Abstract:
The multiple cleat bin of the present invention includes a base, a front wall, two opposing sidewalls, and a substantially vertical rear wall having an upper rim. The rear wall includes a cleat near the upper rim of the rear wall and a second cleat formed at the base of the rear wall. A third cleat formed in the rear wall may also be included. A fourth cleat formed in the rear wall may also be included. Preferably, a forewall and kick out wall are included to form a stacking space such that a second may be placed within bin for increased packing density for shipping or storage. The additional cleats provide additional strength for bins manufactured of more economical or recycled polymers that tend to be softer or less rigid. The use of multiple cleats allows for improved strength and flexibility in use. The bin may also include multi-element structural trusses at the front wall, right sidewall, rear wall and left sidewall are integrally formed such that they form a single structural element that encircles the upper edge of bin.

Description:
FIELD OF THE INVENTION 
       [0001]    The present invention relates to storage and transport systems and more particularly to bin system for use in storing parts for use in assembly. The multiple cleat bin of the present invention includes a base, a front wall, two opposing sidewalls, and a substantially vertical rear wall having an upper rim. The rear wall includes a cleat near the upper rim of the rear wall and a second cleat formed at the base of the rear wall. A third cleat formed in the rear wall may also be included. A fourth cleat formed in the rear wall may also be included. Preferably, a forewall and kick out wall are included to form a stacking space such that a second may be placed within bin for increased packing density for shipping or storage. The additional cleats provide additional strength for bins using less costly materials that may not have the strength and rigidity of currently used materials. 
       BACKGROUND 
       [0002]    Bin systems are often used in industrial sites to aid in storing and sorting a number of small parts. Typically, the bins are open topped and hung horizontally from a single cleat formed on the back wall of the bin when the bin is molded or manufactured. 
       SUMMARY 
       [0003]    In accordance with embodiments of the present invention, a bin for industrial applications having a plurality of cleats on the back wall is provided. The bin may also include multi-element structural trusses at the front wall, right sidewall, rear wall and left sidewall are integrally formed such that they form a single structural element that encircles the upper edge of bin. The bin may be thermoformed, injection molded, blow molded, or rotocasted and may be formed of any suitable polymer such as polypropylene, polyethylene, polycarbonate, SMMA and HIPS or other injection grade polymers. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0004]    A more complete appreciation of the invention and the many embodiments thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, wherein: 
           [0005]      FIG. 1A  illustrates a perspective view of a four cleat bin in accordance with the present invention; 
           [0006]      FIG. 1B  illustrates a side plan view of a four cleat bin in accordance with the present invention; 
           [0007]      FIG. 1C  illustrates a rear plan view of a four cleat bin in accordance with the present invention; 
           [0008]      FIG. 1D  illustrates a bottom plan view of a four cleat bin in accordance with the present invention; 
           [0009]      FIG. 2  shows a side plan view, in detail, of a top cleat in a multicleat bin of the present invention. 
           [0010]      FIG. 3  shows a front plan view of a multicleat bin of the present invention. 
           [0011]      FIG. 4  shows a top plan view of a multicleat bin of the present invention. 
           [0012]      FIG. 5A  illustrates a perspective view of a three cleat bin in accordance with the present invention; 
           [0013]      FIG. 5B  illustrates a side plan view of a three cleat bin in accordance with the present invention; 
           [0014]      FIG. 5C  illustrates a rear plan view of a three cleat bin in accordance with the present invention; 
           [0015]      FIG. 6A  illustrates a perspective view of a two cleat bin in accordance with the present invention; 
           [0016]      FIG. 6B  illustrates a side plan view of a two cleat bin in accordance with the present invention; 
           [0017]      FIG. 6C  illustrates a rear plan view of a two cleat bin in accordance with the present invention; 
       
    
    
     DETAILED DESCRIPTION 
       [0018]    The present invention will now be described with occasional reference to the specific embodiments of the invention. This invention may, however, be embodied in different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. 
         [0019]    Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. The terminology used in the description of the invention herein is for describing particular embodiments only and is not intended to be limiting of the invention. As used in the description of the invention and the appended claims, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. 
