Abstract:
A container is disclosed having a base, opposed side walls, and a rear wall. The base has an upper surface with a downward slope (α) towards the rear wall. The rear wall has a surface which is preferably angled to be perpendicular to the upper surface of the base. Such a configuration permits squared items to be stored within the container on a edge while maintaining full contact along an adjacent edge with the rear wall. The side walls and rear wall are hingedly attached to the base and connected to one another using interlocking connectors along juxtaposed edges. Alternatively, the present invention may include a double sloped base upper surface angled toward a center wall panel. The surfaces on each side of the center wall are preferably sloped to be perpendicular to the upper surface of the adjacent base upper surface. A double-sloped container using at least one center wall panel is also disclosed with similar features to the single-sloped container.

Description:
TECHNICAL FIELD 
     The present invention generally relates to containers, and more particularly, to a novel plastic container that is foldable or collapsible and is used for storing, transporting and displaying goods, such as glass panels, windows, door panels, or rectangular boxes. 
     BACKGROUND OF THE INVENTION 
     Currently, containers are used for storing and transporting numerous items. Certain fragile items, like door mirrors, windows, glass panes, frames, etc. are difficult to store in such a manner. In particular, these items are generally thin (relatively) rectangular items. If stored on there faces (e.g., the front and back surfaces) and stacked on top of one another, problems can occur. In addition, often times the front and back faces of the objects are not designed to bear any significant weight. For example, twenty stacked mirrors (i.e., stacked on top of one another) can be quite dangerous, both as to the objects themselves and to individuals nearby, as the faces are subjected to substantial loads. For this reason, such items are frequently stored side-by-side, like books on a shelf in a library. In this matter, the load caused primarily of the weight of the object is borne by an edge or side of the object. Thus, doors are transported, stored and displaced on their side edge, namely the bottom surface of the door. The door is transported in much the same way it is oriented in use. 
     One problem associated with storing, transporting and displaying objects standing on an edge is the absolute need for side walls on the structure supporting, transporting or displaying the object. For example, a pallet supporting twenty mirrors, standing on their side edges will fall over unless either tied tightly together, e.g., encircling the entire group with rope, or supported by side walls attached to the pallet. A four walled bin (pallet with four side walls) will hold the side-by-side objects. Nevertheless, with four walls, it becomes difficult to remove the objects being stored in the bin or on the pallet. To remove a single object, one must lift the object over a significantly high wall. This manipulation can, of course, cause breakage. 
     For this reason, sometimes three-walled bins are desired. Three walled bins (a pallet with three side walls attached thereto) have many advantages. The items being stored, transported and displayed (again like books on a book shelf) can be easily supported (two side walls take much of the weight bearing loads and the absence of one wall permits both easy viewing of the objects and easy removing of the objects off the pallet supporting them. 
     Accordingly, there is a need for devices and mechanisms to facilitate and improve upon the safety and improve upon existing systems associated with the storage and transporting of bins. 
     SUMMARY OF THE INVENTION 
     The present invention is a collapsible container that includes a base, opposed side walls and a rear wall. The base has an upper surface that slopes downwardly towards the rear wall. The rear wall is further sloped from the vertical. The walls are hinged to the base and can be removed when desired or rotated relative to the base. The hinge permits strong interconnection and minimum risk of separation between the components. The container rests upon a plurality of feet. 
     The collapsible container is designed for transporting and displaying doors, mirrors, ironing boards, ready-to-assemble (RTA) products, such as furniture and other long carton box packages. Packages can stand on the short ends (side edges) while leaning against the back panel to remain stable. The open front allows easy retrieval of packages without significant lifting over the side panels. Moreover, packages of different sizes and different products can be mixed on the same container. Additionally, packages can be divided up to about a dozen sections to allow for easy assortment and retrieval. There is no stacking of packages, thus avoiding breakage of products. The container can be further used for shipping, storing, and displaying items. In addition, the back and side panels can be folded down to reduce storage and transportation volume when the containers are shipped empty. Fork lifts and hand jacks can be easily used to move the container as four way entry is permitted. 
