Abstract:
A basket comprises one or more bendable sheets of material that are configured to cooperate to bend and engage their cooperating edges to form a continuous basket side wall. A bottom frame is attachable to the sheets of material to provide a bottom to the basket and lend rigidity to the side wall. An upper ring is configured to attach to the sheets of material opposite the bottom frame to define an upper opening and further provide rigidity to the basket. The basket may be disassembled such as for storage, shipping, and transportation in a flattened configuration.

Description:
RELATED APPLICATIONS  
       [0001]    The present application claims priority to U.S. Provisional Application having Serial No. 60/425,956 filed on Nov. 12, 2002, the entire contents of which is incorporated herein by reference. 
     
    
     
       BACKGROUND OF THE INVENTION  
         [0002]    1. Field of the Invention  
           [0003]    The present invention relates to the field of quick-assembly baskets, such as for waste or recyclables. More specifically, the present invention is for a composite basket that is quick to assemble, can be economically stored and shipped in a space-saving flattened state, and is very lightweight.  
           [0004]    2. Description of the Related Art  
           [0005]    Waste baskets for paper and other household or office refuse are available in a broad range of sizes and shapes. A typical waste basket is molded plastic or may be formed of other sheet materials to form a generally open container defining an interior waste compartment.  
           [0006]    While the conventional waste basket is relatively convenient and simple to manufacture and use, there are drawbacks with regards to transporting, storing, and stacking one or more baskets. In particular, conventional waste baskets are relatively bulky, which adversely affects the portability and ease of storage, a factor which is considerable for a user who relocates frequently or where space is scarce. Further, any reduction of material usage in a waste basket that can be made without reducing its waste storage capacity would be desirable as a cost savings measure.  
           [0007]    In light of these and other needs, embodiments of the present invention provide a composite basket that can packaged and stacked in one configuration, and then assembled and used in a second configuration.  
         SUMMARY  
         [0008]    According to one embodiment, a basket includes one or more side panels each having an upper edge, a lower edge, a first side edge and a second side edge. The first side edge is in engaging relation with a second side edge such that the one or more side panels form a continuous basket side wall. A bottom frame is configured for secure attachment to the side panel lower edge. An upper ring is configured for secure attachment to the side panel upper edge. The basket may further comprise at least a first side panel and a second side panel wherein the first side panel includes a tab on the first side edge and the second panel includes a slot on the second edge configured to receive the tab from the first side panel. The side panels may be formed from a bendable material. One way of attaching the bottom frame to the side panel lower edge is by forming a groove in the bottom frame configured to accept and securely hold the side panel lower edge. Likewise, the upper ring can define a groove configured to accept and securely hold the side panel upper edge. Finally, the bottom frame is optionally configured with a lock and the side panel lower edge is configured with a hole configured to engage the lock to securely hold the side panel to the bottom frame.  
           [0009]    According to another embodiment, a basket is formed from one or more flexible side panels, each side panel having an upper edge and a lower edge, with each of the upper edge and lower edge having one or more holes formed adjacent thereto. The side panels also each have a male side edge having tabs protruding therefrom, and a female side edge having slots formed therein configured to receive the tabs. A bottom frame defines a longitudinal groove configured to receive the side panel lower edge. The bottom frame further has an engagement structure configured for cooperation with the holes formed in the side panel lower edge to securely hold the side panel lower edge within the bottom frame longitudinal groove. An upper ring defines a longitudinal groove configured to receive the side panel upper edge. The upper ring further has an engagement structure configured for cooperation with the holes formed in the side panel upper edge to securely hold the side panel upper edge within the upper ring longitudinal groove. The basket may utilize two or more side panels. In one embodiment, the side panel male side edge comprises one or more lock tabs configured to be securely inserted into a corresponding slot that inhibits subsequent withdrawal of the lock tab from the slot. The lock tab may be wider than the slot to inhibit subsequent withdrawal.  