         [0020]    Unless otherwise indicated, all numbers expressing quantities of ingredients, properties such as molecular weight, reaction conditions, and so forth as used in the specification and claims are to be understood as being modified in all instances by the term “about.” Accordingly, unless otherwise indicated, the numerical properties set forth in the specification and claims are approximations that may vary depending on the desired properties sought to be obtained in embodiments of the present invention. Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the invention are approximations, the numerical values set forth in the specific examples are reported as precisely as possible. Any numerical values, however, inherently contain certain errors necessarily resulting from error found in their respective measurements. 
         [0021]    The perspective view of a four cleat bin  10  of the present invention is shown in  FIG. 1A . Bin  10  includes front wall  12 , right sidewall  14 , rear wall  16  and left sidewall  18  and bin floor  20 . Front wall  12  includes an upper rim  12   a , hand hold  28 , label holder  26 . Handhold  28  is angled away from front wall  12  forming hollow  24 , into which the fingers may be inserted to pull bin  10  toward the user. Handhold  28  includes a rearward extension  22 . Right sidewall  14  includes upper rim  14   a , kick out wall  14   b , forewall  14   c , base rail  14   d , and footer  14   e . Upper rim  14   a  includes a depression  14   f  and inner flat  14   g , which receive footer  14   e  and base rail  14   d  of a second bin  10  stacked above the first bin  10 . Rear wall  16  includes top rail  16   a  that includes top cleat  30 , central cleats  32 ,  34  are integrally formed with the rear wall, and base cleat  36  is formed at the lower edge of rear wall  16  and notched out of sidewalls  14 ,  18 . Left sidewall  18  includes upper rim  18   a , kick out wall  18   b , forewall  18   c , a base rail (not shown) and a footer (not shown) the upper rim  18   a  includes a depression  18   f  and inner flat  18   g , which receive the footer and base rail of a second bin  10  stacked above the first bin  10 . 
         [0022]    The side view of a four cleat bin  10  of the present invention is shown in  FIG. 1B . The side view of bin  10  shows front wall  12 , right sidewall  14 , and rear wall  16 . Front wall  12  includes an upper rim  12   a , hand hold  28 , label holder  26 . Handhold  28  is angled away from front wall  12  forming hollow  24 , into which the fingers may be inserted to pull bin  10  toward the user. Handhold  28  includes a rearward extension  22  that reinforces the handhold when in use. Right sidewall  14  includes upper rim  14   a , kick out wall  14   b , forewall  14   c , base rail  14   d , and footer  14   e . Rear wall  16  includes top rail  16   a  that includes top cleat  30 , central cleats  32 ,  34  are integrally formed with the rear wall, and base cleat  36  is formed at the lower edge of rear wall  16  and notched out of sidewalls  14 ,  18 . Kick out wall  14   b  is angled forward by between 5° and 30°, sidewall  14  is angled outwardly from vertical by between 2° and 10°, and forewall  14   c  is displaced outwardly to forma stacking space such that a second bin  10  may be placed within the lower bin for increased packing density for shipping or storage. 
         [0023]    The rear wall  16  of a four cleat bin  10  of the present is shown in  FIG. 1C . Rear wall  16  includes top rail  16   a  that includes top cleat  30 , central cleats  32 ,  34  in the center of the rear wall, and base cleat  36  at the lower edge of rear wall  16 . Handhold  28  includes a rearward extension  22  on the right and left sides. Right sidewall  14  includes upper rim  14   a , kick out wall  14   b , a forewall  14   c , base rail  14   d , and footer  14   e  (not shown). Left sidewall  18  includes upper rim (not shown), kick out wall  18   b , forewall  18   c , a base rail  18   d , and a footer (not shown). When placed on a louvered panel or rack system, bin  10  engages four rows of louvers with the cleats  30 ,  32 ,  34 ,  36  such that bin  10  is substantially horizontal. Bin  10  may also be placed on a shelf and pulled forward on the shelf using handhold  28 . 
