Abstract:
A storage container includes a base and a plurality of walls extending upwardly from the base. At least one of the walls includes a plurality of projections on its exterior at different heights. The interior of the wall includes a plurality of channels into which the projections of a like container would be slidably received when the empty containers are nested. A plurality of supports are pivotably connected to the container and can be selectably pivoted to block selected ones of the plurality of channels such that the projections are supported on the supports and do not enter the channels, thereby supporting the upper container at a selected height.

Description:
RELATED APPLICATIONS 
       [0001]    This application is a continuation of application Ser. No. 11/073,336, filed on Mar. 4, 2005. 
     
    
     BACKGROUND 
       [0002]    Portable storage containers that both stack and nest with similar containers are commonly used in industry for transporting and storing goods. Nesting is typically achieved with an empty container receives a like container therein such that there is overlap between the walls and container. On the other hand, the stacking feature is typically used when an occupied container has a like container supported thereon, such that there is relatively little or no overlap between the walls of the container, and the goods contained in the lower container are preferably not contacted or damaged by the upper container. 
         [0003]    Many containers include bail members to achieve this stacking feature. Bail members are typically slidably and pivotally connected to opposite walls. The bail members can be positioned out of the way for purposes of nesting, and can be moved to one or more stacking positions (i.e., vertically aligned with the floor) to permit another container to be stacked thereon. 
       SUMMARY 
       [0004]    A storage container according to the present disclosure includes a base, a pair of opposed end walls extending upwardly from the base and a pair of opposed side walls extending upwardly from the base. A support system is mounted proximate each end wall. Each support system includes a plurality of supports pivotably connected to the end wall. Each end wall further includes a plurality of projections from the exterior of the end wall. The projections are formed at different heights from the base in pairs. For example, in the embodiment described, there are three pair of projections on each end wall, the two projections within each pair are at the same height and each pair of projections is at a different height. Each projection forms corresponding vertically-extending channel on the interior of the end wall, such that the projections of one container would be aligned and would be slidably received within the channels of a similar container into which it is nested. 
         [0005]    When pivoted inwardly to a support position, each of the supports selectably blocks one pair of the channels such that the projections of the upper container would not be received within the blocked channel, but would be supported upon the support. By selectively blocking different channels, and thereby providing support to projections of different heights, the upper container is supported at varying heights relative to the base of the lower container. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0006]    Other advantages of the present disclosure can be understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein: 
           [0007]      FIG. 1  is a perspective view of the storage container with the supports in the open, nesting position. 
           [0008]      FIG. 2  is a perspective view of the storage container of  FIG. 1  with the first support in the stacking position and the second support and the third support pivoted upwardly for illustration. 
           [0009]      FIG. 3  is a perspective view of one corner of the storage container of  FIG. 1  in the nesting position with a similar container nested therein. 
           [0010]      FIG. 4  is a perspective view of the containers of  FIG. 3  in a first stacked position. 
           [0011]      FIG. 5  illustrates the containers of  FIG. 3  in a second stacked position. 
           [0012]      FIG. 6  illustrates the containers of  FIG. 3  in a third stacked position. 
           [0013]      FIG. 7  is an end view of the storage container of  FIG. 1 . 
           [0014]      FIG. 8  is a side view of the storage container of  FIG. 1 . 
           [0015]      FIG. 9  is a top view of the storage container of  FIG. 1 . 
           [0016]      FIG. 10  is a bottom view of the storage container of  FIG. 1 . 
           [0017]      FIG. 11  is an end view of the storage container of  FIG. 1  indicating one possible color scheme. 
           [0018]      FIG. 12  is a top view of a portion of a end wall and support on a storage container according to a second embodiment of the present disclosure. 
           [0019]      FIG. 13  illustrates the end wall of  FIG. 12  with the support in a first support position. 
           [0020]      FIG. 14  illustrates the end wall of  FIG. 12  with the support in a second support position. 
