Container with locking strips

The present invention provides for a container that has a base and a pair of side walls extending upwardly therefrom, the side walls having a concave portion and a plurality of apertures. Partitions are positioned between the side walls, each having tabs at each end which extend through the side wall apertures. Locking strips extend through the slots in the tabs of the partitions and are positioned in the concave portions of the container side walls. In an alternative embodiment, each locking strip has a locking member to prevent movement of the locking strip.

FIELD OF THE INVENTION

The present invention relates to containers in general and in particular to containers with partitions for holding products.

BACKGROUND OF THE INVENTION

Traditionally containers, and especially containers with partitions for holding and/or separating products for storage or shipment, were manufactured by placing plurality of partitions in a U-shaped pad which formed the base and side walls of the container. The partitions typically had a pair of slots, positioned at opposite ends of the partition, and rising from the bottom of the partition. These slots were adapted to engage corresponding slots in the side walls of the U-shaped pad, which descended from the top of the side walls of the U-shaped pad. The far end portions of the partitions outside of the slots would then be folded over and sonically welded to the side walls of the U-shaped pad. In this style of container, the exterior dimensions of the container would be increased by twice the thickness of the partition due to the folded over portion of the partition outside each of the side walls of the U-shaped pad. For example, if the partition had a thickness of ¼″, after the partition was folded over and attached to the side walls of the U-shaped pad, the overall outside width of the container would be increased by at least ½″ to account for the thickness of the partition on either side of the container. When multiple containers were positioned next to one another, as would be the case in shipping or storage, the space between these containers was unusable. Again, in a case where the thickness of a partition was ¼″, there would be ½″ of space wasted between containers stacked side by side. Such wasted space is obviously undesirable in both a shipping and storage context, as wasted space costs the shipper or the storer additional cost as more space is required to store or ship the same amount of product. In addition, the process of sonically welding the partitions to the outside walls of the U-shaped pad adds cost.

An alternative method of constructing such a container is to use a container with a locking strip which would secure the partitions to the side walls of the U-shaped pad. In this type of container, the partitions did not have slots, but rather had tabs at each end which were adapted to extend through slits in the side walls of the U-shaped pad. The tab on either end of the partition contained an aperture that would allow for a locking strip to slide through and secure the partitions to the U-shaped pad. In a typical example, the tabs would extend approximately ½″ from the exterior of the side walls of the U-shaped pad, to allow for adequate space for the locking strip to slide through. While this style of a container had the advantage of eliminating the cost associated with the sonically welding partitions to the sides of the container, it had the disadvantage of increasing the overall outside width of the container, which again increased the amount of space that would be wasted in shipping or storage. For example, if the tab of the partition extended ½″ outside the exterior wall of the U-shaped pad, when two containers were put side by side, approximately an inch of unusable or wasted space would result between the containers. This increases shipping or storage costs as more space is needed to ship the same amount of product.

It is an object of the present invention to provide a container that reduces the cost involved in attaching partitions to the side walls of a container. Another object of the invention is to provide a container that minimizes the unusable space between containers when they are positioned next to each other during shipping or storage. It is yet another objective of the present invention to maximize the internal storage space in a particular container while minimizing the exterior dimensions of that container.

SUMMARY OF THE INVENTION

According to one aspect of the present invention, a container is provided that has a base and a pair of side walls extending upwardly from the base. Each side wall has a concave portion which bows inwardly towards the interior of the container. The concave portion has a plurality of parallel side wall apertures. A plurality of partitions are positioned between the side walls of the container, each partition having a first end with a tab and a second end with a tab, the tabs each having a generally linear slot formed therein. The tabs of the partitions extend through the side wall apertures of the container to secure the partitions in a generally vertical orientation. Additionally, a pair of locking strips extend through the slots in the tabs of the partitions and are positioned in the concave portions of the side walls. The locking strips are sandwiched between an exterior surface of the side walls and the tabs to secure the partitions to the side walls.

In an alternative embodiment, the side walls of a U-shaped pad are planarly biased or biased towards a planar orientation, and adapted to inwardly flex in the portion where the side wall apertures are located, to allow a locking strip to pass outside this concave portion in the side wall. In yet further embodiments, the entire side wall may have a concave or bowed configuration or the entire side wall may be adapted to inwardly flex to create a depression or concavity in the plane of the flexible side wall.

In additional embodiments, the locking strip may be further attached or affixed to the side walls by stapling, gluing, heat bonding, or sonic welding. Additionally, in another embodiment, the locking strip may further contain a hinged locking tab or member which is adapted to extend through a locking aperture in one of the side walls and be secured to the side wall or to a partition in any suitable manner.

The present invention provides for a method of making a container comprising the steps of providing a U-shaped member that has a base and a pair of side walls extending upwardly therefrom. In at least one embodiment, each side wall has a concave portion, the concave portion having a plurality of side wall apertures. The method further provides for positioning a plurality of partitions between opposed side walls, each partition having a first end with a tab and a second end with a tab, the tabs each having a slot. The method further provides for inserting the tabs of the partitions in the side wall apertures and sliding a locking strip through the slots in the tabs whereby the locking strip is positioned in the concave portions of a side wall, and is sandwiched between the exterior surface of the side wall and the tabs.

The above and other objects and advantages of the present invention shall be made apparent from the accompanying drawings and the brief description thereof.

