Abstract:
A lift van system that includes: a top and bottom cap, each comprising a folded sheet, wherein each folded sheet has substantially similar design specifications; first and second side wall sections, each comprising a single sheet, wherein the first and second side wall sections have substantially similar design specifications; and a cardboard pallet, wherein the pallet fits into the bottom cap.

Description:
CLAIM OF PRIORITY  
   The present invention claims priority to U.S. Provisional Application Ser. No. 60/532,293 filed on Dec. 23, 2003, entitled “CARDBOARD LIFT VAN SYSTEM.” 

   BACKGROUND OF THE INVENTION 
   1. Technical Field 
   The present invention relates generally to packaging and containers, and relates more specifically to a corrugated fiberboard lift van system. 
   2. Related Art 
   Lift vans are widely utilized in the moving and transportation industries as containers for storage, packaging, and transport. Lift vans provide a relatively large uniform sized container in which items can be easily stored and moved. Typical dimensions are, e.g., 88″ in length×45″ in width×88″ in height. Because of their uniform dimensions, the containers can be easily placed on pallets (or incorporate a pallet) that allow the container to be moved with a forklift. 
   Most prior art lift vans are constructed from plywood. Accordingly, constructing, packaging and moving the lift vans involve costly operations. Also, some countries are beginning to place restrictions on the import of plywood due to environmental issues involving bugs and the like infesting the wood. 
   One solution to the problem involves utilizing cardboard or fiberboard instead of plywood. Unfortunately, significant complexity is introduced in designing a cardboard/fiberboard lift van due to the fact that the container must provide significant structural resiliency. To address this, prior art cardboard lift vans require many different cardboard/fiberboard parts that are expensive and complicated to manufacture. Assembly of the prior art designs is also complicated given the many parts involved in constructing such a large containment device. In addition, the cardboard/fiberboard lift van must be collapsible so that it can be broken down for storage when not in use. Accordingly, a need exists for a simple to manufacture and assemble lift van system. 
   SUMMARY OF THE INVENTION 
   The present invention addresses the above-mentioned problem, as well as others, by providing a lift van container that can manufactured from a small number of parts, and be easily collapsed or erected as needed. 
   In a first aspect, the invention provides a lift van system that includes: a top and bottom cap, each comprising a folded sheet, wherein each folded sheet has substantially similar design specifications; first and second side wall sections, each comprising a single sheet, wherein the first and second side wall sections have substantially similar design specifications; and a pallet, wherein the pallet sits within the bottom cap. 
   In a second aspect, the invention provides a lift van container, comprising: a top and bottom cap, each comprising a folded sheet of material, wherein both folded sheets have substantially similar design specifications; first and second side wall sections, each comprising a foldable sheet of material, wherein the first and second side wall sections have substantially similar design specifications; and a pallet, wherein the pallet can be snapped into a lip of the bottom cap. 
   In a third aspect, the invention provides a container, comprising: a top and bottom cap, each comprising a folded sheet of material, wherein both folded sheets have substantially similar design specifications; and first and second side wall sections, each comprising a foldable sheet of material that forms three walls when erected, wherein the first and second side wall sections have substantially similar design specifications. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  depicts an isometric view of a lift van container in a collapsed position in accordance with the present invention. 
       FIG. 2  depicts an isometric view of a bottom of the lift van container of  FIG. 1  with the pallet being installed. 
       FIG. 3  depicts an isometric view of a bottom of the lift van container of  FIG. 1  with a first part of a sidewall installed and an end flap folded down for loading. 
       FIG. 4  depicts an isometric view of an erected lift van system in an erected position in accordance with the present invention. 
       FIG. 5  is design schematic of a top and bottom cap. 
       FIG. 6  is a design schematic of a sidewall part. 
       FIG. 7  is a design schematic of a pallet design. 
       FIG. 8  is a side view of the design schematic of  FIG. 7 . 
       FIG. 9  is an alternative design schematic of a top and bottom cap. 
       FIG. 10  is a top cross-sectional view of the sidewall sections of the container. 
