Abstract:
The present invention relates to a reusable, collapsible container, which when in a disassembled state is completely contained in an area no larger than the base member thereof, is easy to assemble, and due to the interlocking features of a number of the component parts of the container, requires a minimal number of separate locking/fastening devices.

Description:
RELATED APPLICATION 
       [0001]    This application is claiming the benefit, under 35 U.S.C. 119(e), of the provisional application filed Dec. 28, 2009 under 35 U.S.C. 111(b), which was granted Ser. No. 61/290,261. This provisional application is hereby incorporated by reference. 
     
    
     BACKGROUND 
       [0002]    The invention relates to a collapsible reusable container. More specifically, the invention relates to a multi-component container, which when disassembled, forms an extremely compact self-contained “kit” which contains all of the components needed to construct a complete container which may be reused indefinitely. 
         [0003]    The patent literature contains reference to many examples of containers which are said to be reusable, as well as examples of containers which are said to be collapsible. Many of these containers, upon further inspection, when disassembled, merely result in a collection of many loose components which may become separated, damaged or lost during return transport. The more truly “collapsible” such containers become, the more fragile, and less reusable, they tend to be. 
         [0004]    It would, therefore, be desirable to have a container which is easy to assemble, forms a truly self-contained “kit” when disassembled, while at the same time being robust enough to withstand multiple cycles of transport. 
       SUMMARY OF THE INVENTION 
       [0005]    The present invention relates to a reusable, collapsible container which, when in a disassembled state is completely contained in an area no larger than the base member thereof, is easy to assemble and due to the interlocking features of a number of the component parts of the container, requires a minimal number of separate locking/fastening devices. 
         [0006]    The base member of the container of the present invention serves multiple functions. It functions as a relatively conventional base/pallet when the container is assembled, but serves, unconventionally, as the storage container for all of the remaining component parts of the container. Access openings in the base member preferably allow transport of the container in either the assembled or disassembled state by forklift, or other types of container transport equipment 
         [0007]    The interaction of various other components of the present container with the base member is an important aspect of the invention. More specifically, a first horizontal support member, having a plurality of locking tab receiving openings formed in the peripheral area thereof, is disposed in the base member, the first horizontal support member having a shape, generally, corresponding to the shape of the base member. The base member may have any predetermined geometric shape, but is preferably square or rectangular. 
         [0008]    Locking tabs are formed in the bottom peripheral portions of vertical wall members in predetermined positions, so as to align with the locking tab receiving openings in the first horizontal support member. The locking tabs of one or more of the vertical wall members are lockingly inserted into the locking tab receiving openings of the first horizontal support member and are thus preferably interlocked for each individual vertical wall member, but are not integrally interlocked as an overall structure. 
         [0009]    Such overall, or integral interlocking of one or more of the vertical wall members may be accomplished by placement of the second horizontal support member over the first horizontal support member, and peripherally lockingly contacting one of more of the vertical wall members. Greatly enhanced structural rigidity of the structure of the container results therefrom. “Front-end” loading of the present container is possible in one configuration of the container. 
         [0010]    The vertical wall members also have locking device receiving openings formed therein, as does a top member. Locking devices, preferably locking clips are configured so as to fit into locking device receiving openings in adjacent container members, for example the top member and vertical wall member, or two adjacent vertical wall members. Due to the enhanced container rigidity created by the utilization of the locking tabs and the second horizontal support member, the number of locking devices necessary to meet container integrity requirements is minimized. 
         [0011]    Methods of assembling the container of the invention are also provided. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0012]    Additional objects, advantages and features of the present invention will become apparent from the following description and appended claims taken in conjunction with the accompany drawings in which: 
           [0013]      FIG. 1  is a perspective view of the container according to the invention in a disassembled state. 
           [0014]      FIG. 2  is a perspective view of typical base reinforcing members and a portion of the horizontal sub-base member of the container according to the invention. 
           [0015]      FIG. 3  is a perspective view of the first horizontal support member having T-shaped locking tab receiving openings inserted into the base member of the container according to the invention. 
           [0016]      FIG. 4  is a perspective view of a vertical wall member having a T-shaped locking tab formed in a bottom peripheral portion thereof so as to be lockingly insertable into the correspondingly shaped locking tab receiving opening formed in the first horizontal support member of the container according to the invention. 
           [0017]      FIG. 5  is a perspective view of a T-shaped locking tab lockingly engaged in a locking tab receiving opening in the first horizontal support member of the container according to the invention. 
           [0018]      FIG. 6  is a perspective view of the substantially assembled container according to the invention, showing the second horizontal support member integrally locking in the vertical wall members. 
           [0019]      FIG. 7  is a perspective view of the container according to the invention having a front end loading option. 
           [0020]      FIG. 8  is a perspective view of a vertical wall member having an alternative locking tab shape usable with the front end loading option of the container according to the invention. 
           [0021]      FIG. 9  is a similar view to  FIG. 4  of a vertical wall member having the alternative shape locking tab formed in a bottom peripheral portion thereof so as to be lockingly insertable into a correspondingly shaped locking tab receiving opening formed in the first horizontal support member, but accessible when the second horizontal support member of the container of the invention is already disposed in the base member. 