     The container is designed for multi-trip uses, thus reducing packaging cost as compared with one trip wood pallets and containers. This results in reduced material and waste handling for wholesalers and retailers compared with one trip boxes. 
     These and other aspects of the present invention set forth in the appended claims may be realized in accordance with the following disclosure with particular reference to the accompanying drawings. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     In the accompanying drawings forming part of the specification, and in which like numerals are employed to designate like parts throughout the same, 
     FIG. 1 is a front perspective view of one embodiment of a container made in accordance with the teachings of the present invention; 
     FIG. 2 is a rear perspective view of the container of FIG. 1; 
     FIG. 3 is a sectional side perspective view of the container; 
     FIG. 4 is a front perspective view of the container in the folded, empty position; 
     FIG. 5 is an sectional end perspective view of the container in the folded and empty position along line  5 — 5  in FIG. 4; 
     FIG. 6 is bottom perspective schematic view of the side wall panel having a male component for a preferred hinge assembly; 
     FIG. 7 is top perspective schematic view of the pallet base having a female component for a preferred hinge assembly; 
     FIG. 8 is a perspective schematic view of one part of an interlocking finger connector attached to the rear wall panel; 
     FIG. 9 is a perspective schematic view of another part of an interlocking finger connector attached to the side wall panel; 
     FIG. 10 is a perspective schematic view of the connector of FIGS. 8 and 9 interlocked; 
     FIG. 11 is identical to the drawing of FIG. 3 with the addition of two boxes supported thereon; 
     FIG. 12 is a top perspective view of another embodiment of a container made in accordance with the teachings of the present invention; and 
     FIG. 13 is a sectional side perspective view of the embodiment shown in FIG.  12 . 
    
    
     DETAILED DESCRIPTION 
     While this invention is susceptible of embodiments in many different forms, there is shown in the drawings and will herein be described in detail a preferred embodiment of the invention with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the broad aspect of the invention to the embodiments illustrated. 
     Turning to the FIGS. 1-11, one embodiment of a container  10  is shown in its various views. The preferred container  10  has a base pallet  20 , two optional side walls  40 ,  50  and a rear wall  60 . The base  20  has an inner (top or upper) surface  21  and an outer (bottom or lower) surface  22 . Similarly, each side wall  40 ,  50  has an inner surface  41 ,  51  and an outer surface  42 ,  52 . Likewise, the rear wall  60  has inner and outer surfaces  61 ,  62 . 
     The outer surfaces  42 ,  52 ,  62  of the side and end walls  40 ,  50 ,  60  and inner surface of the base  20  are substantially planar. The surfaces are, however, not necessarily parallel, as will be explained. The inner surfaces  41 ,  51 ,  61  of the walls and outer surface of the base have projecting ribs added to strengthen the members. The construction of these ribs or cells is well known in the art. The walls and base also have holes or openings therein to reduce the weight of the components and the entire assembly. This too is well known in the industry. Feet  30  are integral with the outer surface  22  of the base pallet  20 . These feet can be molded with the base as one unified and integral member or attached, such as by sonic welding, with the base. The location and general construction of the feet  30  can be seen in FIG.  2 . The feet lift the base off the ground and permit four ( 4 ) way entry of forklift tines and hand truck tines in the spaces between the feet. 
     The specific construction of the base  20  can be best seen in FIG.  3 . The base  20  has a substantially flat outer surface  22  that is substantially parallel to the ground when the container  10  rests upon the ground. The inner surface  21  is not parallel to the outer surface  22 ; rather, the inner surface  21  is sloped or inclined downwardly towards the rear wall  60 . In particular, the angle α formed by the imaginary planes formed by extending the existing planes of the inner surface  21  and outer surface  22  of the base  20  is approximately 2.5°. A front lip  23  is constructed it the front of the base  20 . Its purpose is to act as a stop or bumper. 
     Still referring to FIG. 3, the rear wall  60  has a substantially flat outer surface  62  that is substantially perpendicular to the ground when the container  10  rests upon the ground. The inner surface  61  is also sloped or inclined. In particular, the angle β formed by the imaginary planes formed by extending the existing planes of the inner surface  61  and outer surface  62  of the rear wall  60  is approximately 2.5°. 
