A collapsible nestable container is provided. The collapsible nestable container may comprise a plurality of panels, each having one or more locking features that interlock with the locking features of the other panels to form an assembled container. The panels further comprise one or more nesting features, that interlock with the nesting features of the other panels to allow the panels to nest in a collapsed configuration with similar or dissimilar panels.

FIELD OF INVENTION

The present disclosure relates to collapsible storage containers. More particularly, the present disclosure relates to a collapsible nestable container for use in storing and transporting liquids.

BACKGROUND

Collapsible containers are used in the food shipment industry. The containers typically include six panels that form a cube-like structure when assembled. Traditionally, the panels are made from wood and are not easily returned in an collapsed configuration and are not designed for ease of transport while in the collapsed configuration. In addition, the wood allows bacteria to build up on the insides of the containers, absorbs water and algae, and requires the use of nails, making sanitization of the containers difficult, if not impossible, and making it likely that the plastic bags that hold the product inside of the containers would be punctured or damaged during use. It would be beneficial to have a container made of plastic that was easily collapsible, nestable, and easily cleaned and sanitized.

SUMMARY

In one embodiment, a collapsible nestable container is provided, the collapsible nestable container includes a plurality of panels that can be assembled to form a container. The plurality of panels each include at least one locking feature that is configured to mate with one or more locking features of one or more of the other panels when in the assembled configuration, forming a locking connection thereto. The plurality of panels further include at least one nesting feature that is configured to mate with at least one nesting feature of at least one other panel in a nested configuration to form a connection that prevents the panels from moving significantly while in the nested configuration.

DETAILED DESCRIPTION

FIG. 1illustrates a perspective view of one embodiment of a collapsible nestable container100(hereinafter “the container”) having a lid panel105, two support panels110, two flat panels115, and one base120in an assembled configuration. In this embodiment, the base120provides support for the two support panels110and the two flat panels115. The support panels110and flat panels115form the walls of the container100when in an assembled configuration. The lid panel105, support panels110, flat panels115, and the base120may be made of plastic or other suitable material. In one embodiment, all of the components may be injection molded so that all of the surfaces that are exposed to the contents of the container are smooth and are generally free from sharp edges, splinters, nails, or other unwanted protrusions or crevices.

Once assembled, bands125may be wrapped about the container100along the vertical and horizontal planes. The bands125maintain the container100in the assembled configuration during transport and storage of the contents. The bands125may be comprised of metal or other suitable material. It is anticipated that other mechanisms may be used to provide additional support to the assembled container100instead of or in conjunction with the bands125, including but not limited to mechanical fasteners such as nails, screws, bolts, etc. or chemical fasteners such as adhesives, welds, etc. It is also contemplated that the container100may be assembled and used without the bands125.

In other embodiments, the container may include more or less than two support panels110and two flat panels115. Different numbers of panels may be used to form a differently shaped assembled containers without departing from the scope of the present invention. Additionally, the panel labels of “lid,” “support,” “flat,” and “base” are merely used as terms of convenience, and are not intended to limit the panels to any particular orientation or shape. When the collapsible nestable container is configured in assembled form, it may be used to store or transport any number of items, including both perishable and non-perishable products such as tomato paste.

As shown inFIG. 2, which illustrates a perspective view of one embodiment of the container100with one flat panel115removed to provide an interior view, the container100may include at least two support panels110. The outer surface of each support panel110may include nesting protrusions130that extend outwardly therefrom.

Generally, the nesting protrusions130are configured about the outer surface in a pattern that creates banding recesses135capable of receiving the bands125(as shown inFIG. 1) when the container100is assembled and nesting recesses160capable of receiving the nesting protrusions130when the support panels110are in a collapsed and nested position.

As shown inFIG. 2, in one embodiment, each support panel includes a plurality of the nesting protrusions130that are generally rectangular in shape and extend perpendicularly between a top portion140of the support panel110and a bottom portion145of the support panel110. In one embodiment, the nesting protrusions130may be aligned in single or double vertical columns along a first vertical side150of the support panel110and in single or double vertical columns on a second vertical side155of the support panel110. Generally, the alignment of the nesting protrusions130enables a first support panel110to nest with a second support panel110′, as shown inFIG. 6, and prevents the support panels110from moving relative to one another in either the horizontal or vertical direction when nested. In other embodiments, the nesting protrusions130may be arranged in any configuration, and may be provided in any number or shape without departing from the scope of the present invention.

As shown inFIG. 2, the nesting recesses160run parallel to the array of nesting protrusions130. In one embodiment, the nesting recesses160are located on either side of the arrays of nesting protrusions130. It is anticipated that other configurations and numbers of nesting protrusions130and nesting recesses160may be used without departing from the scope of the present invention.

As discussed above, the support panels110may include banding recesses135disposed horizontally between each nesting protrusion130. The banding recesses135may be configured to receive the bands125so that the bands125remain in direct contact with the outer surface of support panels110, reducing the chances that an affixed band125will be snagged by machinery, slip from position, or be broken when the outer surface of the container100contacts or hits another hard surface.