         [0024]    The bottom view of a multicleat bin of the present invention is shown in  FIG. 1D . Bin  10  includes front wall  12 , right sidewall  14 , rear wall  16  and left sidewall  18  and bin floor  20 . Front wall  12  includes an upper rim  12   a , handhold  28 , label holder  26 . Handhold  28  is angled away from front wall  12  and includes a rearward extension  22 . Positioned between front wall  12  and handhold  28  are a number of reinforcing beams  12   b , which are formed in the molding process and extend from front wall  12  to handhold  28 . Beams  12   b , in combination with front wall  12  and handhold form a multi-element structural truss. Right sidewall  14  includes upper rim  14   a , kick out wall  14   b , forewall  14   c , base rail  14   d , and footer  14   e . Upper rim  14   a  includes a depression  14   f  and inner flat  14   g . Reinforcing beams  14   i , which are formed in the molding process span the inner flat  14   g  and extend from sidewall  14  to rim  14   a . Reinforcing beams  14   h , also formed in the molding process span the upper rim  14   a . The beams  14   i ,  14   h  in combination with sidewall  14 , upper rim  14   a  and inner flat  14   g  form a multi-element structural truss. 
         [0025]    Rear wall  16  includes top rail  16   a  that includes top cleat  30 , central cleats  32 ,  34  are integrally formed with the rear wall, and base cleat  36  is formed at the lower edge of rear wall  16  and notched out of sidewalls  14 ,  18 . Reinforcing beams  30   a ,  30   b , formed during the molding process extend from sidewall  16  to the top cleat  30 . Beams  30   a ,  30   b  in combination with sidewall  16  and top cleat  30  form a multi-element structural truss. 
         [0026]    Left sidewall  18  includes upper rim  18   a , kick out wall  18   b , forewall  18   c , base rail  18   d , and footer  18   e . Upper rim  18   a  includes a depression  18   f  and inner flat  18   g . Reinforcing beams  18   i , which are formed in the molding process span the inner flat  18   g  and extend from sidewall  18  to rim  18   a . Reinforcing beams  18   h , also formed in the molding process span the upper rim  18   a . The beams  18   i ,  18   g  in combination with sidewall  18 , upper rim  18   a  and inner flat  18   g  form a multi-element structural truss. 
         [0027]    Rearward extensions  22  link the front wall  12  to sidewalls  14 ,  18 . The rearward extension  22  is formed with a diagonal beam  12   c  as well as perpendicular beam  22   a . On right sidewall  14  the forewall  14   c  is linked to the rearward extension  22  by and top rail  14   a  by beams  12   a ,  12   c  to form a multi-element structural truss. On left sidewall  18  the forewall  18   c  is linked to the rearward extension  22  by and top rail  18   a  by beams  12   a ,  12   c  to form a multi-element structural truss. 
         [0028]    Base  20  may include longitudinal reinforcements  20   a , latitudinal reinforcements  20   b  and/or curved reinforcements  20 . Reinforcements  20   a ,  20   b ,  20   c  serve to reinforce the base of the bin in high load situations. 
         [0029]    The multi-element structural trusses at the front wall  12 , rearward extensions  22 , right sidewall  14 , rear wall  16  and left sidewall  18  are integrally formed such that they form a single structural element that encircles the upper edge of bin  10  provide improved strength and rigidity in high load applications. 
         [0030]    A detailed side view of a cleat suitable for use with bin of the present invention is shown in  FIG. 2 . Cleat  30  includes projection  30   a  that descends from rear wall  16 . The projection includes a curved transition  42 . A louver of a louvered rack or a rail of a rail system fits into cleat  30  and contacts the radius  42  and the inner surface of projection  30   a . Radius  42  and projection  30   a  support a portion of the weight of bin  10 . The radius  42  and projection  30   a  also bear the torque generated by a loaded bin  10  when hung. 
         [0031]    The front view of bin  10  of the present invention is shown in  FIG. 3 . Front wall  12  includes an upper rim  12   a , hand hold  28 , label holder and rearward extension  22 . Right sidewall  14  includes upper rim  14   a , kick out wall  14   b , forewall  14   c , base rail  14   d , and footer  14   e . Upper rim  14   a  includes a depression  14   f  and inner flat  14   g , which receive footer (not shown) and base rail  14   d  of a second bin  10  stacked above the first bin  10 . Rear wall  16  includes top rail  16   a  to form cleat  30 , a central cleat  32  is also shown. Opposed rails  40  formed on rear wall  16  form an insert for a longitudinal bin separator. Left sidewall  18  includes upper rim  18   a , kick out wall  18   b , forewall  18   c , a base rail  18   d  and footer (not shown) the upper rim  18   a  includes a depression  18   f  and inner flat  18   g , which receive the footer and base rail of a second bin  10  stacked above the first bin  10 . 