     The inner surfaces  41 ,  51  and outer surfaces  42 ,  52  of the side walls  40 ,  50  are preferably substantially parallel to one another. 
     The walls  40 ,  50 ,  60  are hingedly connected to the base  20 . More particularly, each wall is connected to the base by two or more hinges. Additionally, the walls are interconnected. The hinges permit the walls to be upright (FIGS. 1,  2  and  3 ) or folded (FIGS.  4  and  5 ). The interconnection between the walls strengthens the walls and distributes the loads between them. 
     The hinge assembly components  70  shown in FIGS. 6 and 7 are schematic and represent the preferred female and male components of a hinge assembly. The position, orientation, construction and working of these hinges shall now be explained. The side walls  40 ,  50  and rear wall  60  have spaced apart male connectors  71  projecting from their bottom edges  72 . Each of these male connectors  71  is preferably T-shaped, having a body  73  and an arm  74 . In the present embodiment of FIG. 6, the body is formed of three parallel elements ( 73   a ). The arm  74  (the cross member of the T-shaped member at the distal end of the body  73 ) has a horizontal thickness of T 1 , a vertical thickness of T 2 , a leading surface  75 , and a trailing surface  76 . The leading and trailing surfaces  75 ,  76  are substantially flat. The side surfaces  77  connecting the leading and trailing surfaces are arcuate. 
     The base  20  has a girdle  24  projecting inwardly (up) therefrom. The girdle  24  houses the spaced apart female connectors  81  (FIG. 7) that mate with the male connectors  71 . The girdle  24  is hollow, formed of two parallel walls  24   a,    24   b  (FIG.  3 ). A cross-shaped aperture  83  is cut into the inner parallel wall  24   a  ( 82   a,    82   b  in FIGS.  6  and  7 ). This cross-shaped aperture  83  has a body  84  and cross arm  85 . The cross arm  85  has a vertical thickness of T 4 , which is slightly greater than the thickness of the arm  74  of the male connector  71  (the distance between the leading surface  75  and the trailing surface  76 ), permitting the arm  74  to slip into the arm  85 . The thickness of male connector T 1  is slightly less than the distance between the parallel walls  82   a,    82   b,  permitting the male arm to slide between the parallel walls. However, once the male T-connector is between the parallel walls  82   a,    82   b,  it cannot slide out as the upper edge  86  prevents movement out of the walls. Yet, the wall (side or rear) having the male connector  71  can rotate relative to the base&#39;s girdle having the female connector  81 . 
     The connectors work as follows. Each wall ( 40 ,  50 ,  60 ) has male connectors  71  projecting downwardly from the bottom edge. The base has corresponding female apertures  81  in the girdle thereof. The male T-shaped connectors are aligned with the female T-shaped apertures. The male arm is moved toward the female arm and inserted. The male connector is then dropped into position. The wall is thus pivoted outwardly and then moved downwardly (in the slot between the parallel walls). While this motion occurs the three walls interlock through a simple finger system. 
     Each wall  40 ,  50 ,  60  preferably has at least two connectors  45 ,  55 ,  65 , as illustrated in FIGS. 1 and 2. Referring to FIGS. 8,  9 , and  10  the connector dynamics between the side wall  50  and the rear wall  60  can be more readily understood. While not discussed, the other side wall  40  is constructed similarly to the side wall  50  shown. The side wall  50  has a connector  55  projecting from the rear edge  50   a  of the wall. The connector  55  comprises a extension  56 , projection  57  and tip  58 . The connector  65  projecting from the side edge  60   a  of the rear wall  60  includes a projection  67  and tip  68 . The connectors  55 ,  65  are capable of interlocking, as illustrated in FIG. 10, when the side wall  50  is lowered onto the base  20  during the attachment of the hinge assembly discussed above. To rotate the interlocked walls  40 ,  50 , they must initially be lifted or raised slightly above the base  20  to allow the connectors  45 ,  55 ,  65  to be disconnected. The walls  50 ,  60  are thus free to rotate relative to the base  20  or be removed from the base  20 . 
