Abstract:
A multi-panel collapsible container able to support the weight of the goods and provide a quick and easy access to the contents of the container from the sides and the top, the container is configured to be collapsed for ease of storage when not in use.

Description:
RELATED APPLICATIONS  
       [0001]     This application claims priority to U.S. Provisional Patent Application 60/668,768 filed Apr. 6, 2006, which is incorporated herein by reference. 
     
    
     FIELD OF THE INVENTION  
       [0002]     The invention relates generally to a collapsible tote. More specifically, the invention relates to a multi-panel bin formed of corrugated materials that can be easily assembled and collapsed when not in use.  
       BACKGROUND OF THE INVENTION  
       [0003]     Many types of containers are used for holding goods during storage and transportation. These containers are made of various materials, such as cardboard, wood, metal, and plastics. However, many of the known containers have various disadvantages, such as moisture immersion, high cost, or excessive weight. Moreover, they are not always suitable for all environmental conditions, such as sunshine or hot environments, wet or humid conditions, cold or frozen conditions, and forming stacks with heavy loads. Therefore, there is a need or demand for a durable container that can be used in any kind of environment in which a container would be used. At the same time, the container must be cost efficient or economical, easily foldable without use of any glue, tape, nails, or tools, easily transportable as a flat piece or pieces, reusable, light weight, moisture resistant, washable, and capable of stacking to bear heavy loads for a relatively long period of time. The container should also be recyclable.  
         [0004]     At present, most collapsible containers are made of cardboard, waxed cardboard, or thin plastics because thick plastic boards cannot be easily folded. Such containers usually utilize laminate layers or fillers to reinforce the side and end walls or corners of the box for better support. An example of this type of container is disclosed in U.S. Pat. No. 3,310,219 to Dlugopolski. However, the container is not strong enough to hold the various panels of the container together when the box is used in severe conditions, such as moisture, heat, and heavy load.  
         [0005]     Some containers incorporate a tab and slot locking system. An example of inset tabs and the slots are shown in U.S. Pat. No. 3,310,219 to Dlugopolski, and U.S. Pat. No. 3,708,103 to Evants. Barbed tabs are used in U.S. Pat. No. 4,463,997 to Densen, and U.S. Pat. No. 3,991,932 to Carmel et al. These locks are designed for cardboard material that is relatively soft and flexible. The locking system of Densen is a combination of the tab-slot engagement and barbed tabs. The barbed tabs must be bent over at the box corner to assure the locking of the tab-slot engagement. Accordingly, the assembly of such box is relatively slow and such locking cannot be used on boxes of thicker plastic materials. Moreover, the tab-slot engagement or barbed tab locking systems typically become worn-out or weakened due to moisture immersion.  
         [0006]     The containers referenced above do not permit access to their contents when the containers are stacked in close proximity to a ceiling or upper shelf Rather, the container generally must be removed from the shelf so the container may be accessed through the lid. Accordingly, removing items from prior art containers can often be time consuming and labor intensive.  
       SUMMARY OF THE INVENTION  
       [0007]     In view of the shortcomings set forth above, it is an object of the invention to provide an improved foldable container that meets all requirements stated above.  
         [0008]     It is another object of the present invention to provide a container that facilitates the quick assembly or disassembly of the box, while providing the container with enhanced strength and stability.  
         [0009]     It is a further object of the present invention to provide a foldable container that will allow access to the contents of the container when the container is located in close proximity to a ceiling or top shelf.  
         [0010]     The invention includes a multi-panel collapsible container able to support the weight of the goods and provide a quick and easy access to the contents of the container from the sides and the top, the container is configured to be collapsed for ease of storage when not in use.  
         [0011]     The container includes a support structure, a first end, and a second end. A bottom insert may be positioned in the interior of the container to lock the ends of the container in place and provide additional support for the contents of the container.  
         [0012]     The container walls are securely locked by the content of the container, rather than mechanically fastened. This configurations enables the contents of the container to be accessible from multiple sides and from the top. The container can also be easily collapsed when not in use. Moreover, the container can be quickly assembled without the need for additional materials like packing tape.  
         [0013]     The components of the container are fabricated of an extrusion of laminated, profile, or corrugated paper sheets, die-cut, assembled, welded or glued. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0014]     The invention may be more completely understood in consideration of the following detailed description of various embodiments of the invention in connection with the accompanying drawings, in which:  
         [0015]      FIG. 1  shows a top view of the flattened components of the container pursuant to the invention.  
         [0016]      FIG. 2  shows a top view of the flattened components of the container integrally fastened by a wire pursuant to the invention.  