           [0022]      FIG. 10  is a similar view to  FIG. 7  of the container according to the invention, the container shown having the front end opening option such that at least the front vertical wall member is not integrally locked into place by the second horizontal support member. 
           [0023]      FIG. 11  is a perspective view of a substantially assembled container (minus the top member) also showing several locking devices inserted into locking device receiving openings, according to the invention. 
           [0024]      FIG. 12  is a perspective view of a completely assembled container, according to the invention. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0025]    The present invention relates to a compactly storable, easily assembled, reusable container for transporting many different types of cargo. 
         [0026]    While the container can be made from any suitable material, apart from certain base reinforcing members, which are preferably made from wood, and locking devices which are preferably made from metal, most of the other components of the container are preferably made from wood composite materials, such as oriented strand board (OSB). 
         [0027]    Applicants note at the outset, that while the container of the present invention is formed from a number of components, it is more than just a collection of components in the novel manner in which the components interact when assembled and in the manner in which they neatly and logically self-store when disassembled. 
         [0028]    The multi-functional base member  12  of the reusable container  10  is made up of a plurality of base reinforcing members  22  to which are mechanically fastened, by any suitable fastening device, parallel front and rear vertical base members  14 ,  16  which are separated by a distance substantially equal to the length of parallel first and second vertical side base members  18 ,  20 . First and second vertical side base members  18 ,  20  are substantially perpendicular to front and rear vertical base members  14 ,  16 , and when mechanically fastened to one another, form the substantially square or rectangular periphery of base member  12 . (See  FIG. 1 .) Within the boundary of the peripheral area formed by vertical base members  14 ,  16 ,  18 ,  20 , a horizontal sub-base member  24  is mechanically fastened to one or more base reinforcing members  22 . (See  FIG. 2 ). 
         [0029]    Over the horizontal sub-base member  24 , a first horizontal support member  26 , having a shape substantially corresponding to that formed by vertical base members  14 ,  16 ,  18 ,  20 , is disposed. In the peripheral area of the first horizontal support member  26 , a plurality of locking tab receiving openings  30 ,  130  are formed. (See  FIG. 3 .) Locking tab receiving openings are substantially T-shaped and rectangular, respectively, however, other shapes are possible. It is also possible, and in some configurations, preferred, that locking tab receiving openings  30 ,  130  having more than one shape may be formed in a single first horizontal support member  26 . Preferably the vertical base members  14 ,  16 ,  18 ,  20  have a predetermined height so as to extend a predetermined distance above the first horizontal support member  26 , thus forming a retaining lip, which as will be seen serves a variety of functions. 
         [0030]    Other components of the present container include at least one vertical wall member. Preferably, the container is provided with front and rear vertical wall members  32 ,  34  and first and second side vertical wall members  36 ,  38 . Each of the vertical wall members has at least one locking tab  40 ,  140  formed in a bottom peripheral portion of vertical wall members  32 ,  34 ,  36 ,  38 . (See  FIGS. 4 and 8 ). The locking tabs  40 ,  140  may vary in shape between one vertical wall member and another. Preferably, the shapes of the locking tabs  40 ,  140  are substantially T-shaped or rectangular shaped to correspond to the shapes of the locking tab receiving openings  30 ,  130  formed in the first horizontal support member  26 . 
         [0031]    Still another component of the present container is second horizontal support member  44  which is disposed over the first horizontal support member  26 . (See  FIG. 6 .) Besides providing the capability of transporting heavier cargoes, the peripheral area of the second horizontal support member  44  contacts one or more of the bottom peripheral portions of vertical wall members  32 ,  34 ,  36 ,  38 . If the locking tab  40 ,  140  of the vertical wall member  32 ,  34 ,  36  or  38  has been inserted into locking tab receiving openings  30 ,  130  prior to disposal of second horizontal support member  44  over the first horizontal support member  26 , the peripheral edge of second horizontal support member  44 , preferably integrally locks all such vertical wall members  32 ,  34 ,  36  or  38  into a finally assembled state. (See  FIG. 6 .) It may be desirable, however, to provide an option for front-loading of the container  10  by allowing for installation of one or more vertical wall members, preferably front and/or rear vertical wall members  32 ,  34  after the second horizontal support member  44  has been disposed in the container, and has integrally interlocked those previously installed vertical wall members into place, as earlier described herein. (See  FIGS. 7-9 ). To facilitate the front-loading option, it may be desirable for the peripheral dimensions of second horizontal support member  44  to be smaller, by a predetermined amount, in comparison to the peripheral dimensions of the first horizontal support member  26 , so as to allow engagement of locking tabs  40 ,  140 , into locking tab receiving openings  30 ,  130  even though second horizontal support member  44  is already in place. 
