Abstract:
The collapsible container includes a plurality of side walls connected via hinges to a base. The side walls are moveable about the hinges between a collapsed position on the base and an upright, use position generally perpendicular to the base. Each of the hinges includes a hinge pin rotatably received within a hinge receiver. Each hinge pin includes at least one radial projection that abuts a portion of the hinge receiver when the side wall is in the upright position. The radial projection resists over rotation of the side wall and prevents the hinge pin from leaving the hinge receiver during the application of an over rotation force.

Description:
BACKGROUND OF THE INVENTION 
   This present invention relates generally to collapsible containers and more particularly to an improved hinge for such containers. 
   Collapsible containers typically have a base to which four side walls are connected via hinges. The side walls are pivotable about the hinges between a collapsed position and an upright, use position, generally perpendicular to the base. Collapsible containers usually include a latch or interference fit connecting adjacent side walls in the corners to keep the side walls in the upright, use position. 
   The hinges connecting the side walls to the base often include a hinge pin rotatably received in a hinge receiver. In at least one known container, if excessive outward force is applied on a side wall already in the upright position, the hinge pins may be forced out of the hinge receivers, disconnecting the side wall from the container. 
   SUMMARY OF THE INVENTION 
   The collapsible container of the present invention provides improved hinges that resist over rotation and prevent the hinge pins from being released from the hinge receivers in response to excessive over rotation force. 
   The collapsible container of the present invention includes a plurality of side walls connected via hinges to a base. The side walls are moveable between a collapsed position on the base and an upright, use position, generally perpendicular to the base. Each of the hinges includes a hinge pin rotatably received in a hinge receiver. In a preferred embodiment, each hinge pin includes at least one radial projection that abuts a portion of the hinge receiver when the side wall is in the upright position. The projection resists over rotation and prevents the hinge pin from popping out of the hinge receiver even when an over rotation force is applied to the side wall. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     Other advantages of the present invention can be understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein: 
       FIG. 1  is a perspective view of the collapsible container of the present invention with the side walls in the upright, use position. 
       FIG. 2  is an exploded perspective view of the container of  FIG. 1 . 
       FIG. 3  is the collapsible container of  FIG. 1  showing two of the side walls in the collapsed position. 
       FIG. 4  is the collapsible container of  FIG. 1  with all of the side walls in the collapsed position. 
       FIG. 5  is an enlarged interior view of two of the hinge pins on one of the side walls. 
       FIG. 6  is a perspective interior view of the hinge pins of  FIG. 5 . 
       FIG. 6A  is a side view of the side wall shown in  FIG. 6 . 
       FIG. 6B  is an enlarged view of the lower end of the side wall of  FIG. 6A . 
       FIG. 7  is a perspective, interior view of two hinge receivers for receiving the hinge pins of  FIGS. 5 and 6 . 
       FIG. 8  is an interior perspective view of the hinge pins of  FIG. 5  received in the hinge receivers of  FIG. 7 . 
       FIG. 9  is an exterior perspective exploded view, partially broken away between the hinge pins in  FIG. 5 . 
       FIG. 10  illustrates the hinge pins and hinge receivers of  FIG. 9  in the assembled position. 
       FIG. 11  is an interior perspective view of the hinge pins and hinge receivers of  FIG. 9  with the side wall in the upright position. 
       FIG. 12  is an interior perspective view of the hinge pins and hinge receivers of  FIG. 9 , partially broken away through one of the hinge pins and one of the hinge receivers. 
       FIG. 13  illustrates the hinge pins and hinge receivers of  FIG. 12 , in the assembled position. 
       FIG. 14  is a bottom view of the hinge pins and hinge receivers. 
   

   DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     FIG. 1  illustrates a collapsible container  10  according to the present invention. The collapsible container  10  includes a base  12  to which a pair of opposed side walls  14  and a pair of opposed end walls  16  are connected via hinges  20 , including hinges  20   a ,  20   b  and  20   c , which are described in more detail below as representative of all of the hinges  20 . Unless otherwise specified, the term “side wall” below is intended to include any of the side walls  14  or end walls  16 . In  FIG. 1 , the side walls  14 ,  16  are shown in their upright, use position, where adjacent side walls  14 ,  16  are connected via latches  22  in the corners. 
     FIG. 2  is an exploded view of the collapsible container  10  of  FIG. 1 . Each of the hinges  20  includes a hinge member  26  and hinge receiver  28 . For each hinge  20 , the hinge member  26  is shown mounted on the side wall  14 ,  16 , while the hinge receiver  28  is shown mounted to the base  12 ; however, it should be understood that these locations could be reversed for any or all of hinges  20 . 
   The side walls  16  are moveable about the hinges  20  between the upright position shown in  FIG. 1  and a collapsed position on the base  12 , as shown in  FIG. 3 . Similarly, the side walls  14  are moveable about the hinges  20  between the upright position shown in  FIG. 3  to a collapsed position on the base  12  as shown in  FIG. 4 . 