         [0032]    The top view of bin  10  of the present invention is shown in  FIG. 4 . Front wall  12  includes an upper rim  12   a , label holder  26 , opposed rails  46   a ,  46   b  and opposed rails  44   a ,  44   b  forming a retainers for a longitudinal bin separator. Right sidewall  14  includes upper rim  14   a , kick out wall  14   b , forewall  14   c . Upper rim  14   a  includes a depression  14   f  and inner flat  14   g , which receive footer (not shown) and base rail (not shown) of a second bin  10  stacked above the first bin  10 . An optional second depression  14   h , which may include an orifice  14   i , receives a tab to lock stacked bins together. Rear wall  16  includes top rail  16   a . Rear wall  16  may also include opposed rails  40   a ,  40   b  and  42   a ,  42   b  forming retainers for a longitudinal bin separator. Left sidewall  18  includes upper rim  18   a , kick out wall  18   b , forewall  18   c . Upper rim  18   a  includes a depression  18   f  and inner flat  18   g , which receive footer (not shown) and base rail (not shown) of a second bin  10  stacked above the first bin  10 . A second depression  18   h , which may include an orifice  18   i , receives a tab to lock stacked bins together. 
         [0033]    The perspective view of a three cleat bin  110  of the present invention is shown in  FIG. 5A . Bin  110  includes front wall  112 , right sidewall  114 , rear wall  116 , left sidewall  118 , and bin floor  120 . Front wall  112  includes an upper rim  112   a , hand hold  128 , label holder  126 . Handhold  128  is angled away from front wall  112  forming hollow  124 , into which the fingers may be inserted to pull bin  110  toward the user. Handhold  128  includes a rearward extension  122 . Right sidewall  114  includes upper rim  114   a , kick out wall  114   b , forewall  114   c , base rail  114   d , and footer  114   e . Upper rim  114   a  includes a depression  114   f  and inner flat  114   g , which receive footer  114   e  and base rail  114   d  of a second bin  110  stacked above the first bin  110 . Rear wall  116  includes top rail  116   a  that includes top cleat  130 , central cleat  132  is formed with rear wall  116 , and base cleat  136  is formed at the lower edge of rear wall  116  and notched out of sidewalls  114 ,  118 . Left sidewall  118  includes upper rim  118   a , kick out wall  118   b , forewall  118   c , a base rail (not shown) and a footer (not shown) the upper rim  118   a  includes a depression  118   f  and inner flat  118   g , which receive the footer and base rail of a second bin  110  stacked above the first bin  110 . 
         [0034]    The side view of a three cleat bin  110  of the present invention is shown in  FIG. 5B . The side view of bin  110  shows front wall  112 , right sidewall  114 , and rear wall  116 . Front wall  112  includes an upper rim  112   a , hand hold  128 , label holder  126 . Handhold  128  is angled away from front wall  112  forming hollow  124 , into which the fingers may be inserted to pull bin  110  toward the user. Handhold  128  includes a rearward extension  122  that reinforces the handhold when in use. Right sidewall  114  includes upper rim  114   a , kick out wall  114   b , forewall  114   c , base rail  114   d , and footer  114   e . Rear wall  116  includes top rail  116   a  that includes top cleat  130 , central cleat  132 , and base cleat  136  is formed at the lower edge of rear wall  116  and notched out of sidewalls  114 ,  118 . Kick out wall  114   b  is angled forward by between 5° and 30°, sidewall  114  is angled outwardly from vertical by between 2° and 10°, and forewall  114   c  is displaced outwardly to form a stacking space such that a second bin  110  may be placed within the lower bin for increased packing density for shipping or storage. 
         [0035]    The rear wall  116  of bin  110  of the present is shown in  FIG. 5C . Rear wall  116  includes top rail  116   a  that includes top cleat  130 , central cleat  132  in the center of the rear wall, and base cleat  136  at the lower edge of rear wall  116 . Handhold  128  includes rearward extensions  122  on the right and left sides. Right sidewall  114  includes upper rim  114   a , kick out wall  114   b , a forewall  114   c , base rail  114   d , and footer  114   e  (not shown). Left sidewall  118  includes upper rim (not shown), kick out wall  118   b , forewall  118   c , a base rail  118   d , and a footer  118  (not shown). When placed on a louvered panel or rail system, bin  110  engages three rows of louvers with cleats  130 ,  132 ,  136  such that bin  110  is substantially horizontal. Bin  110  may also be placed on a shelf and pulled forward on the shelf using handhold  128 . 