           [0021]      FIG. 15  is a perspective view of a portion of an upper container and a lower container according to a third embodiment of the present disclosure. 
           [0022]      FIG. 16  is a sectional view through the end walls of the containers of  FIG. 15 , with the supports in a first support position. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0023]    A storage container  10  according to the present disclosure is shown in  FIG. 1 . The storage container  10  generally includes a floor or base  12 , a pair of side walls  14  and a pair of end walls  16  extending upwardly from a periphery of the base  12 . A support system  18  is mounted to the container  10  proximate each end wall  16 . In the embodiment shown, the support system  18  is mounted to an upper edge of the end wall  16 . The support system  18  includes a first support  20  hingeably mounted to the end wall  16 . A second support  22  and a third support  24  are each hingeably mounted to the end wall  16 . The first, second and third supports  20 ,  22  and  24  are each independently pivotable relative to one another and relative to the end wall  16  about a common axis  26  adjacent an outer edge of an upper surface  28  of the end wall  16 . 
         [0024]    Each end wall  16  includes an exterior surface  30  and an interior surface  32 . A horizontal lip or flange  34  protrudes outwardly from the exterior  30  of each end wall  16 . The interior  32  of each end wall  16  includes a pair of vertically extending first channels  40  a pair of vertically extending second channels  44  outward of the first channels  40  and a pair of vertically extending third channels  48  outward of the second channels  44 . The channels  40 ,  44 ,  48  open upwardly and inwardly. The channels  40 ,  44 ,  48  define alternate first, second and third columns  41 ,  45 ,  49  that extend to the upper surface  28  of the end wall  16 . Each channel  40 ,  44 ,  48  also forms a corresponding first, second and third projection  42 ,  46 ,  50 , respectively, on the exterior surface  30  of the end wall  16 . A lower end of each projection  42 ,  46 ,  50  forms an interlocking member  43 ,  47 ,  51 , respectively. The lower ends of the first projections  42  are at a first height above a plane containing the base  12 . The lower ends of the second projections  44  are at a second height relative to the base  12 , the second height being less than the first height. The lower ends of the third projections  48  are at a third height relative to the base  12 , the third height less than the second height. Each side wall  14  also includes a horizontal lip or flange  56  and further includes an opening to form a handle  58 . 
         [0025]    As can be seen in  FIG. 2 , the first, second and third supports,  20 ,  22 ,  24  are each pivotable relative to the container. Each support  20 ,  22 ,  24  includes a pair of flaps  60  hingeably connected to the end wall  16  and connected to one another by a beam  62 . In  FIG. 2 , the first supports  20  have been pivoted to a stack position. In the stack position, the flaps  60  cover and block the first channels  40  while being supported on the first columns  41  and the upper surface  28  of end wall  16 . Similarly, the second support  22  can be pivoted to a stacked position in which the flaps  60  would cover and block the second channels  44  and be supported on the first and second columns  41 ,  45 . Similarly, a third support  24  can be pivoted to the stacked position where the flaps  60  would rest on the second and third columns  45 ,  49  and hover and block the third channels  48 . 
         [0026]      FIG. 3  illustrates the storage container  10  with the support system  18 , including the first support  20 , second support  22  and third support  24 , in the open or nest position and with a like storage container  10 ′ nested therein. The upper container  10 ′ and lower container  10  are identical and corresponding components on the upper container  10 ′ will be indicated with identical reference numerals appended with a prime designation. Thus, descriptions of any components on the upper container  10 ′ apply equally to the lower container  10  and vice versa. In this position, the empty containers  10 ,  10 ′ can be stored or shipped while occupying the least amount of space. Other similar containers can be nested within the upper container  10 ′ and so on. 