         [0017]      FIG. 3  shows a top view of a partially assembled container pursuant to the invention.  
         [0018]      FIG. 4  shows a top view of a partially assembled container with bottom insert pursuant to the invention.  
         [0019]      FIG. 5  shows a top view of an assembled container with dust cover pursuant to the invention.  
         [0020]      FIG. 6  shows a side view of a collapsed container pursuant to the invention.  
         [0021]      FIG. 7  shows a side view of an assembled container pursuant to the invention.  
         [0022]      FIG. 8  shows a side view of the bottom insert and dust cover of the container. 
     
    
       [0023]     While the invention is amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and will be described in detail. It should be understood, however, that the intention is not to limit the invention to the particular embodiments described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the appended claims.  
       DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0024]     Container  10  is shown in  FIG. 1 . Container  10  includes a support structure  12 , a first end  14 , a second end  16 , and a bottom insert  18 . Support structure  12  includes a base  20 , first sidewall  22 , and second sidewall  24 . Support structure  12  also includes a first flap  26  and a second flap  28 . The area between first sidewall  22  and first flap  26  is defined by edge  30 . Similarly, the area between second sidewall  24  and second flap  28  is defined by edge  32 . Edge  30  includes a first margin  38  and a second margin  40 . Edge  32  includes a first margin  34  and a second margin  36 . Base  20  includes a first margin  42  and a second margin  44 . Base  20 , first sidewall  22 , and second sidewall  24  are bounded by a front edge  46  and a back edge. First flap  26  is bounded by front edge  50  and back edge  52 . Second flap  28  is bounded by front edge  54  and back edge  56 . Edges  46 ,  48 ,  50 ,  52 ,  54 , and  56  are shown parallel to one another, although this feature is not necessary for the invention.  
         [0025]     First end  14  will now be discussed. End  14  includes side  58 , bottom  60 , extension  62 , extension  64 , and flap  66 . Edge  68  is disposed between side  58  and flap  66 . Aperture  70  is disposed in side  58 . Handle  72  is located along the top side of aperture  70 . The boundary between side  58  and handle  72  is defined by margin  74 . Edge  68  is bounded by margin  76  and margin  78 . The boundary between side  58  and bottom  60  is defined by margin  80 . The boundary between side  58  and extension  64  is bounded by margin  69 . The boundary between side  58  and extension  62  is bounded by margin  67 . End  14  includes a first side  82  and a second side  84 . Similarly, end  14  includes a top edge  86  and a bottom edge  88 . Bottom  60  is defined by a first side  90  and a second side  92 . Flap  66  and edge  68  each share a first side  94  and a second side  96 .  
         [0026]     The details of second end  16  will now be discussed. End  16  includes side  98 , bottom  100 , extension  102 , extension  104 , and flap  106 . Edge  108  is disposed between side  98  and flap  106 . Aperture  110  is disposed in side  98 . Handle  112  is located along the top side of aperture  110 . The boundary between side  98  and handle  112  is defined by margin  114 . Edge  108  is bounded by margin  116  and margin  118 . The boundary between side  98  and bottom  100  is defined by margin  120 . The boundary between side  98  and extension  104  is bounded by margin  122 . End  16  includes a first side  124  and a second side  126 . Similarly, end  16  includes a top edge  128  and a bottom edge  130 . Bottom  100  is defined by a first side  132  and a second side  134 . Flap  106  and edge  108  each share a first side  94  and a second side  96 .  
         [0027]     Insert  18  includes a central portion  140  located between sides  142  and  144 . A first margin  146  defines the boundary between portion  140  and side  142 . A second margin  148  defines the boundary between portion  140  and side  144 . An aperture  150  is disposed through portion  140 . Aperture  150  is circular, but may comprise a variety of shapes while remaining within the scope of the invention. Insert  18  also includes a top side  152  and a bottom side  154 . Top side  152  is generally parallel to bottom side  154 .  
         [0028]     During construction of container  10 , a wire  156  generally forming the rectangular configuration of the perimeter of base  20  is attached to support structure  12 , first end  14 , and second end  16 . First, a segment of wire  156  is positioned in close proximity to edge  30 . Next, first flap  26  is rotated about to margin  38  and margin  40  such that first flap  26  rests against first sidewall  22 . Flap  26  is then secured against sidewall  22  with adhesive, sonic welding, or other fastening means. An opposing segment of wire  156  is then positioned in close proximity to edge  32 . Second flap  28  is then rotated about margin  34  and margin  36  so that second flap  28  rests against second sidewall  24 . Flap  28  is then secured against sidewall  24  with adhesive, sonic welding, or other fastening means.  
