Collapsible container with recessed side-panel latch

A collapsible container includes a base, and pairs of opposed side and end walls that are pivotally mounted on the base. When the side walls are pivoted to a raised position against inward flanges defined on the end walls, latch members on the side walls engage complementary shoulders defined on end wall flange projections to thereby lock the side walls relative to the end walls. Each latch member includes a base portion mounted proximate to a respective lateral edge of the side wall, a lever arm portion extending away from the side wall's lateral edge, and an intermediate portion having a camming surface and adjacent shoulder with which to engage the respective end wall flange projection. When raised, edge portions of each side wall are received in recessed shelves defined in the base while the side wall's inner face simultaneously engages cantilevered stop members defined in the base.

BACKGROUND OF THE INVENTION

1. Technical Field

The invention relates to a collapsible container whose panels are interlocked and latched together at their respective edges when raised to thereby provide the assembled container with improved structural integrity.

2. Background Information

The prior art teaches collapsible containers featuring a generally square or rectangular bottom panel, and two pairs of opposed side panels (the latter sometimes being referred to as respective pairs of side and end panels or “walls”). Each side panel is pivotally connected to a respective bottom panel edge to move between a raised or “assembled” position in which each side panel is roughly perpendicular to the bottom panel, and a collapsed position. The side and bottom panels may include hinge components that conveniently permit the side panels to be “snapped” into place on the bottom panel, for example, by moving the basal edge of the side panel laterally (outwardly) relative to the bottom panel's peripheral edge.

The prior art teaches the placement of latch mechanisms on the adjacent edges of the raised side panels to thereby provide the container with greater structural integrity and improved vertical stacking capability when assembled. Generally, known latch mechanisms employ a resilient, cantilevered latch member that either is flush with, or projects from the nominal lateral edge or inner face of one side panel into engagement with a complementary recess defined in the opposed edge of an adjacent side panel. An example of a flush latch member is disclosed in U.S. Pat. No. 6,073,790. The projecting latch member and, often, the complementary recess respectively include a camming surface that cooperate to urge the latch member into engagement with the recess, whereupon opposed abutting shoulders on the latch member and the recess provide a “snap-in” engagement to secure the one side panel to the other.

When such a container is to be collapsed, the latch member is resiliently biased, for example, by application of finger pressure on a portion of its length so as to swing the latch member clear of the recess or striker, whereupon the one side panel may be pivoted free of the other side panel. One or more inwardly- or outwardly-directed flanges, defined on the opposed edges of the adjacent side panels, are often used in conjunction with such latches to prevent the overtravel of one side wall relative to the other. Interlocking webbing defined within one or more such flanges may be used to further enhance the torsional rigidity of the assembled container by preventing relative movement of one side panel edge along the other side panel edge.

Unfortunately, because the quality of the resulting interconnection between adjacent side panels is dependent upon the nature of the engagement between the opposed abutting shoulders of the latch member and the corresponding recess/aperture/striker, any damage to the exposed latch member, for example, during container assembly or use, including an unintended permanent bending of the latch member relative to the nominal edge of the side panel, may impair latch functionality. Moreover, when the latch member is integrally molded with the typically polymeric side panel, such outwardly-cantilevered latch members may exhibit a reduced service life due to a bending-induced failure mode.

Accordingly, what is needed is a latch mechanism for securely interconnecting the side panels of a collapsible container featuring a resilient latch member on one side panel proximate to an edge whose camming surface and associated abutting shoulder are neither located along, nor project beyond, the panel's edge, and further featuring an improved service life relative to known, outwardly-cantilevered latch members. It is also desirable to provide an inwardly-collapsible container that includes convenient, “snap-in” hinge components on the side and bottom panels while nonetheless better resisting the application to the side wall of external lateral loads.