           [0010]    A method of assembling a basket comprises the steps of providing one or more sheets of bendable material, each sheet having a first edge and a second edge, wherein each edge is configured with engagement structure such that the first edge can be engaged with the second edge. The first edge is engaged with the second edge to define a closed generally cylindrical side wall. A bottom frame is provided and is configured to engage the one or more sheets of bendable material. The one or more sheets of bendable material is attached to the bottom frame. The method may optionally further include the step of providing an upper ring and attaching the upper ring to the one or more sheets of bendable material.  
           [0011]    In the following description, reference is made to the accompanying drawings which form a part of this written description which show, by way of illustration, specific embodiments in which the invention can be practiced. It is to be understood that other embodiments may be utilized and structural changes may be made without departing from the scope of the present invention. Where possible, the same reference numbers will be used throughout the drawings to refer to the same or like components. Numerous specific details are set forth in order to provide a thorough understanding of the present invention; however, it should be obvious to one skilled in the art that the present invention may be practiced without the specific details or with certain alternative equivalent devices and methods to those described herein. In other instances, well-known methods, procedures, components and devices have not been described in detail so as not to unnecessarily obscure aspects of the present invention. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0012]    [0012]FIG. 1 illustrates a plan view of a side panel for use with embodiments of the present invention.  
         [0013]    [0013]FIG. 2 is a close-up plan view of the side panel of FIG. 1.  
         [0014]    [0014]FIG. 3 is a plan view of two side panels such as the ones illustrated in FIGS. 1 and 2 in cooperative engagement.  
         [0015]    [0015]FIG. 4 is a perspective view of two side panels engaged to form side walls of a basket.  
         [0016]    [0016]FIG. 5 is a perspective top view of a bottom frame.  
         [0017]    [0017]FIG. 6 is a bottom perspective view of a bottom frame.  
         [0018]    [0018]FIG. 7 is a close-up perspective view of a locking wedge of the bottom frame.  
         [0019]    [0019]FIG. 8 is a perspective view illustrating the bottom frame attached to the assembled side walls.  
         [0020]    [0020]FIG. 9 is a perspective view of an upper ring configured to cooperate with the basket side walls.  
         [0021]    [0021]FIG. 10 is a close-up perspective view of clips formed on the upper ring.  
         [0022]    [0022]FIG. 11 is a top plan view of the clips of FIG. 10.  
         [0023]    [0023]FIG. 12 is a perspective view of an assembled basket. 
     
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS  
       [0024]    With reference to FIGS. 1-4, a basket side panel  32  is preferably shaped to be substantially rectangular and has an opposing top edge  34  and a bottom edge  36 , and opposing side edges  38 ,  40 . Of course, the basket side panel  32  could be configured in any one of many geometrical shapes, including a square, trapezoid, parallelogram, or may have non linear edges. In one preferred embodiment, the basket side panel  32  is formed of a pliable plastic, such as polyurethane, polyethylene, polypropylene, or any of a number of other easily deformable materials.  
         [0025]    In the embodiments of FIGS. 1-4, a pair of cooperating basket side panels  32  are connected together to form a substantially cylindrical basket  42 . Of course, the same could be accomplished with only 1 side panel, or with more than 2 side panels as will be apparent to those of skill in the art. In addition, rather than having a bendable side wall  32 , it could be configured with fold lines or hinges defining segments that are moveable relative to other segments. In this type of embodiment, the side wall  32  could be bent or folded to shape any of a number of polygons. However, in one preferred embodiment, two cooperating side panels  32  are used in cooperation and are bent to form a circular of oval cylinder. Each side wall  32  has a plurality of slots  44  formed along a female side edge  40  and a plurality of tabs  46  extending from the opposing male edge  38 . The slots  44  are configured to accept the tabs  46  of the opposing male edge  38 . Preferably there is a one-to-one correspondence between the number of slots  44  and the number of tabs  46 , such that each slot  44  receives one tab  46 .  