         [0036]    The perspective view of a two cleat bin  210  of the present invention is shown in  FIG. 6A . Bin  210  includes front wall  212 , right sidewall  214 , rear wall  216  and left sidewall  218  and bin floor  220 . Front wall  212  includes an upper rim  212   a , hand hold  228 , label holder  226 . Handhold  228  is angled away from front wall  212  forming hollow  224 , into which the fingers may be inserted to pull bin  210  toward the user. Hand hold  228  includes a rearward extension  222 . Right sidewall  214  includes upper rim  214   a , kick out wall  214   b , forewall  214   c , base rail  214   d , and footer  214   e . Upper rim  214   a  includes a depression  214   f  and inner flat  214   g , which receive footer  214   e  and base rail  214   d  of a second bin  210  stacked above the first bin  210 . Rear wall  216  includes top rail  216   a  that includes top cleat  230 , and base cleat  236  is formed at the lower edge of rear wall  216  and notched out of sidewalls  214 ,  218 . Left sidewall  218  includes upper rim  218   a , kick out wall  218   b , forewall  218   c , a base rail (not shown) and a footer (not shown) the upper rim  218   a  includes a depression  218   f  and inner flat  218   g , which receive the footer and base rail of a second bin  210  stacked above the first bin  210 . 
         [0037]    The side view of a two cleat bin  210  of the present invention is shown in  FIG. 6B . The side view of bin  210  shows front wall  212 , right sidewall  214 , and rear wall  216 . Front wall  212  includes an upper rim  212   a , hand hold  228 , label holder  226 . Handhold  228  is angled away from front wall  212  forming hollow  224 , into which the fingers may be inserted to pull bin  210  toward the user. Hand hold  228  includes a rearward extension  222  that reinforces the hand hold when in use. Right sidewall  214  includes upper rim  214   a , kick out wall  214   b , forewall  214   c , base rail  214   d , and footer  214   e . Rear wall  216  includes top rail  216   a  that includes top cleat  230 , and base cleat  236  is formed at the lower edge of rear wall  216  and notched out of sidewalls  214 ,  218 . Kick out wall  214   b  is angled forward by between 5° and 30°, sidewall  214  is angled outwardly from vertical by between 2° and 10°, and forewall  214   c  is displaced outwardly to form a stacking space such that a second bin  210  may be placed within the lower bin for increased packing density for shipping or storage. 
         [0038]    The rear wall  216  of a two cleat bin  210  of the present is shown in  FIG. 6C . Rear wall  216  includes top rail  216   a  that includes top cleat  230 , and base cleat  236  at the lower edge of rear wall  216 . Handhold  228  includes a rearward extension  222  on the right and left sides. Right sidewall  214  includes upper rim  214   a , kick out wall  214   b , a forewall  214   c , base rail  214   d , and footer  214   e  (not shown). Left sidewall  218  includes upper rim (not shown), kick out wall  218   b , forewall  218   c , a base rail  218   d , and a footer (not shown). When placed on a louvered panel or rack system, bin  210  engages two louvers with the cleats  230 ,  236  such that bin  210  is substantially horizontal. Bin  210  may also be placed on a shelf and pulled forward on the shelf using handhold  228 . 
         [0039]    The bin of the present invention may be formed by any suitable method including thermoforming, injection molding, blow molding, and rotocasting. The bin and dividers may be formed of any suitable material, such as: polypropylene, polyethylene, polycarbonate, SMMA (styrene methyl methacrylate, acrylic blend), or HIPS high impact polystyrene or other such materials commonly used in the manufacturing of polymeric parts and/or parts made by common forming techniques. 
         [0040]    The present invention should not be considered limited to the specific examples described herein, but rather should be understood to cover all aspects of the invention. Various modifications, equivalent processes, as well as numerous structures and devices to which the present invention may be applicable will be readily apparent to those of skill in the art. Those skilled in the art will understand that various changes may be made without departing from the scope of the invention, which is not to be considered limited to what is described in the specification.