     FIGS. 5 and 6  are enlarged views of hinge members  26   a, b  as viewed adjacent an interior surface  32  of side wall  14 . Each hinge member  26   a, b  includes a hinge pin  34  mounted between the ribs  36  extending from a lower edge of the side wall  14 . An opening  38  is defined among the side wall  14 , hinge pin  34  and ribs  36 . Each of the hinge pins  34  includes a plurality of radial projections  40 , extending downwardly and slightly inwardly from the hinge pins  34 . In the embodiment shown, each hinge pin  34  includes four radial projections  40 , but any number could be used. A support  44  extends downward from the side wall  14  between the hinge members  26   a  and  26   b  and connects to a generally cylindrical support surface  46 , which is generally coaxial and continuous with the hinge pins  34 . 
     FIG. 6A  is a side view of the side wall  14  shown in  FIG. 6 . Each radial projection  40  extends downwardly and inwardly from the hinge pin  34 . Referring to  FIG. 6B , each radial projection  40  extends downwardly and approximately thirty degrees inwardly from the vertical, as indicated by the angle α. 
     FIG. 7  is an interior, perspective view of the hinge receivers  28   a  and  28   b  of  FIG. 1 . A flange  48  extending upward from the base  12  includes a recess  49  in which the hinge receivers  28   a, b  are formed. Each hinge receiver  28   a, b  includes a retainer  50 . Between the hinge receivers  28   a, b  is a generally concave hinge support surface  52 . Each of the hinge retainers  50  includes a plurality of ribs  54  extending upwardly and then inwardly to form an upper, concave surface  56 . An opening  57  is defined between an inner lower edge of the retainer  50  and an upper edge  59  of an interior wall  60  of the flange  48  of the base  12 . A cavity  63  is defined between the interior wall  60  and the retainer  50 . 
     FIG. 8  is an interior view of the hinge members  26   a  and  26   b  assembled into the hinge receivers  28   a  and  28   b . In the assembled position, the ribs  36  are disposed on either side of the hinge retainers  50 . The hinge pins  34  are rotatably received below the hinge retainers  50 , such that their upper surfaces abut the concave surfaces  56  on the underside of the hinge retainers  50 . The radial projections  40  are trapped in the cavity  63  behind the upper edge  59  of the interior wall  60  of the flange  48  on the base  12 , such that lateral surfaces of the radial projections  40  abut the edge  59 . The side wall  14  is supported by the surface  46  resting on the hinge support surface  52  between the hinge receivers  28   a, b . In the assembled position shown in  FIG. 8 , over rotation of the side wall  14  is resisted by the radial projections  40 , which contact the upper edge  59  of the interior wall  60 . Further, the radial projections  40 , by contacting the upper edge  59  of the interior wall  60 , prevent the hinge pin  34  from popping out of the hinge retainer  50 . 
     FIG. 9  illustrates the hinge members  26   b  and  26   c  of  FIG. 1 . Again, each of the hinge members includes a hinge pin  34  between ribs  36  extending downward and outward as shown. Between hinge members  26   b  and  26   c  is simply the Lower surface  61  of the side wall  14 , unlike the surface  46  between hinge member  26   b  and  26   a  ( FIG. 6 ). Between the hinge receivers  28   b  and  28   c  is a convex cylindrical support surface  62 , for abutting and supporting the lower surface  61  of the side wall  14 . For assembling the side wall  14  to the base  12 , the side wall  14  is positioned as shown in  FIG. 9 , approximately  10  degrees relative to the base  12 . The radial projections  40  on the hinge pins  34  are then inserted through the openings  57  into the hinge receivers  28   b, c  to be positioned below the hinge retainers  50  as shown in  FIG. 10 . As can be seen in  FIG. 10 , the ribs  36  of each hinge member  26   b ,  26   c  are positioned on either side of the hinge retainer  50  for lateral stability. 
   When assembled, the side wall  14  is moveable about the hinges  20  to an upright, use position, generally perpendicular to base  12 , as shown in  FIG. 11 . It is shown again in  FIG. 11  that the radial projections  40  of the upper edge flange  48  prevent over rotation of the side wall  14  and prevent the hinge pins  34  from popping out of the hinge retainers  50  due to over rotation. 
     FIG. 12  is a perspective of the side wall  14  and base  12  and sectioned through the hinge member  26   b  and hinge receiver  28   b .  FIG. 12  shows the side wall  14  and base  12  in the unassembled position, with the side wall  14  rotated to the proper angle for insertion of the radial projections  40  through the openings  57  into the cavities  63  of the hinge receivers  28   b ,  28   c .  FIG. 13  shows the hinge pin  34  of the hinge member  26   b  received within the hinge retainer  50 , with an upper convex, cylindrical surface of the hinge pin  34  rotatably abutting the convex upper surface  56  of the hinge retainer  50 . 
     FIG. 14  is a bottom view of the hinge members  26   b ,  26   c  and hinge receivers  28   b, c  of the collapsible container  10  of the present invention. 
   The invention has been described in an illustrative manner, and it is to be understood that the terminology that has been used is intended to be in the nature of words of description rather than of limitation. Obviously, many modifications and variations of the present invention are possible in light of the above teachings. It is, therefore, to be understood that within the scope of the appended claims the invention may be practiced otherwise than as specifically described.