         [0026]    As best illustrated in FIG. 2, one or more tabs  46  may be specially configured to provide a lock once assembled. For example, the middle tab  48  of FIG. 2 is shaped as a trapezoid, with the inserting edge  50  narrower than the attached edge  52 . The attached edge  52  is preferably not attached to the basket side panel  32  along its entire length and is configured to be slightly longer than the slot  44 , and thus provides a “lock tab.” 
         [0027]    Accordingly, as the lock tab  48  is inserted into its corresponding slot  44  in a cooperating side panel  32 , the lock tab  48  must deform in order to be fully inserted into the corresponding slot  44 , at which time, the lock  48  tab resiliently returns to its undeformed shape, and the length of the attached edge  52  inhibits unintentional removal from its slot  44 . However, if desired, a user can manually manipulate the lock tab  48  and force its removal from the slot  44 .  
         [0028]    In order to provide quick assembly of the basket, it is preferred that only one tab  46  is configured as a lock tab  48 ; however, more than one tab  46  may be so configured. The remaining tabs  46  are preferably configured in a simple square or rectangular shape for easy insertion and subsequent removal from their corresponding slots  44 . The tab corners may be rounded to allow easier manipulation and provide a modicum of safety to the user.  
         [0029]    As shown in FIG. 3, each tab  46  is inserted into a corresponding slot  44  on the cooperating side panel  32 . As mentioned above, while only 2 side panels  32  are illustrated, the basket may be assembled with one or more side panels. It can be seen that the side panels  32  overlap and thus cooperate to provide support and increased strength to better withstand subsequent hoop stresses and bending stresses exerted on the assembled basket.  
         [0030]    As discussed, each side panel  32  is configured with tabs  46  and slots  44 , such that two side panels  32  may be connected to each other by aligning each of their respective tabs  46  and slots  44 , as shown in FIG. 4. The lock tabs  48  further allow the assembled side panels  32  to remain assembled until the user attaches the remaining components and secures the basket in its assembled configuration. As illustrated, the assembled side panels  32  cooperate to define a continuous basket side wall.  
         [0031]    The side panels  32  may be formed of any suitable material, such as a polymeric material which exhibits flexibility, and offers the additional benefits of allowing additives mixed in with the resin. Such additives may be in the form of plasticisers, colorant dyes, and other additives which may affect surface finish, malleability, hardness, and opacity. Such suitable materials may include, for example, polyester, polypropylene, polyvinyl chloride (PVC), and the like. The side panels may also be formed from any suitable process, such as by stamping, cutting, molding, and the like.  
         [0032]    [0032]FIGS. 5 and 6 show one embodiment of a bottom frame  60  comprising a circumferential edge defining an annular groove  62  configured to receive the bottom edge  36  of the side panels. The bottom frame  60  further comprises a plurality of locking wedges  64  for securely attaching to the side panels  32 , as will be discussed below in further detail. Preferably, one side of the bottom frame  60 , either the top or the bottom, is configured with strengthening ridges  66 , such as those shown in FIG. 6. The strengthening ridges offer increased rigidity to the bottom plate such that it can maintain its shape in response to stresses exerted on it by the side panels and by any loads resulting from waste deposited within the assembled basket.  
         [0033]    The illustrated bottom frame  60  embodiment is shaped as an oval. Of course, it should be apparent to one of ordinary skill that the bottom frame may take on any of a number of perimeter shapes. For example, the bottom frame  60  could be shaped as a circle, ellipse, octagon, or any other regular or non-regular geometric shape.  
