Abstract:
A crate, such as for transporting egg cartons or other items, includes a base, opposed side walls and a rear wall extending upward from the base. A front wall opposite the rear wall is selectably moveable between a closed position and a retracted, open position. In the retracted position, access to the interior of the crate is provided. In one embodiment, the front wall includes a plurality of pivotably connected sections, such that the front wall can be retracted to provide access to the interior. A latch selectively prevents movement of the front wall to the retracted position.

Description:
[0001]    This application claims priority to U.S. Provisional Patent Application Nos. 60/968,507 and 60/975,497, filed Aug. 28, 2007 and Sep. 26, 2007, respectively. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    The present invention relates generally to containers and more particularly to a crate that is particularly useful for transporting egg cartons or other items to a store. 
         [0003]    Currently, egg cartons are shipped to stores in metal crates. The crates must be unloaded onto shelves for the customers to select and purchase. This requires labor for handling the egg cartons in the store. The metal crates are expensive and are damaged easily. They are also subject to rust and are not recyclable. They are also not easily repairable. 
       SUMMARY OF THE INVENTION 
       [0004]    The present invention provides a crate or container, such as for transporting egg cartons or other items. The crate includes a base, opposed side walls and a rear wall extending upward from the base. A front wall opposite the rear wall is selectably moveable between a closed position and a retracted, open position. In the retracted position, access to the interior of the crate is provided. A latch selectively prevents the front wall from being retracted. 
         [0005]    In use, egg cartons (or other items) would be shipped to a store in the crate with the front wall closed. At the store, the front wall would be retracted to provide access to the egg cartons in the interior of the crate by customers or by store workers. The empty crate can then be returned to be reused in shipping additional egg cartons. 
         [0006]    These and other features of the present invention can be best understood from the following specification and drawings, the following of which is a brief description. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0007]      FIG. 1  is a front perspective view of a crate according to a first embodiment of the present invention. 
           [0008]      FIG. 2  is a rear perspective view of the crate of  FIG. 1 . 
           [0009]      FIG. 3  is an interior perspective view of the front of the crate of  FIG. 1 . 
           [0010]      FIG. 3A  is a front perspective view of one of the latches of the front wall. 
           [0011]      FIG. 3B  is a rear perspective view of the latch of  FIG. 3A . 
           [0012]      FIG. 3C  is a front perspective view of the middle section of the front wall of the crate of  FIG. 1 . 
           [0013]      FIG. 3D  is a rear perspective view of the middle section of  FIG. 3C . 
           [0014]      FIG. 4  is an enlarged interior view of one of the latches in the front wall of the crate of  FIG. 1  in a locked position. 
           [0015]      FIG. 5  illustrates the latch of  FIG. 4  in an unlocked position. 
           [0016]      FIG. 6  is an interior view of the front wall of the crate of  FIG. 1  with the latches unlocked so that the front wall can be retracted. 
           [0017]      FIG. 7  illustrates a second step in retracting the front wall of the crate of  FIG. 1 . 
           [0018]      FIG. 8  illustrates the crate of  FIG. 1  with the front wall in a retracted position. 
           [0019]      FIG. 9  is a section view through the retracted front wall of  FIG. 8 . 
           [0020]      FIG. 10  is a perspective view of the crate of  FIG. 1  with another crate stacked thereon. 
           [0021]      FIG. 11  illustrates the crate of  FIG. 1  in a collapsed condition. 
           [0022]      FIG. 12  is illustrates the crate of  FIG. 11  with a similar crate stacked thereon. 
           [0023]      FIG. 13  is a front perspective view of a crate according to a second embodiment of the present invention. 
           [0024]      FIG. 14  is a rear perspective view of the crate of  FIG. 13 . 
           [0025]      FIG. 15  shows the upper section of the front wall slightly removed from the front opening. 
           [0026]      FIG. 16  shows the upper section and middle section lifted relative to the lower section and side walls. 
           [0027]      FIG. 17  shows the upper section and middle section moving toward the retracted position. 
           [0028]      FIG. 18  shows the front wall in the retracted position. 
           [0029]      FIG. 19  shows an optional front wall for the container of  FIG. 13 . 
           [0030]      FIG. 20  shows the optional front wall of  FIG. 19  in a second position. 
           [0031]      FIG. 21  shows the optional front wall of  FIG. 19  in a retracted position. 
           [0032]      FIG. 22  is a perspective view of the container of  FIG. 13  with a similar container stacked thereon. 
           [0033]      FIG. 23  is a perspective view of the container of  FIG. 13  in a collapsed position. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0034]    A crate  10 , such as for transporting egg cartons or other items, according to a first embodiment of the present invention is shown in  FIG. 1 . The crate  10  includes a base  12  having integrally molded upstanding portions  13  to which are hingably connected side walls  14 . A rear wall  16  is also hingably connected to the base  12  and latched to the side walls  14 . 