To that end, each support panel110may include rounded edges at each vertical side150and155. The vertical sides150and155are configured to mate with the corresponding flat panel115, as shown inFIG. 3. In this embodiment, the rounded edges of the vertical sides150and155each terminate in a rounded edge lip165. Rounded edge lips165of each support panel110extend toward the rounded edge lips165of the opposite support panel110when the container100is in an assembled configuration. The rounded edge lips165may further include one or more notches170and recesses175that are configured to mate with corresponding notches180on the vertical sides185of the flat panels115.

In this embodiment, the corresponding notches180protrude slightly from the end of the vertical side walls185of the flat panels115and are configured to fit within the recesses175along the vertical sides150and155of the support panels110. Similarly, the vertical side walls185of the flat panels115have a thickness that is less than the thickness of the rest of the flat panels115, enabling the user to insert a vertical side wall185of a flat panel115into the rounded edge lip165of a support panel110.

The support panels110further include an upper surface190and a lower surfaces195. The upper surface190and the lower surface195are configured to mate with either the base120or lid panel105. As shown inFIG. 3, the upper surface190and the lower surface195include notches200and recesses205that are similar to the notches170and recesses175disposed along the vertical sides150and155of the support panel110. In one embodiment, the upper surface190and lower surface195each have four notches200and three recesses205spaced evenly across each surface. The notches200may be beveled when formed so that the side walls of the notches200are not perpendicular to the horizontal plane of the upper surface190and lower surface195. In other embodiments the notches200may take other configurations, including but not limited to a slit or a rounded cut out and may be spaced unevenly across each surface.

As shown inFIGS. 2 and 3, the base120includes an outer side wall210and an inner side wall215, which together form a channel220. In one embodiment, the channel220includes three evenly spaced apart protrusions225that are configured to mate with the recesses205disposed within the lower surface195of each support panel110. When assembled the notches200on the lower surface195of the side wall110may be disposed within the channel220of the base120and held in place by fitting the protrusions225in the channel220within the recesses205of the side wall110. A similar configuration may be used to secure the lower surface230of the flat panel115to the base120and the lid panel105to the upper surface190of the support panel110and the upper surface235of the flat panel115.

On the interior surfaces of support panels110and the flat panels115, there may be one or more storage recess(es)240. As shown inFIGS. 2 and 3, the storage recesses240can be formed into the support panels110and the flat panels115to increase the capacity of the container100. The storage recesses240may also be configured to mate with other storage recesses240when the support panels110and the flat panels115are in a collapsed or nested configuration. It is anticipated that storage recesses240may alternatively not be included in the support panels110without departing from the scope of the present invention.

FIGS. 4 and 5show one embodiment of the container100in a collapsed, nested configuration. As shown inFIG. 4, the lid panel105may have one or more water drain grooves245disposed on its upper surface to facilitate the drainage of liquid from the lid panel105. The water drain grooves245may have angled bottom portions so that liquid may flow towards the edges of the lid panel105. In the embodiment shown inFIG. 4, the water drain grooves245are perpendicular to the edges of lid panel105. It is anticipated that other configurations of water drain grooves245are possible without departing from the scope of the present invention.

As also shown inFIG. 4, the lid panel105may further include a raised lid surface250thereon. The raised lid surface250may include a plurality of polygonal shapes that define the water drain groves245, banding recesses255, and a plurality of foot recesses260. As shown inFIG. 5, the foot recesses260facilitate stability when the containers100are stacked on each other in a collapsed configuration or in an assembled configuration, as shown inFIG. 7. It is anticipated that a different number of variously shaped raised lid surfaces250and foot recesses260may be used without departing from the scope of the present invention.

Referring again toFIG. 3, the base120may include one or more pallet feet connectors270supporting one or more pallet feet275. The pallet feet connectors270may engage the pallet feet275via snap-fit connections, mechanical fasteners such as screws or bolts, chemical fasteners, or alternatively may be integrated with pallet feet275.

Referring toFIG. 6, the base120may further comprises one or more angled edges280on a bottom side thereof. The angled edges280may guide forklift prongs underneath the base120and in between the pallet feet275. In one embodiment, two angled edges280are provided between the pallet feet275. Other configurations are anticipated without departing from the scope of the present invention.

As shown inFIG. 8, drainage ports285may be provided along the edges of base120to facilitate fluid drainage. When assembled, fluid or condensation may build up on the outside or within the container100. The drainage ports285allow the fluid build-up to shed down the container100from the outside, collect in the channel220, and drain out of the container. Similarly, any fluid build-up on the inside surfaces of the container is able to drain out of the container from the inside. In this way, water build-up from either the inside or outside surfaces is prevented from forming bacteria or mold on the container100.