         [0034]    As shown in FIG. 7, the bottom frame  60  preferably includes one or more locking wedges  64  configured to hold the side panels  32 . With added reference to FIG. 1, each side panel  32  has one or more holes  66  formed adjacent to its respective upper edge  34  and lower edge  36  for cooperation with the locking wedges  64  of the bottom frame  60 . Each locking wedge  64  comprises a tab  68  configured to fit within the holes  66  of the side panels  32 . Additionally, each locking wedge  64  has one or more biasing members  70  that push the side panels  32  toward the tabs  68  thereby inhibiting subsequent unintentional withdrawal of the side panels  32  from the annular groove  62  in the bottom frame  60 .  
         [0035]    In practice, once the side panels  32  are connected to one another as described above, their respective lower edges  36  are forced into the annular groove  62  of the bottom frame  60  and the holes  66  formed in the side panel lower edges  36  align with the tabs  0 . 68  of the bottom frame  60 . The tabs  68  of the bottom frame  60  are captured within the holes  66  formed in the side panel lower edges  36  thus maintaining the attachment of the side panels  32  with the bottom frame  60 .  
         [0036]    The biasing tabs  70  of the bottom frame  60  serve to maintain the side panels  32  in their assembled position with respect to the tabs  68 , and further force the side panels  32  to be adjacent to the outer wall  72  defining the annular groove  62 , thereby providing rigidity to the assembled basket. Moreover, the biasing members  70  extend into the annular groove  62 , such that as the side panel lower edge  36  is inserted into the groove  62 , the biasing members  70  deflect downward into the groove  62 . Subsequent withdrawal of the side panels  32  would cause the biasing members  70  to contact the side panels  32  with greater force, thereby inhibiting unintentional withdrawal of the side panels  32  from the groove  62 .  
         [0037]    [0037]FIG. 8 shows the partially assembled basket attached to the bottom frame  60 . There is no limitation as to the number of holes and cooperating locking wedges, so long as there is a sufficient number to provide adequate structural rigidity to the assembled basket. Likewise, the number of side panels  32  may be as few as one, or as great as about eight or more. However, for convenience, two cooperating side panels  32  are preferred.  
         [0038]    [0038]FIG. 9 shows one embodiment of an upper ring  80  configured to be used with the side walls  32  disclosed herein. The upper ring  80  generally corresponds with the desired upper surface periphery shape of the finished basket. As such, the upper ring  80  may be shaped as desired in any regular or non regular closed geometric shape. For example, the upper ring  80  may be formed as a circle, oval, ovoid, ellipse, rectangle, polygon, or non-regular continuous band or hoop.  
         [0039]    With reference to FIGS. 9-11, the upper ring  80  has a substantially U-shaped cross section, but may also be substantially J-shaped, N-shaped, or other desired shape. In any case, a groove  82  is formed along the entirety of the upper ring  80  into which the side panels  32  are inserted. The upper ring  80  is further configured with a number of clips  84  designed to interact with holes  66  formed along the upper edge  34  of each side panel  32 . Each upper ring clip  84  is configured with a protruding tab  86  that extends into the groove  82  and is configured to fit within the hole  66  formed in the side panel upper edge  66 . Additionally, a pair of notches  88  are formed on both sides adjacent the clip  84  in a direction that is transverse to the longitudinal direction of the upper ring  80 . These notches  88  allow a portion  90  of the upper ring  80  to deflect to allow entry of the side panels  32  into the groove  82 . The upper ring portion  90  is then free to resiliently return to its natural position, and thus exerts a force on the side panels  32  that tends to force the side panels  32  toward the outer edge of the groove  82  thereby providing a more positive lock between the tab  86  and the holes  66  formed in the side panels  32 , and increasing the surface friction between the side panels  32  and the interior of the groove  82 .  
         [0040]    The upper ring  80  generally conforms with the perimeter shape of the bottom frame  60 ; however, there is no such requirement. In fact, the upper ring  80  may be a different shape than the bottom frame all together. For example, the bottom frame  60  may be elliptical, while the upper ring  80  may be circular. Such versatility allows for the customization of each basket by mixing or matching the shape of the bottom frame  60  and the upper ring  80 .  