         [0035]    The front wall  18  includes an upper section  20 , a middle section  22  and a lower section  24 . The upper section  20  is connected to the middle section  22  by a hinge  26 . The middle section  22  is connected to the lower section  24  by a hinge  28 . Rotatable latches  80  selectively prevent pivoting of the upper section  20 , middle section  22  and lower section  24  relative to one another. The latches  80  include protruding handle portions  82 . An opening through the middle section  22  forms a handle  86  for lifting and carrying the crate  10 . 
         [0036]    The side walls  14  each include a small outer flange portion  38  having a lower opening  48 . The outer flange portion  38  is spaced outwardly of an inner flange portion  44  to define a channel  42  therebetween, as can be seen in  FIG. 2 . Lateral protrusions  40  near an upper edge of the upper section  20  of the front wall  18  are trapped between the outer flange portion  38  and a flexible latch  50  protruding from the side wall  14  when the front wall  18  is in the upright, closed position as shown. To collapse the front wall  18 , the flexible latch  50  can be deflected downward by force inward on the front wall  18 . 
         [0037]    The interior of the side walls  14  each include a curved channel  30  extending from an upper portion of the upper section  20  down to the base  12  in an arcuate path. The curved channels  30  accommodate the lateral protrusions  40  when the front wall  18  is moved toward the collapsed position onto the base  12 . 
         [0038]      FIG. 3  is an interior perspective view of the front of the crate  10  of  FIG. 1 . The latches  80  each include a pair of elongated fingers  88  extending therefrom. One finger  88  of each latch  80  is received in a slot  90  in the lower section  24 . One finger  88  of each latch  80  is received in a slot  92  in the upper section  22 . The fingers  88  prevent the upper section  20 , middle section  22  and lower section  24  from pivoting relative to one another on hinges  26 ,  28 . 
         [0039]      FIGS. 3A and 3B  are front and rear perspective views, respectively, of one of the latches  80  of the front wall  18 . The latch  80  includes a generally circular body portion  81  from which the handle portion  82  protrudes forwardly. Axially and circumferentially offset rear ears  94  and front ears  96  extend radially from the body portion  81 . The fingers  88  extend radially outward, then axially forward, then radially outward from the rear ears  94 . At least one of the fingers  88  includes a recess  98  for retaining the latch  80  in a desired rotational position, as will be explained below. 
         [0040]      FIGS. 3C and 3D  are front and rear perspective views of the middle section  22  of the front wall  18 . The middle section  22  includes an opening  100  on either side of the handle  86 . A plurality of short tabs  102  and long tabs  104  protrude into each opening  100 . As shown in  FIG. 3D , the interior surface of the middle section  20  includes a pair of bosses  106 ,  108  circumferentially spaced from each opening  100 . One boss  106  is aligned with the recess ( FIG. 3A ) to form a detent when the latch  80  is in the unlocked position and the other boss  108  is aligned with the recess to form a detent when the latch  80  is in the locked position, as shown in  FIG. 4 . 
         [0041]      FIG. 4  is an enlarged interior view of one of the latches  80  in the locked position with the fingers  88  received in the slots  90 ,  92 . 
         [0042]      FIG. 5  illustrates the latch  80  rotated to an unlocked position, such that the fingers  88  are not received in the slots  90 ,  92 .  FIG. 6  illustrates both latches  80  unlocked so that the front wall  18  can be retracted. With the latches  80  unlocked, the middle section  22  can pivot relative to the upper section  20  and lower section  24  on hinges  26 ,  28  as shown in  FIG. 7 . The top of the middle section  22  pivots outwardly and the lateral protrusions  40  of the upper section  20  slide downwardly within the channels  42  in the side walls  14  until the lateral protrusions  40  can be removed from the channels  42  via the openings  48 , as shown in  FIG. 8 . The middle section  22  and upper section  20  are then positioned in front of the lower section  24  when the front wall  18  is in the retracted position as shown in  FIG. 8 . 
         [0043]      FIG. 9  is a section view through the retracted front wall  18  of  FIG. 8 . In the retracted position, the upper section  20  is in contact with the middle section  22 . A lip  114  snaps past a lip  116  on the middle section  22  to retain the upper section  20  in place in the retracted position. 
         [0044]      FIG. 10  is a perspective view of the crate  10  with another crate  10 ′ stacked thereon. It should be appreciated that the front wall  18  of the lower crate  10  could be retracted according to  FIGS. 5-8  while the upper crate  10 ′ is supported thereon. 
         [0045]      FIG. 11  illustrates the crate  10  of  FIG. 1  in a collapsed condition, with the front and rear walls  18 ,  20  collapsed onto the base  12  and the side walls  14  collapsed onto the base  12  on top of the front and rear walls  18 ,  20 . A similar collapsed crate  10 ′ can be stacked on the collapsed crate  10 , as shown in  FIG. 12 . 