         [0032]    Once vertical wall members  32 ,  34 ,  36 ,  38  are installed as previously described, a top member  50  is brought into closing contact with upper peripheral portions of vertical wall members  32 ,  34 ,  36 ,  38 . Preferably, top member  50  (See  FIG. 1 ) is better secured and accurately located with respect to vertical wall members  32 ,  34 ,  36 ,  38  by top locating tabs  52  and top locating notches  54  formed in top member  50 , and in the upper peripheral portions of vertical wall members  32 ,  34 ,  36 ,  38 . 
         [0033]    Even though all of the previously described components of the reusable container  10  are interlocked with one or more other adjacent components, it will in most instances, be desirable to further increase the structural integrity of the container  10 . This is accomplished by utilization of a plurality of locking devices  48 , having first and second ends. Typically, such locking devices are substantially L-shaped and are made from a metal having certain spring-like qualities. Preferably, each of vertical wall members  32 ,  34 ,  36 , and  38 , and top member  50  are provided with a plurality of locking device receiving openings  42  in the near-peripheral area of each of the aforementioned components of container  10 . By inserting the first end of a locking device  48  into a locking device receiving opening  42  in, for example, front vertical wall member  32 , and the second end of the locking device  48  into a locking device receiving opening in, for example, first side vertical wall member  36 , these two components are positively interlocked. This process is repeated as necessary to ensure interlocking of component of container  10  as deemed necessary. Due to the interlocking of the components provided in the inventive container apart from the locking devices  48 , the number of locking devices needed may be only 50% of the number needed in conventional containers, for example, 50% of  24 - 32  locking devices. 
         [0034]    With this overview, the container of the invention will now be described in more detail with reference to the figures which are a part of this application. 
         [0035]    As can be seen in, for example  FIGS. 1 and 11 , at least one lifting device access opening  56  is formed in one or more of vertical base members  32 ,  34 ,  36 ,  38  to allow access to, for example, the forks of a forklift truck for transporting container  10 , whether in an assembled or a disassembled state. 
         [0036]    As best seen in  FIG. 3 , substantially T-shaped locking tab receiving openings  42  are formed in the peripheral area of first horizontal support member  26  which is disposed within base member  12 . 
         [0037]    Alternatively, as shown in  FIG. 9 , substantially rectangularly shaped locking tab receiving openings  130  may be formed in first horizontal support member  26 . While other reasons for utilizing the alternatively shaped locking tab receiving openings  130  are possible, it is envisioned that they will be utilized primarily in containers  10  which have a front loading option. 
         [0038]    With reference to  FIG. 4  a substantially T-shaped locking tab  40  is provided in the lower peripheral portion of any of vertical wall members  32 ,  34 ,  36 ,  38 . By referring to  FIGS. 4 and 5  the interlocking action of locking tab  40  into locking tab receiving opening  30  is illustrated. Locking tab  40  is preferably inserted into locking tab receiving opening  30  at its widest point and moved laterally so that the top of the “T” of locking tab  40  is lockingly retained under the surface of first horizontal support surface  26 . 
         [0039]    Alternatively, as best seen in  FIGS. 8-10 , a substantially rectangularly shaped locking tab  140  is formed in the bottom peripheral portion of any of vertical wall members  32 ,  34 ,  36 ,  38 , and is capable of being inserted into correspondingly shaped locking tab receiving opening  130  with second horizontal support member  44  in place. As previously mentioned such an arrangement may be utilized to facilitate a front loading option for reusable container  10 , illustrated in, for example,  FIG. 7 . 
         [0040]    As can be seen in, for example  FIGS. 1 ,  7 , and  11 , substantially alternating locating tabs  52  and locating notches  54  are formed in top member  50 , and any one of vertical wall members  32 ,  34 ,  36 ,  38 . 
         [0041]    As shown in  FIG. 1 , a plurality of a preferred form of locking device  48  is stored in base member  12  of reusable container  10 . In  FIG. 11 , such preferred locking devices, i.e., formed from heavy gauge metal wire having spring-like properties, are lockingly inserted into locking device receiving openings  42  thus securing, for example, vertical wall members  32 ,  34 ,  36 ,  38  one to another, or top member  50  to vertical wall members  32 ,  34 ,  36 ,  38 . 
         [0042]    While  FIGS. 2-11  illustrate various configurations of the reusable container  10 , in various stages of assembly,  FIG. 1  illustrates an important aspect of the container of the invention, namely, the compact size and well organized storage of the components thereof when disassembled. As shown in  FIG. 1 , base member  12  as delineated by vertical base members  14 ,  16 ,  18 ,  20 , contain within the “footprint” of the base member  12  all of the previously described components of reusable container  10 , including first and second horizontal support members  26  and  44 , vertical wall members  32 ,  34 ,  36 ,  38 , top member  50 , and a plurality of locking devices  48 . These components are vertically contained by the predetermined height of vertical base members  14 ,  16 ,  18 ,  20 . 
         [0043]    The foregoing discussion discloses and describes exemplary embodiments of the present invention. One skilled in the art will readily recognize from this discussion and from the accompanying drawings and variations can be made therein without departing from the spirit and scope of the invention as defined in the following claims.