         [0041]    As with the locking wedges  64  of the bottom frame, there is no limitation on the number of clips  84 , so long as the upper ring  80  is securely fastened to the side panels  32 . In one embodiment, there are four locking wedges  64  that cooperate with four holes on the upper edge of the side panels. Additionally, there can be additional biasing members placed within the grooves  62 , 82  of the bottom frame  60  and upper ring  80 , respectively, to bias the side panels  32  outwardly within the respective grooves  62 , 82 .  
         [0042]    Alternatively, the clips  84  may be omitted and the upper ring groove  82  can be configured with a portion having a decreased width configured to frictionally engage and hold the side panel  32  securely in the upper ring groove  82 .  
         [0043]    Preferably, the upper ring  80  and bottom frame  60  are formed of a material that is more rigid than the side panels  32 , such that the upper ring  80  and bottom frame  60  force the side panels  32  to conform to the desired shape. Furthermore, the upper ring  80  and bottom frame  60  experience the hoop stresses caused by bending and forming the side panels  32  into their desired shape, and should be formed of a suitable material to withstand such stresses, such as polymers exhibiting a relatively low modulus of elasticity compared to that of the side walls  32 , such as PVC, for example.  
         [0044]    The components of the Composite Basket described herein may be stored in a disassembled, flattened state. This allows the basket components to be economically packaged, shipped, and stored. Furthermore, the materials described herein lend other advantages, both aesthetic and otherwise, such as transparency, colored translucency, light-weight, flexibility, formability to desired shapes, ability to take on surface textures, and other advantages which will become apparent to those of skill in the art.  
         [0045]    Assembly of the basket comprises three simple steps. First, a user connects the one or more side panels  32  to each other by inserting the tabs  46  into corresponding slots  44  until the side panel  32  resembles a cylinder. Secondly, the side panel lower edges  36  are inserted into the groove  62  formed in the bottom frame  60  while aligning the holes  66  in the side panel lower edges  36  with the locking wedges  64  of the bottom frame  60  until the bottom frame tabs  68  are captured within the side panel lower edge holes  66 . As the side panels  32  are inserted into the bottom frame groove  62 , the locking wedges  64  will engage the holes  66  of the side panels  32  and securely hold the side panels  32  in place. Thirdly, the upper ring  80  is pushed onto the upper edge  34  of the side panels  32  such that the side panels  32  enter the upper ring groove  82 . As the upper ring  80  is forced onto the side panels  32 , the upper ring clips  84  will engage the side panel holes  66  and capture the same thus forming a secure connection with the side panels  32 . An assembled basket is represented in FIG. 12.  
         [0046]    The bottom frame  60  and upper ring  80  provide suitable rigidity to allow the basket to maintain its assembled configuration, even during rough use. The basket can be subsequently disassembled, as desired, by removing the side panels  32  from the upper ring  80  and bottom frame  60 . The illustrated basket thus comprises 4 components that are easily assembled and disassembled, yet provides a rigid container able to withstand considerable abuse during use.  
         [0047]    Although this invention has been disclosed in the context of certain preferred embodiments and examples, it will be understood by those skilled in the art that the present invention extends beyond the specifically disclosed embodiments to other alternative embodiments and/or uses of the invention and obvious modifications and equivalents thereof. In addition, while a number of variations of the invention have been shown and described in detail, other modifications, which are within the scope of this invention, will be readily apparent to those of skill in the art based upon this disclosure. It is also contemplated that various combinations or subcombinations of the specific features and aspects of the embodiments may be made and still fall within the scope of the invention. Accordingly, it should be understood that various features and aspects of the disclosed embodiments can be combined with or substituted for one another in order to form varying modes of the disclosed invention. Thus, it is intended that the scope of the present invention herein disclosed should not be limited by the particular disclosed embodiments described above, but should be determined only by a fair reading of the claims that follow.