         [0027]    While nested, the flange  56 ′ of the upper container  10 ′ is supported on the flange  56  of the lower container  10  and the flange  34 ′ of the upper container  10 ′ is supported on the flange  34  of the lower container  10 . As can be seen more clearly in  FIG. 3 , the upper surfaces of the columns  41 ′,  45 ′ and  49 ′ each include a plurality of tenons  66 ′ which are positioned to be received in mortises  68 ′ on the flaps  60 ′ of the first, second and third supports  20 ′,  22 ′,  24 ′. 
         [0028]    In  FIG. 4 , the first supports  20 ,  20 ′ of the lower and upper containers  10 ,  10 ′ have been pivoted to the stacked position in which the flaps  60 ,  60 ′ cover the first channels  40 ,  40 ′ ( FIG. 1 ). In this first stack position, the flap  60  of the lower container  10  thus prevents the first projection  42 ′ of the upper container  10 ′ from entering the first channel  40 . The first projection  42 ′ is supported on the flap  60  on the first support  20 . The second and third projections  46 ′,  50 ′ of the upper container  10 ′ are partially received within the second and third channels  44 ,  48  of the lower container  10  respectively. The base  12 ′ of the upper container  10 ′ is supported at a first distance above the base  12  of the lower container  10 . The interlocking member  43 ′ of the first support  42 ′ is received within a recess in the flap  60  of the first support  20 . Referring to the upper container  10 ′ where it can be seen more clearly, the second support  22 ′ includes a tapered surface  72 ′ that engages a tapered surface  74 ′ of the first support  20 ′ such that the second support  42 ′ cannot be pivoted to the stack position without also pivoting the first support  20 ′ to the stack position. Similarly, the second support  22 ′ includes a tab  76 ′ that is engaged by the third support  24 ′, such that the third support  24 ′ cannot be pivoted to the stack position without also pivoting the second support  22 ′ (and therefore the first support  20 ′) to the stack position. 
         [0029]    In  FIG. 5 , the second supports  22 ,  22 ′ and the first supports  20 ,  20 ′ are pivoted to the stack position. The flap  60  of the second support  22  of the lower container  10  covers and blocks the second channel  44  thereby preventing the second projection  46 ′ of the upper container  10 ′ from entering the second channel  44  ( FIG. 1 ). The flap  60  of the second support  22  is supported on the first column  41  ( FIG. 1 ) and the second column  45 . The interlocking member  47 ′ of the second projection  46 ′ of the upper container  10 ′ is received within a recess of the flap  60  of the second support  22  of the lower container  10 . The third projection  50 ′ of the upper container  10 ′ is partially received within the third channel  48  of the lower container  10 . The base  12 ′ of the upper container  10 ′ is supported at a second height above the base  12  of the lower container  10 , the second height is greater than the first height. 
         [0030]      FIG. 6  illustrates the support systems  18 ,  18 ′ in the third stacking position, with the first, second and third supports  20 ,  20 ′,  22 ,  22 ′,  24 ,  24 ′ in the stack position. In this position, the flap  60  of the third support  24  of the lower container  10  covers and blocks the third channel  48  ( FIG. 1 ) and is supported on the second and third columns  45 ,  49  ( FIG. 1 ). The interlocking member  51 ′ of the third projection  50 ′ of the upper container  10 ′ is received in a recess of the flap  60 . In this position, the base  12 ′ of the upper container  10 ′ is supported at a third, maximum distance above the base  12  of the lower container  10 . This provides the maximum storage container in the lower container  10  with the upper container  10 ′ stacked on it. 
         [0031]      FIG. 7  is an end view of the storage container  10 . As shown, the pair of first projections  42  on end wall  16  are at the same height from the base  12  and are laterally aligned with the flaps  60  of the first support  20 . The pair of second projections  46  are at equal heights from the base  12 , both lower than the first projections  42 , and are laterally aligned with the flaps  60  on the second support  22 . The pair of second projections  46  are laterally outward of the first projections  42 . The pair of third projections  50  are at equal heights from the base  12 , both lower than the second projections  46 , and are laterally aligned with the flaps  60  on the third support  24 . The pair of third projections  50  are laterally outward of the second projections  46 . 