SUMMARY OF INVENTION

It is an object of the invention to provide a collapsible container that includes a latch mechanism for securely interconnecting the edges of adjacent, pivoting side panels, wherein the latch mechanism features featuring a resilient latch member whose camming surface and associated abutting shoulder does not define a part of, or otherwise project beyond, the edge.

It is also an object of the invention to provide a collapsible container having a latch mechanism along an edge of one side panel that engages a striker defined on an opposed edge of an adjacent side panel, wherein the striker includes an abutting shoulder that is substantially shielded by a raised flange on the adjacent side panel to thereby minimize potential damage to the striker's abutting shoulder during assembly or use of the container.

It is also an object of the invention to provide a collapsible container featuring engagement, in the assembled condition, between adjacent side panels along a substantially continuous length along their respective contiguous edges.

It is a further object of the invention to provide a collapsible container with a bottom panel and a pivoting side wall that is pivotally mounted on the bottom panel, wherein the side panel includes a latch mechanism having no part projecting beyond the panel's nominal edge.

Yet another object of the invention to provide a latch mechanism for an inwardly-collapsible container that is conveniently operated using finger pressure applied to an exterior surface on the supporting side panel.

Yet another object of the invention is to provide an inwardly-collapsible container having a side panel that is laterally bolstered when raised to thereby further resist disengagement of the basal edge of the side panel from the bottom panel in response to a lateral impact.

Yet another object of the invention is to provide a lateral bolster for a side panel of an inwardly-collapsible container that is integrally-formed in the bottom panel and that facilitates attachment of the side panel to the bottom panel.

Under the invention, a collapsible container includes a bottom panel defining a peripheral edge; and a plurality of side panels, each side panel being mounted on the bottom panel along a respective portion of the peripheral edge for pivoting movement about a respective pivot axis. A first side panel includes an outer face and a lateral edge bordering the outer face, while a second side panel includes an inner face, a lateral edge bordering the inner face, and a flange projecting from the inner face along at least a portion of the lateral edge. When respectively pivoted to a raised position relative to the bottom panel, the respective lateral edges of the first and second side panels engage each other such that the flange of the second side panel overlies the outer face of the first panel.

In accordance with the invention, the first side panel includes a latch member having a base portion mounted on the first side panel proximate to its lateral edge, a lever arm portion extending generally away from the lateral edge, and a first intermediate portion disposed between the base portion and the lever arm portion, wherein the first intermediate portion includes a first camming surface and a first shoulder adjacent to the first camming surface. The second side panel correlatively includes an inward projection, for example, integrally molded with and projecting inwardly from the second side panel's flange. The inward projection has a second camming surface and a second shoulder adjacent to the second camming surface, wherein the camming surfaces and shoulders of the latch member and the inward projection are generally disposed at a same height above the bottom panel when the first and second side panels are respectively pivoted to the raised position. In this manner, when the lateral edges of the first and second side panels are raised and brought into engagement with one another, the respective camming surfaces engage to resiliently flex the latch member, predominantly along its base portion, whereupon the respective shoulders of the latch member and the inward projection abuttingly engage to thereby interlock the first and second side panels.

In accordance with feature of the invention, the base portion of each latch member includes a pair of spaced legs joined to the intermediate portion on either side of the camming surface. Most preferably, the legs of the base portion extend to respective positions outboard of the intermediate portion of the latch member such that deflection of the latch member relative to the outer face of the first side panel generates both flexural and torsional bending of each leg. In this way, each latch member features an improved service life over known cantilevered latch members.

In accordance with another feature of the invention, the first side panel is molded, for example, from a polymeric material and includes an integrally-molded strengthening rib proximate to and, most preferably, defining the lateral edge of the first panel, such that the rib extends generally perpendicular to the pivot axis of the first side panel. Preferably, in an exemplary collapsible container in accordance with the invention, the base portion of the latch member is integrally formed with the rib. Still further, the second side panel of the collapsible container preferably includes an interior corner proximate to its lateral edge, as defined by an intersection of its inner face and its flange, and the rib defines a substantially-continuous first length along the first side panel's lateral edge that is received in the second side panel's interior corner when the first and second side panels are respectively pivoted to the raised position. In this manner, the container provides a nearly continuous engagement of the two lateral edges which serves to further protect the container's ultimate contents while further enhancing the structural integrity of the assembled container.