   

   DETAILED DESCRIPTION OF THE INVENTION 
     FIG. 1  depicts an isometric view of a lift van container  10  (“container  10 ”) in a broken down or collapsed position, suitable for storage and transport before being erected and loaded with wares.  FIG. 4 , described below, depicts the container  10  in its erected position, suitable for holding wares. In the collapsed position, container  10  is completely packaged within a top cap  12  and a bottom cap  14 . Enclosed with the top cap  12  and bottom cap  14  are a pallet  20  (described below) and side wall sections  30 ,  40  (also described below). 
   Both of the top and bottom caps  12  and  14  are identical in that they are created from the same (or substantially the same) dye/design specifications, i.e., they are produced from identical (or substantially identical) cut sheets, e.g., cardboard, fiberboard, etc.  FIG. 5 , described below, depicts a design schematic of the top and bottom cap  12 ,  14 .  FIG. 9  depicts an alternative embodiment of a top and bottom cap. Because the top and bottom share the same specifications, the complexity of the manufacturing process is greatly reduced. 
   As shown in  FIG. 1 , both the top and bottom caps  12 ,  14  have interlocking tabs  16  that allow the container  10  to be securely packaged in the collapsed position. In particular, each of the top and bottom caps  12 ,  14  has a first side flap  17  with two exterior tabs and one interior tab, and a second side flap  19  with one exterior tab and two interior tabs (the tab features are described in further detail in  FIG. 5 ). When a first side flap  17  of the bottom cap  14  is mated with a second side flap  19  of the top cap  12  as shown, the exterior tabs interlock with the interior tabs, thereby securing the top cap  12  to the bottom cap  14 . The alterative embodiment shown in  FIG. 9  does not include interlocking tabs  16 . 
   Each cap also includes a plurality of forklift holes  18  that allow the container  10  to be lifted and moved from any of the four sides with a standard forklift. The forklift holes  18  are accessible in both the collapsed and erected positions. 
     FIG. 2  depicts an isometric view of the bottom cap  14  of the lift van container  10  with a pallet  20  being installed. Pallet  20  is comprised of a pallet surface  22 , a plurality of bocks  24 , and a bottom floor  26 . Defined within the entire inside bottom edge of the bottom cap  14  is a lip  28  for receiving the bottom floor  26 . The bottom floor  26  of the pallet  20  is sized to fit securely into an edge  28  of the bottom cap, and thus, obviate the need for any additional parts to secure the pallet. It should be noted any system for receiving and securing pallet  20  in bottom cap  14  could be utilized.  FIG. 7 , described below, depicts a design schematic of the pallet  20 . 
     FIG. 3  depicts an isometric view of the container  10  with a first sidewall section  30  installed. First sidewall section  30  includes three segments  32 ,  34 , and  36  that form two full walls (segments  32  and  34 ) and a partial wall (segment  36 ). A second sidewall section  40  (not shown), of the same design specifications as the first sidewall section  30  is placed opposite the first sidewall section  30  and overlaps with segments  32  and  36  to form the remain walls of the container.  FIG. 6 , described below, depicts a design schematic of side wall sections  30 .  FIG. 10  depicts a cross-sectional top view of both wall sections  30  and  40 . 
   As also shown in  FIG. 3 , bottom cap  14  includes a fold down end flap  38  that allows a first side edge of the bottom cap  14  to be folded down into an open position for loading/unloading. Fold down end flap  38  includes rounded edges  39  that pivot in and out of folds  41  formed between layers that make up side flaps  17  and  19  ( 19  not shown) of the bottom cap  14 . The configuration shown in  FIG. 3  would be typical for loading and unloading the container  10 . Once the loading/unloading process is complete, fold down end flap  38  can be secured back into folds  41  of the bottom cap  14 . Note that no additional parts are required to open and/or secure the fold down end flap  38 . 