         [0032]      FIG. 8  is a side view of the storage container  10 . The third projections  50  and the interlocking member  51  are shown. 
         [0033]      FIG. 9  is a top view of the storage container  10 , illustrating the columns  41 ,  45 ,  49  and the channels  40 ,  44 ,  48  formed on the interior  32  of the end walls  16 .  FIG. 10  is a bottom view of the storage container  10 , illustrating the projections  42 ,  46 ,  50  and interlocking members  43 ,  47 ,  51  formed on the exterior  30  of the end walls  16 . 
         [0034]      FIG. 11  is an end view of the storage container  10 , with shading to indicate one potential useful color scheme. As shown, the first support  20  is preferably a first color as are the first projections  42 . The second support  22  and the second projections  46  are a second color. The third support  24  and the third projections  50  are a third color. The end wall  16  (and the rest of the container  10 ) are preferably a fourth color. In this manner, it is easier for a user to select one of the supports  20 ,  22 ,  24  by clearly recognizing the corresponding projection  42 ,  46 ,  50 . The supports  20 ,  22 ,  24  are molded separately from the end wall  16 , and thus may be molded of a plastic of the appropriate color. The projections  42  may be painted, covered with stickers or molded of a plastic of the appropriate color using a multi-shot mold. 
         [0035]    An end wall  114  of a storage container  110  according to a second embodiment is shown in  FIGS. 12-14 .  FIGS. 12-14  are top views of an end wall  114  that could be used in place of the end walls  14  in the storage container  10  of  FIGS. 1-11 . Except as otherwise described, the storage container  110  could be identical to the storage container  10  of the first embodiment except as otherwise described or shown below. The end wall  114  includes a first channel  140  and a second channel  144  on an interior surface  132 . The support system  118  includes a support  119  that is slideable along the upper surface of the end wall  114 , such that a support surface or flap  60  can selectively cover and block neither of the channels  140 ,  144 , the first channel  140  ( FIG. 13 ) or the second channel  144  ( FIG. 14 ). Additional channels (such as a third channel, like the first embodiment) could be added. Like the first embodiment, the end wall  114  of the storage container  110  includes a pair of first channels  140  (one shown) and a pair of second channels  144  (one shown) and the support  119  includes a pair of flaps  160  for covering the pairs. 
         [0036]    In the description above and in the claims, the term “projection,” such as the first, second and third projections  42 ,  46 ,  50 , means any surface that protrudes laterally, or in a plane parallel to the base  12 , relative to a surface above or below it vertically (i.e. perpendicular to the base  12 ). This is demonstrated by a third embodiment shown in  FIGS. 15-16 . 
         [0037]      FIG. 15  illustrates a lower container  210 ′ and an upper container  210 . The upper container includes a first projection  242  defined by a first recess  282  therebelow formed in the exterior surface  234  of the end wall  214 . Similarly, a second projection  242  is defined by a second recess  284  therebelow. 
         [0038]    By selectively pivoting a first support  220 ′ of the lower container  210 ′ inwardly, the first projection  242  of the upper container  210  can be supported at a first height by the first support  220 ′ of the lower container  210 ′, as shown in  FIG. 16 . The first recess  282  forms a corresponding first column  241  on a interior surface  232  of the storage container  210 . 
         [0039]    Similarly, (although not illustrated) by selectively pivoting a second support  222 ′ of the lower container  210 ′ inwardly, the second projection  244  of the upper container  210  can be supported at a second height by the second support  222 ′ of the lower container  210 ′. Additional supports and projections could be used to provide different support heights, as in the first embodiment. 
         [0040]    While embodiments of the disclosure have been illustrated and described, it is not intended that these embodiments illustrate and describe all possible forms of the disclosure. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the disclosure.