         [0046]    In use, egg cartons (or other items) would be shipped to a store in the crate  10  with the front wall  18  closed ( FIG. 1 ). At the store, the front wall  18  would be collapsed ( FIGS. 5-8 ) to provide access to the egg cartons in the interior of the crate  10  by customers or by store workers. When empty, the side walls  14  and rear wall  16  are collapsed onto the base  12  as shown in  FIG. 10  so that the crates  10  occupy less volume and can be efficiently returned to be reused in shipping additional egg cartons (or other items). 
         [0047]      FIG. 13  is a front perspective view of a crate  410  according to a second embodiment of the present invention. The crate  410  includes a base  412  having integrally molded upstanding portions  413  to which are hingably connected side walls  414 . A rear wall  416  is also hingably connected to the base  412  and latched to the side walls  414 . The front wall  418  includes an upper section  420 , a middle section  422  and a lower section  424 . The upper section  420  is connected to the middle section  422  by a hinge  426 . The middle section  422  is connected to the lower section  424  by a hinge  428 . 
         [0048]    The front wall  418  is hooked to the side wall  414  in several locations. The upper section  420  includes a pair of hooks or downwardly extending tabs  432  that interlock with rails  434  on the side wall  414 . The upper section  420  also includes a pair of latches  480  for selectively locking behind projections  482  of the side walls  414  to prevent the upper section  420  from moving outwardly. An upper wall  484  of each side wall  414  extends over the upper section  420  to prevent the upper section  420  (and the entire front wall  418 ) from moving upwardly relative to the side walls  414 . 
         [0049]    A handle opening  486  is formed through the middle section  422 . It should be noted that the crate  410  can be lifted using handle opening  486  without releasing the front wall  418 , because the front wall  418  will contact the upper walls  484  of the side walls  414 . 
         [0050]      FIG. 14  is a rear perspective view of the crate  410 . The interior of the side walls  414  each include a curved channel  430  extending from an upper portion of the upper section  420  down to the base  412  in an arcuate path. 
         [0051]      FIG. 15  shows the upper section  420  slightly removed from the side walls  414 . Each latch  480  includes a pair of laterally-projecting, vertically-spaced tabs  488  that are slidable behind the projections  482  of the side walls  414 , as in  FIG. 13 . In  FIG. 13 , the latches  480  are in a lower, latched position with the tabs  488  locked behind the projections  482 . In  FIG. 15 , the latches  480  are in an upper, unlatched position with the tabs  488  above the projections  482 , so that the upper panel  420  can be tilted outwardly as shown in  FIG. 15 . This moves the upper edge of the upper section  420  out from under the upper walls  484  of the side walls  414 , so that the upper section  420  (and with it, the middle section  422 ) can be lifted relative to the side walls  414  and the lower section  424  (via translating hinge  428 ) as shown in  FIG. 16 . The front wall  418  can then be collapsed as shown in  FIGS. 17-18 . 
         [0052]      FIGS. 19-21  illustrate an optional front wall  418 A for the crate  410 . At least one of the tabs  488 A of each of the latches  480 A (only one illustrated) includes a rearward arm  490  and a lateral projection  492 , as shown in  FIG. 19 . When the upper section  420  and middle section  422  (not visible in  FIG. 20 ) is moved against the crate  410 , the rearward arm  490  and lateral projection  492  of the latch  480 A extend into a recess  494  formed in the side wall  414  above a flange  496 . When the latch  480 A is then moved downwardly, as shown in  FIG. 21 , the lateral projection  492  interlocks behind the flange  496 . In this manner, the folded front wall  418  is retained in place against the crate  410 . 
         [0053]    In use, egg cartons (or other items) would be shipped to a store in the crate  410  with the front wall  418  closed ( FIG. 13 ). In this embodiment, the crate  410  can be carried using the handle  486  in the front wall  418 . The crate  410  supports a similar crate  410 ′ stacked thereon, as shown in  FIG. 22 , and could also support a similar crate  410 ′ stacked thereon with the front wall  418  open. At the store, the front wall  418  would be retracted ( FIG. 18  or  21 ) to provide access to the egg cartons in the interior of the crate  410  by customers or by store workers. When empty, the side walls  414  and rear wall  416  are collapsed onto the base  412  as shown in  FIG. 23  so that the crates  410  occupy less volume and can be efficiently returned to be reused in shipping additional egg cartons (or other items). 
         [0054]    It should be noted that the front wall in any embodiment is only designated “front” for convenience of reference, and that by itself, the term “front” does not require any specific wall (or walls) of the container to have these features. In the particular application of shipping egg cartons, it is expected that the retractable wall would be oriented toward the customers; however this invention is not limited to that application or to only the “front” wall being retractable. Unless otherwise required by the claims, the long walls could be retractable. 
         [0055]    Further, the retractable wall could also be provided in a nestable container in which the other walls do not collapse onto the base. The other walls may be integrally molded with the base. 
         [0056]    In accordance with the provisions of the patent statutes and jurisprudence, exemplary configurations described above are considered to represent a preferred embodiment of the invention. However, it should be noted that the invention can be practiced otherwise than as specifically illustrated and described without departing from its spirit or scope.