     FIG. 4  depicts an isometric view of an erected lift van container  10  having both sidewall sections  30  and  40  installed and the top cap  12  placed thereon. Note that the sidewall sections  30 ,  40  overlap with each other, such that only side wall section  40  is visible in the view shown. As noted above, both sidewall sections  30 ,  40  comprise the same design specifications—i.e., they are interchangeable and thus comprise the same (or substantially the same) part. Second side wall section  40  includes three segments  42 ,  44 ,  46  ( 46  not visible in this view).  FIG. 10  shows a cross-sectional top view of the first and second side wall sections  30 ,  40 . 
   Referring now to  FIG. 5 , a design schematic of bottom cap  14  (“cap  14 ”) is shown. (As noted above, top cap  12  is identical to bottom cap  14 .) Cap  14  include a flat surface  50 , opposed side flaps  17  and  19 , a fold down end flap  38 , and a fixed end flap  52 . As described above, fold down end flap  38  includes rounded edges  39  that allows fold down end flap  38  to be pivoted into and out of folds  41  (formed when side flaps are folded as described below). Opposed side flaps  17 ,  19  each comprise an interior and exterior layer folded together. In particular, side flap  17  includes an exterior section  70 , an interior section  72 , an inner fold line  74  and an outer “double” fold line  76 . Interior section  72  can be folded inwardly along the outer “double” fold line  76  to mate with the exterior section  70 , both of which can then be folded inwardly perpendicular to the surface  50  to form side flap  17 . Interior section  72  includes a plurality of locking tabs  78  that lock into receiving holes  80  to secure the flap in position. Side flap  19  is constructed in a similar fashion. 
   When constructed, side flaps  17 ,  19  form folds  41  (shown in  FIG. 3 ) that receive the rounded edges  39  of the fold down end flap  38  at one end, and fixed edges  86  of the fixed end flap  52  at the other end. 
   As can be seen, interlocking tabs  16  are cut into the side flaps  17 ,  19 . The tabs that extend from the interior section  72  form interior tabs (e.g.,  82 ), and the tabs that extend from the exterior section form exterior tabs (e.g.,  84 ). Fork lift holes  18 , as described above, are also provided. As noted,  FIG. 9  depicts an alternative embodiment of a cap  100 , which is substantially similar to that shown in  FIG. 5 , except that it does not include interlocking tabs  16 . 
   Referring now to  FIG. 6 , a schematic diagram of side wall section  30  is shown, which forms three wall segments  32 ,  34 , and  36 , described above in  FIG. 3 . Side wall section  30  includes three folds  90 ,  92  and  94 , which allow the side wall section  30  to be folded for storage in the collapsed position within top cap  12  and bottom cap  14  ( FIG. 1 ). Folds  92  and  94  are used to fold the wall section  30  when erected ( FIGS. 3 and 4 ). Fold  92  may be reverse scored, allowing the sidewall section  30  to be folded in both directions. Side wall section  30  also includes fork lift cutouts  68  that match up with the forklift cutouts  18  in the bottom cap  14 . As noted above, both side wall sections  30  and  40  are interchangeable. 
   Referring now to  FIGS. 7 and 8 , pallet  20  is shown, which comprises a bottom floor  26 , a plurality of blocks  24 , and a pallet surface  22  ( FIG. 8 ). Blocks  24  are spaced to form openings  92  to provide a four way entry for a fork lift device. Blocks  24  may be formed from any type of structure, e.g., corrugated layers, etc. Pallet floor  22  may be comprised from, e.g., a two-piece cross laminated/corrugated structure. 
   The foregoing description of the preferred embodiments of the invention has been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the invention to the precise form disclosed, and obviously many modifications and variations are possible in light of the above teachings. Such modifications and variations that are apparent to a person skilled in the art are intended to be included within the scope of this invention as defined by the accompanying claims. 
   It should be appreciated that the invention could be fabricated from any type of material, including, but not limited to cardboard, corrugated fiberboard, boards constructed from polymers, composites, plastics, foam, etc. Moreover, while the caps  12 ,  14  (as well as the side wall sections) are described as being identical, they need not be exactly the same, i.e., they could include some differences. However, as noted above, by maintaining the same design for both caps and both side wall sections, the manufacturing complexity and cost is reduced. In addition, while the embodiments described above are generally directed toward a lift van container system, the inventive features could be applied to any type of container of any dimension.