In accordance with yet another feature of the invention, the container's first side panel includes at least one and, preferably, two or more locating members projecting outwardly from the panel's outer face proximate to its first edge. By way of example only, in an exemplary embodiment, the locating members are raised, frustoconical bosses that are integrally molded with the first side panel. The flange of the second side panel includes at least one socket adapted to receive the at least one locating member when the first and second side panels are respectively pivoted to the raised position. As the locating members are received within the sockets, the locating members guide the engagement of the camming surfaces of the latch member and the inward projection of the first and second side panels, thereby increasing latch service life. And, once the locating members are fully received in the sockets, the locating members and sockets assist in maintaining the engagement of the opposed shoulders of the latch member and the inward projection until the latch member is resiliently flexed by application of finger pressure on the lever arm portion of the latch member.

In accordance with yet another feature of the invention, recessed shelves are preferably defined about portions of the peripheral edge of the bottom panel, for example, proximate to each lateral edge of the first side panel, and the basal edge of the first side panel pivots into engagement with the recessed shelf when the first side panel is pivoted to the raised position. Moreover, other portions of the peripheral edge of the bottom panel, for example, proximate to the midpoint of the first side panel, preferably include at least one raised flange that overlies the outer face of the first side panel when the first side panel is pivoted to the raised position. The bottom panel preferably also includes at least one integrally-molded stop member having a surface that abuttingly engages the basal edge of the one side panel when the one side panel is pivoted to the raised position. In this manner, the recessed shelves and raised flanges on the peripheral edge of the bottom panel, and the cantilevered stop members together serve to precisely locate and laterally bolster the basal edge of the first side panel when it is pivoted to the raised position, thereby improving the performance of the assembled container.

In accordance with another feature of the invention, the stop member's abutting surface is preferably defined on the free end of a cantilevered portion of the stop member that extends in the direction of the first portion of the bottom panel's peripheral edge. The cantilevered design of the stop members permits each member's free end to resiliently bend downwardly when the side panel's hinge component is snap-fit into the complementary hinge component of the bottom panel, thereby greatly facilitating assembly while thereafter serving to bolster the side panel with respect to lateral loads.

Other features, advantages and benefits of the invention will be apparent from the following description, including the accompanying Drawings.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

FIGS. 1-10show an exemplary inwardly-collapsible container10in accordance with the invention suitable, for example, for transporting and storing a variety of materials. Referring toFIGS. 1 and 2, the container10includes a thin, generally-rectangular bottom panel or base12having two pairs of opposed, raised rails14,16defined about the peripheral edge of the base12. A first pair of opposed side panels18(hereinafter “side walls18,” for convenience only) is pivotally attached to the first pair of opposed rails14to thereby respectively provide a raised pivot axis20for each side wall18. The raised pivot axis20for each side wall18permits the side wall18to be pivoted inwardly so as to overlie at least a portion of the base12.

A second pair of opposed side panels22(hereinafter “end walls22,” again, for convenience only) is similarly pivotally attached to the second pair of opposed rails16to thereby respectively provide a raised pivot axis24for each end wall22. The raised pivot axis24for each end wall22is defined at a relative height on the base12above the raised pivot axis20of each side wall18to thereby permit the end walls22to be pivoted inwardly on top of the collapsed side walls18into a substantially parallel relationship with the base12. In this manner, the container10is collapsed into a compact form with which to facilitate the vertical stacking of a plurality of such containers10.