         [0029]     The process of securing first end  14  and second end  16  to wire  156  will now be discussed. A segment of wire between first sidewall  22  and second sidewall  24  is positioned against edge  68  of first end. Flap  66  is then rotated about margins  76  and  78  so that flap  66  rests against side  58 . Flap  66  is secured to side  58  by adhesive, sonic welding, or other suitable fastening means. Similarly, edge  108  is positioned in close proximity to the segment of wire  156  opposite to first end  14 . Flap  106  is rotated over wire about margins  116  and  118  so that flap  106  rests against side  98 . Side  98  is attached to flap  106  by adhesive, sonic welding, or other suitable fastening means. In this configuration, support structure  12 , first end  14 , and second end  16  are rotatably fastened to wire  156  in a collapsed form, as shown in  FIGS. 2 and 6 .  
         [0030]     The assembly of container  10  will now be discussed. Support structure  12  is rotated so that sidewall  22  and sidewall  24  form 90-degree angles with base  20 . Next, extensions  62  and  64 , and bottom  60  are folded inward toward support structure  12  so that extensions  62  and  64 , and bottom  60  form 90-degree angles with side  58 . Margin  80  of end  14  is then moved against back edge  48  while extensions  62  and  64 , and bottom  60  move into the interior of the container defined by sidewalls  22 ,  24 , and base  20 . Next, sides  124  and  126 , and bottom  100  are folded inward toward support structure  12  so that sides  124  and  126 , and bottom  100  for 90-degree-angles with side  98 . Margin  120  of end  16  is then moved against front edge  46  while sides  124  and  126 , and bottom  100  move into the interior of the container defined by sidewalls  22 ,  24 , and base  20 . This configuration is shown in  FIGS. 3 and 7 .  
         [0031]     Next, side  142  and side  144  of bottom insert  18  are folded upwardly so sides  142  and  144  form approximately 90-degree angles with respect to central portion  140 . Insert  18  is then positioned in the interior of container  10  so that central portion  140  rests against base, bottom  60 , and bottom  100  as shown in  FIG. 4 . Handles  72  and  112  may optionally be folded inward to provide additional comfort for persons moving container  10 .  
         [0032]     A second insert  18  may be used as an optional dust cover by folding sides  142  and  144  at approximately a 90-degree angle with respect to central portion  140 . Second insert  18  and optional dust cover  158  are shown in  FIG. 8 . Sides  142  and  144  are then slid between sidewalls  22  and  24  so that central portion  140  is located in a plane approximately parallel to edges  30  and  32 . This configuration is shown in  FIG. 5 .  
         [0033]     To access the contents of container  10 , it is not necessary to remove cover  158 . Rather, a user may pull margin  80  away from support structure  12  by pulling side  58  outward using aperture  70 . This aspect of the invention is especially useful if container  10  is located on a high shelf so that cover  158  is close to a ceiling of a storage room. This configuration is also useful to access the contents of container  10  when several items are stacked on top of container  10 . Perforation lines  160  and  162  are disposed in end  14  parallel to margin  80 . Lines  160  and  162  facilitate the bending of end  14  that is helpful to manipulate end  14  into a variety of positions. For example, lines  160  and  162  enable a user to more easily fold bottom  60  between cover  158  and the base  20  of another container  10  resting atop cover. Similar perforation lines  164  and  166  are located in second end  16 .  
         [0034]     Wire  156  is preferably fabricated from galvanized metal to inhibit oxidation. Wire  156  may comprise a variety of thicknesses while remaining within the scope of the invention. In a preferred embodiment, wire  156  is at least  1  mm thick. A plastic wire may also be used.  
         [0035]     Support structure  12 , first end  14 , second end  16 , and bottom insert  18  may comprise a variety of materials while remaining within the scope of the invention. In a preferred embodiment, support structure  12 , first end  14 , second end  16 , and bottom insert  18  are fabricated from corrugated paperboard, cardboard, or corrugated plastic. More specific examples include high density polyethylene (HDPE) laminate board, high density polyethylene (HDPE) profile board, polypropylene profile board, or corrugated paper.  
         [0036]     When assembled sides  82  and  84  of first end  14  meet evenly with edges  50  and  52  of first flap. This creates a smooth, even inner profile of the container. Similarly, sides  124  and  126  meet evenly with edges  54  and  56  to create a smooth, even inner profile of the container. This type of finish increases the desirability of the overall container.  
         [0037]     Although the invention has been described with reference to preferred embodiments, workers of ordinary skill will recognize that changes can be made in form and detail without departing from the spirit and scope of the invention.