As shown inFIGS. 9 and 10, the pallet feet275may include anti-slip rubber bottom290feet grooves295. The feet grooves295are configured to fit on to the inner wall215that forms part of the channel220on the base120, providing stability when stacking one base120on top of the other.

Each panel may be formed by permanently welding each panel together to capture a support structure300or similar reinforcement piece, such as steel beam or a high strength protruded fiberglass bar, between a first panel half305and a second panel half310, forming a completed panel as shown inFIG. 11. The panel halves305and310may form ribs315between them when welded together. The panel halves305and310and ribs315may be formed of a plastic material, such as polypropylene or polyethylene, using any suitable molding process. When the panel halves305and310are welded together, the ribs315are heated and then joined to create a finished panel with a smooth exterior and interior surface. WhileFIG. 11shows a flat panel115that has been cut away to depict the inner structure, it should be understood that the support panel110, lid panel105, or the base120may be constructed in a similar manner.

The ribs315may run either vertically or horizontally between the halves305and310of the panel. The support structure300disposed between the panel halves305and310provides rigidity, robustness, and strength to the flat panel115. In this embodiment, the support structure300is in an “I” shape, but other arrangements of support structure300are anticipated without departing from the scope of the present invention. It is contemplated that the support structure300may be formed in any suitable shape and from any suitable material, such as steel, without deviating from the scope of the invention.

As shown inFIG. 12, in one embodiment, the support structure300includes at least a first horizontal beam31, a second horizontal beam32, and a vertical beam32—forming an “I” beam configuration. The first horizontal beam31may be connected to a first end portion330of the vertical beam35and the second horizontal beam32may be connected to a second end portion335of the vertical beam35in order to prevent movement of the vertical beam35with respect to the first and second horizontal beams31and32in the z-axis (Z) direction.

It should be appreciated that any suitable means of connecting the three beams is contemplated, however, in one embodiment, the first and second horizontal beams31and32may include a connection member340that is welded along the y-axis (Y), extending perpendicularly from the horizontal beams. The connection member(s)340may be made of any suitable material, but in one example may be made of a section of steel tube similar to those used for the support structure300, but having a smaller cross-section so that the connection member340may be fitted within the inner surface of either end of the vertical beam35. In one embodiment, the connection member340is configured to allow some movement of the hollow vertical beam35along the x and y-axes, relative to the horizontal beams31and32, but not in along the z-axis.

Another embodiment includes a method for assembling the container100. Each component of the container100is designed to be interchangeable so that, for example, if a lid panel105becomes damaged or unusable, any other lid panel105can be provided to replace it. All panels and pallet feet are similarly designed. When the container100is in an assembled configuration, as shown inFIG. 1and as described above, the surfaces of the panels may be generally flush with one another, with bands125located within banding recesses130.

Another embodiment includes a method for storing and transporting the container100in a collapsed configuration. In this embodiment, the panels of each individual container may be configured to be nested with one another to provide a compact assembly, as shown inFIGS. 4 and 5.

As shown inFIG. 6, the lid panel105is stacked with its interior surface adjacent to the exterior surface of a first flat panel115. In this configuration, the rounded edge lip notches170and recesses175on the support panels110may mate with lid tabs320(as shown inFIG. 13a) to secure the lid panel105to the rest of the container100when collapsed. The first flat panel115is then stacked with its interior surface adjacent to the interior surface of the first support panel110. Protrusions (as shown inFIGS. 1, 3, 6, 8, 11 and 15) on the interior surface of the flat panel115may be configured to mate with storage recesses240of the support panel110.

The first support panel110is then stacked with its exterior surface facing the exterior surface of a second support panel110′. In this orientation, the nesting protrusions130of the first support panel110may be configured to mate with the nesting recesses160′ of the second support panel110′ and vice versa.

The interior surface of the second support panel110′ is then stacked facing the interior surface of a second flat panel115′. Finally, the second flat panel115′ may be stacked with its exterior surface adjacent the interior surface of the base120. The flat panel115may be dimensioned to fit within sloped edges325(SeeFIG. 6) created by the inner wall215of the base120.

In yet another embodiment, each panel may be nested with other panels of the same type, as shown inFIGS. 13-16.FIG. 13shows multiple lid panels105stacked on one another so that the outer lip of a first lid panel105fit within the outer recess around the top of a second lid panel105′ to prevent the lip panels105from moving relative to one another.

As shown inFIG. 14, multiple support panels110may be nested upon one another. In this configuration the support panels are oriented so that the nesting protrusions130of a first support panel110sit within the nesting recesses160′ of a second support panel110′ and vice versa. As shown inFIG. 15, the flat panels115may be stacked on one another, with protrusions (as shown inFIGS. 1, 3, 6, 8, 11 and 15) of a first flat panel115disposed within storage recesses240′ of a second flat panel115′. As shown inFIGS. 16 and 16a, multiple bases120may nest with one another, with pallet feet grooves295mating with the inner wall of the channel220. It should be noted that all of the panels can be turned upside down or from one side to another in a 180° turn and still interlock with like panels.