The base12and walls18,22of the container10are conveniently formed or substantially formed of various types of plastic or polymeric materials (preferably thermoplastic), for example, as by an injection molding process. In a preferred embodiment, the material of the base12and walls18,22is injection molded polypropylene. Of course, components of container10can be constructed using any other material suitable to this application, using any suitable process. As is well understood in the art, the thickness of the base and walls18,22of the container10may vary depending on the intended usage and other characteristics desired from the container10. Additionally, drainage holes and a network of integrally-formed strengthening ribs are preferably molded into the base12and walls18,22to further improve the performance of the container10.

Returning to the Drawings, when the container10is “assembled” as illustrated inFIG. 1with the side and end walls18,22pivoted to their respective raised positions relative to the base12, the lateral edges26of each side wall18are releasably interlocked with the respective adjacent lateral edges28of the end walls22. More specifically, as best seen inFIGS. 2 and 3, the end walls22each include a flange30projecting inwardly from the end wall's inner face32proximate to each of its lateral edges28. When the side and end walls18,22are in their respective raised positions, opposed pairs of the end wall flanges30overlie respective portions of the outer face34of each side wall18proximate to its lateral edges26. In the container10, each of the inwardly-projecting flanges30on the end walls22extends along substantially the entire length of its respective end wall lateral edge28to thereby provide greater lateral support for the side wall18with which it engages.

Referring toFIGS. 3-6, each lateral edge26of each side wall18also includes a latch member36having a base portion38mounted on the side wall18proximate to its respective lateral edge26, and a lever arm portion40that extends generally away from the lateral edge26. Each latch member36further includes an intermediate portion42disposed between the base portion38and the lever arm portion40. The intermediate portion42includes a first camming surface44and a first shoulder46adjacent to the first camming surface44.

Each lateral edge28of each end wall22correlatively includes an inward projection48, for example, integrally molded with and projecting inwardly its respective end wall flange30. The inward projection48has a second camming surface50with an adjacent shoulder52. The respective camming surfaces44,50and shoulders46,52of each associated pair of latch members36and inward projections48are generally disposed at a same height above the base12when the side and end walls18,22are pivoted to the raised position. In this manner, when the lateral edges26of the side walls18are raised and brought into engagement with the lateral edges28of the end walls22, the associated pairs of camming surfaces44,50engage to resiliently flex each latch member36, predominantly along its base portion38. The respective shoulders46,52of each associated pair of latch members36and inward projections48then abuttingly engage to latch the side and end walls18,22together.

In accordance with a feature of the invention, as best seen inFIGS. 5 and 6, the base portion38of each latch member36includes a pair of spaced legs54by which the latch member's intermediate portion42is coupled to its respective side wall lateral edge26, with each leg54being disposed on a respective side of the latch member's camming surface44and associated shoulder46. Most preferably, the legs trace an arcuate path as they extend from the side wall's lateral edge26to their respective outboard positions on the intermediate portion42of the latch member36, and the material of the side walls18is preferably selected such that deflection of the latch member relative to the outer face of the first side panel generates both flexural or “in-plane” bending, and torsional bending of each leg54. In this way, the latch members36of the container10feature an improved service life over known cantilevered latch members.

As best seen inFIGS. 3 and 5, each side wall18includes an integrally-molded strengthening rib56proximate to and, most preferably, defining each of its respective lateral edges26, with the rib56extends generally perpendicular to the pivot axis20of the side wall18to thereby define a substantially-continuous first length along its respective side wall edge26. The base portion38of each of the side wall's latch members36may therefore be conveniently integrally formed with the rib56.

Referring again toFIGS. 3 and 4, the intersection of each flange30with the inner face32of each end wall22defines an interior corner58proximate to each of its lateral edges28. When the side walls18are raised to engage the end wall flanges30, the side wall ribs56are received in the corresponding interior corners58of the end walls22. In this manner, the container10provides a nearly continuous engagement of the two lateral edges26,28which serves to further protect the container's ultimate contents while further enhancing the structural integrity of the assembled container10.