DETAILED DESCRIPTION OF THE INVENTION

Referring to the figures, and particularly toFIG. 1, the container10for holding product is comprised of a generally U-shaped pad12which has a base14and a pair of side walls16,18extending from the base14. These side walls16,18have an exterior surface20and an interior surface21. Additionally, the side walls16,18have a plurality of side wall apertures22, seen perhaps more clearly inFIG. 2, which are generally positioned opposite one another in the respective side walls16,18.

In one embodiment of the container10shown inFIG. 1, a plurality of partitions24are positioned between the side walls16,18of the container10. As shown more clearly inFIG. 2, each partition24is generally rectangular and has a first end portion26, a second end portion28. Each end portion26,28has a tab30extending outwardly from each respective end portion. Each tab30further contains a slot, aperture or slit32. As shown inFIG. 2, the partitions24are positioned between the side walls16,18of the container10and the tabs30extend through the apertures22in the side walls16,18of the container10.

As shown inFIGS. 1-4, each partition24may have a handle34. Although one configuration of handle34is illustrated, any like handle mechanism known by those skilled in the art could be utilized to manipulate a partition24. As also shown inFIGS. 1-4, the base14of the container10may further contain one or more rails36which can be utilized to further guide and position the partitions24. As shown, each partition24has a pair of corresponding notches38in the lower end40of the partition24which are adapted to engage or rest upon the rails36. The base member14of the U-shaped pad12further may contain a flap42which may be folded and attached or affixed to the partition24by staples, glue, heat bonding, sonic welding, or like method of attachment to provide additional support and rigidity to the container10.

As shown inFIGS. 1 and 3, the container10further comprises a pair of locking strips44. Each locking strip44is adapted to be inserted through the slots32in the tabs30of the partitions24when the tabs30of the partitions24have extended through the apertures22in the side walls16,18of the container10. As shown inFIG. 4, in one embodiment, each locking strip44may further comprise a locking tab or member46which is adapted to extend through a locking aperture48in one of the side walls16,18. As more particularly illustrated inFIGS. 4A and 4B, the locking member46may be either left or right hinged and is illustrated, extends through the locking aperture48. Additionally, the locking member46may have the additional benefit of securing or providing additional stability to the first partition50, as well as to the last partition52in the container10if a locking member46is used at both ends of the locking strip44.

FIG. 5illustrates an embodiment of the present invention where the side walls are inherently biased towards a planar orientation or position, yet are flexible enough, at least in a portion or area where the tabs30of the partitions24extend through the apertures22of the side walls16,18, to allow for the side wall16,18to flex inwardly to allow for the insertion of the locking strip44between the exterior surface20of the side walls16,18and the tab30as shown inFIG. 6. The planarly biased nature of the side walls16,18in this particular embodiment, help to secure a locking strip44within the slots32of the tabs30, and frictionally keep it sandwiched between the tab30and the exterior surface20of the side wall16,18. Those skilled in the art can appreciate that by varying the flexibility of the side walls16,18, various degrees of bias force may be obtained thereby providing various levels of securement of the locking strip44between the exterior surface20of the side walls16,18and tabs30.

As illustrated inFIG. 6, in an alternative embodiment, the side walls16,18each contain a concave portion54which allows for the insertion of a locking strip44between the tab30and the exterior surface20of the side wall16,18. In either embodiment, whether the side walls16,18flex or whether they are designed with a concave portion54, the outside dimensions of the container10are minimized, thereby promoting efficiency in storage and shipping of multiple containers. The locking strips44may further be attached to or affixed to the side walls16,18by staples, glue, heat bonding, or sonic welding. Such additional methods of attachment may be utilized separately, in combination, or in combination with, or without, the afore discussed locking members46and locking apertures48in the side walls16,18.

The container10of the present invention may be made by providing a blank made of corrugated plastic which can be hot wire bended to form a base member14and a pair of side walls16,18extending upwardly therefrom. A plurality of partitions24can be placed between the side walls16,18and the tabs30of those partitions inserted through apertures22in the side walls16,18. Thereafter, a locking strip44may be slid through the slots32in the tabs30and sandwiched between the exterior surface20of the side walls16,18and the tabs30. As discussed, the locking strips44may be further attached to the side walls via stapling, gluing, heating, sonic welding, or like method of affixture. Additionally, or in lieu of, the locking strips44may further be attached to the side walls16,18via locking members46extending from the locking strip44through locking apertures48in the side walls16and18.

In addition to the embodiments shown and described, the present invention may further contain other embodiments, for example, embodiments where more than one locking strip44is used on a particular side of a container10. For example, in a container10having tall side walls16,18, it may be desirable to have a plurality of locking strips44versus the one locking strip44as shown in the drawings and described herein. Additionally, in such embodiments, it may be desirable to have different width locking strips44to provide for additional stability or rigidity of the container10. Also, an additional locking strip44may be utilized on the bottom of the container10to provide further rigidity or support. Additionally, the apertures22in the side walls16,18of multiple containers10may be staggered so that the tabs30that extend through the apertures22do not directly abut one another when like containers10are stacked next to one another. Finally, the containers10in the present invention may be comprised of cardboard, plastic, or like container material that those skilled in the art would recognize as adaptable to accomplishing the objectives of the present invention.