     The container  10 , once folded, appears as is shown in FIGS. 4 and 5. The top surface of the container is relatively flat with the walls  40 ,  50  folded downward, seated just below the girdle  24  of the base  20 . The girdle  24  has cut-outs  28  therein for seating the connectors  22  of the walls  50 . 
     Thus, when the container  10  is in the assembled (open) position (see FIG.  1 ), rectangular (relatively narrow) boxes [Boxes M and N], such as those for door mirrors, windows, glass panes, frames, and the like can be stored on the base  20 , between the walls  50  against the rear wall  60 , as shown in FIG.  11 . The boxes are stored neither on their front or back faces S, nor on top of one another; rather, they are transported and stored side-by-side and on their side edges, again much like books on a shelf with their front side edges F facing outwardly. The slope of the top surface of the base  20  (approximately 2.5°) causes the items stored to tilt towards the rear wall  60  where their load can be partially supported by the rear wall  60 . In addition, this reduces the chance of the damage to the contents of the boxes and the chance of them falling off the container  10 . The boxes are nicely displaced with their faces F exposed. 
     The preferred slope of 2.5° is used because it is sufficient to shift part of the load to the rear wall  60 , yet maintain the items (boxed or un-boxed) within the dimensional limitations of the container  10 . Naturally, a range of slopes are contemplated which will sufficiently achieve the goals of the present invention. For smaller items a base surface slope of up to about 10° or more may be used. Larger items may require only a slight slope of maybe 1°. 
     Additionally, a front lip  23  projects from the base  20  and prevents the boxes from sliding from the container  10 . To remove an item [box], it is necessary to lift the item above the lip  23  and slides it forward off the container  10 . 
     An alternative embodiment, shown in FIGS. 12 and 13, utilizes a double-sloped base  120 , two center wall panels  160 , and four collapsible side walls  150 . The center wall panels  160  divide the upper surface of the base  120  into two approximately equal areas—though the base  120  may be disproportionately divided if desired. The side walls  150  complete a three-sided enclosure of the area two areas. 
     FIG. 13 illustrates an approximately 2.5° slope of the left and right areas of the upper surface of the base  120  toward the center panel  160 . The two center wall panels  160  are configured to abut one another along their inner surfaces. Further, each outer surface of the center wall panels  160  is sloped to match the slope of the adjacent sloped upper surface area of the base  120  (i.e., the adjacent surfaces of the base and center panels are perpendicular to one another). Hinge assemblies between the side panels and base and connectors between adjacent side panels and center wall panels are contemplated for this embodiment as well. Such features would be substantially identical to those previously discussed for the single-sloped base container  10 . 
     The double-slopped embodiment permits compaction of the container  110  when empty by folding down each of the center wall panels  160  to form a flat upper surface. By matching the slopes between adjacent surfaces, the result of laying one surface (e.g., the center wall panel  160 ) atop the other (e.g., the base  120 ) is to negate the sloped surface leaving a level upper surface. This allows the side walls  150  to be compacted upon the level surface as well. 
     Another alternative embodiment (not shown) is identical to the single and double sloped embodiments discussed above, without sidewalls. The sidewalls provide lateral support to both the rear wall and the center wall, and help retain any items on the base. However, with large items, side egress from the base (either embodiment) can be prevented by use of a small upward stop. Lateral support can be improved with the rear wall and center wall by the hinge connectors or by creating a single piece construction. Other means for improving the lateral stability of the rear and center wall are known to those skilled in the art. 
     Each of the disclosed embodiments above is discussed as having a preferable modular design. That is, the side walls, rear walls, center wall panels, base, etc. are separately manufactured components which can be fitted together, as discussed. However, while presenting some economic disadvantages, each embodiment could be a single unitary design. Those skilled in the art of plastic molding processes could readily prepare such a unitary design from the discussion and drawings of this application. 
     While the specific embodiments have been illustrated and described, numerous modifications come to mind without significantly departing from the spirit of the invention and the scope of protection is only limited by the scope of the accompanying claim.