    The container  10  is adapted to be cleaned for reuse. A concern is bacterial or other biological hazards or foreign materials remaining on or in the container  10  or in a container&#39;s nooks and crannies. Accordingly, the present container  10  is molded and engineered so that no crevices exist in the surface of any of the base or wall components. A crevice is defined herein as meaning a surface that has a greater than 90° angle between adjacent sections or portions of a surface. To the extent of the topography of the surface of each component, there are no right angle corners. In each case, the component is molded so that those adjacent walls are rounded off. There are no sharp corners where microbial pathogens can hide from a cleaning process. Even where the walls are molded with hinge pins or latches, the place where they are molded together is rounded so that the adjacent surfaces are not sharp angles. Furthermore, when assembled, the container  10  having hinge pin slots  34  and  36  that are open apertures through the face of those corner portions  30  means that any spray cleaning process has access for direct spray around the hinge connection points. 
         [0056]    The feet  26  of the base  20 , when attached to the bottom surface  24  of the base are brought tight enough so that a seal is created. The material that forms the feet  26  is soft or flexible enough to make the seal between the foot  26  and the base  20  a tight seal. There are no crevices formed. 
         [0057]    The design or molded patterns  70  and  98  may be molded texture for support or structural purposes. Alternatively, these molded patterns  70  and  98  may have a primarily distinctive ornamental design purpose. This design and the uneven contour of the outer surface of the walls is not more than one half or 50% of the thickness of the overall wall, or alternatively not more than 25% of the thickness of the overall wall. Again, the contoured surface of the components is engineered so that there are no crevices, that is no adjacent surfaces of 90° or greater at their connection points. 
         [0058]    Other embodiments of the present invention will be apparent to those skilled in the art from consideration of the specification. It is intended that the specification and Figures be considered as exemplary only, with a true scope and spirit of the invention being indicated by the following claims.