And, as best seen inFIGS. 2 and 3, the container's side walls18each include, proximate to each lateral edge26, a plurality of locating members60that project outwardly from the panel's outer face34. While the invention contemplates locating members60of any suitable configuration, by way of example only, the locating members60of the exemplary container10are raised, frustoconical bosses that are integrally molded with the side wall18. The lateral edge flanges30of the end walls22each include a like number of sockets62that are adapted to receive the locating members60when the side walls18are pivoted into engagement with the end wall flanges30.

In accordance with another feature of the invention, as the locating members60of the side walls18are received within the sockets62of the end walls22, the locating members60guide the engagement of the respective camming surfaces44,50of the latch members36and the end wall flange projections48, thereby increasing latch service life. And, once the locating members60are fully received in the sockets62, the locating members60and sockets62assist in maintaining the engagement of the opposed shoulders46,52of the latch members36and the flange projections48until the latch members36are resiliently flexed by application of finger pressure on the latch member's lever arm portion40.

In accordance with yet another feature of the invention, and as best seen inFIGS. 7-10, recessed shelves66are defined about portions of the peripheral edge of the base12, for example, proximate to each lateral edge26of the container's side walls18. When each side wall18is pivoted to the raised position, complementary portions68of the basal edge70of the side wall18pivots into engagement with corresponding recessed shelves66. It will be appreciated that, by locating the recessed shelves66along the outermost portions of the peripheral edges of the base12, the engagement of the side wall basal edges70cooperate with receipt of the side wall lateral edges26within the interior corners58of the end wall lateral edge flanges30(further supplemented by receipt of the locating members60within each flange's complementary sockets62) to thereby provide enhanced lateral stability to the side walls18of the assembled container10.

In accordance with yet another feature of the invention, other portions72of the peripheral edge of the base12, for example, proximate to the midpoint of each side wall18, include a raised flange74that overlies the side wall's outer face34when the side wall18is pivoted to the raised position. Still further, the container's base12also includes a plurality of integrally-molded, ramped or cantilevered stop members76, each of which has a free end surface78that extends outwardly to engage the basal edge60of a respective side wall18when the side wall18is pivoted to the raised position. The cantilevered design of the stop members76facilitates assembly of the side walls18to the base12, for example, wherein the hinge component of each side wall18is slid laterally into engagement with a complementary hinge component defined in the side wall's corresponding rail14, with the cantilevered stop members76resiliently yielding and flexing downwardly relative to the base12as the hinge components mate.

The recessed shelves66and raised flanges74on the base12cooperate with the stop members76to precisely locate and laterally bolster the basal edge of each side wall18intermediate its lateral edges26when the side wall18is pivoted to the raised position, thereby improving the performance of the assembled container. As a further benefit, the recessed shelves66, midpoint flanges74and stop members76of the base12prevent each side wall18from being pivoted beyond a relative vertical orientation with respect to the base12, even if the end walls22are themselves urged outwardly to such an extent that the end wall edge flanges30on the end walls22do not otherwise engage and retain the side wall edges26. As seen inFIG. 1, handles80are preferably defined in the side walls18generally above the midpoint flange74of the base12to facilitate the handling of the container10.

While an exemplary embodiment according to the invention has been illustrated and described, it is not intended that this embodiment illustrate and describe all possible forms of the invention. Rather, the words used in the specification are words of description rather than limitation, and various changes maybe made within the scope of the appended claims. For example, while a rectangular container10is shown and described, the invention is not so limited and contemplates end walls22and side walls18of equal length forming a container having square dimensions, or any other shape feasible according to the desired size and use. And, while the exemplary container10is characterized as an inwardly-collapsing container, it will be readily appreciated that myriad aspects of the invention are equally well suited for use in connection with an outwardly-collapsing container. Similarly, while the locating members60of the exemplary container10are formed on the side walls18and the complementary sockets62are formed on the end wall edge flanges30, it will be appreciated that these components can readily be reversed or mixed on the side and end walls18,22without departing from their function as described above.