Abstract:
A light-weight stackable beverage crate includes a bottom plate, four side walls forming an interior space for placement of objects, and four vertically extending columns interconnecting the side walls and bottom plate. Each side wall includes a pattern of outer and inner arches interconnected by lateral beams, vertical support beams, and cross-beams. Side walls may include handle recesses. A lateral beam defines an upper edge of the side wall and another lateral beam defines a lower edge of the side wall. An upper end of the column extends above the upper edge of the side walls, and a lower end of the column extends below the lower edge of the side walls. The upper and lower ends of the column are capable of distributing a load force. When stacked, the only load-bearing points of contact between crates above are the upper and lower ends of the columns.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application claims the benefit of and priority to U.S. Provisional Patent Application No. 61/185,741, filed Jun. 10, 2009. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates to a light-weight beverage crate and more particularly to a light-weight beverage crate having side walls with arch-shaped supporting members and load-bearing pads. 
     BACKGROUND OF THE INVENTION 
     Plastic molded crates have been used to transport beverages such as milk containers. Standard crates weigh between 2½ lbs. to 3 lbs. The crate carries a load of about 40-45 lbs. Crates are usually stacked forming a column of about six to eight crates. Accordingly, the load of a stacked column of crates may exceed 384 lbs. 
     U.S. Pat. No. 3,353,659 (which is incorporated herein by reference) describes a plastic tote case that may carry milk containers. The case includes cut-out areas in the side walls to provide for visibility of the identification of the case contents. The cut-outs are said to reduce the overall weight of the case. 
     U.S. Pat. No. 4,548,320 (which is incorporated herein by reference) describes a heavy-duty plastic beverage case. The case includes centrally disposed bearing pads on the upper edge of the end walls. The bearing pads are said to contribute to the structural strength of the case by transmitting compressive forces from the upper stacking rim to the bottom of the case. 
     The need still exists for a lighter-weight plastic molded beverage crate that is easier to manipulate, durable and structurally capable of bearing load forces. 
     SUMMARY OF THE INVENTION 
     It is an object of the present invention to provide a light-weight plastic molded beverage crate. 
     It is an object of the present invention to provide a stackable light-weight plastic molded beverage crate structurally capable of bearing load forces. 
     The objects and advantages of the present invention are achieved by the novel plastic molded beverage crate described herein. A stackable crate of the present invention may include a bottom plate, four side walls adjacent to the bottom plate forming an interior space for placement of objects, and four vertically extending columns interconnecting the side walls and bottom plate. Each side wall may include a pattern of outer arches and inner arches interconnected by a plurality of lateral beams, a plurality of vertical support beams, and a plurality of cross-beams. One lateral beam may define an upper edge of the side wall, and another lateral beam may define a lower edge of the side wall. Each column may have an upper end that extends above the upper edge of the side walls and a lower end that extends below the lower edge of the side walls. The upper and lower ends of the column may be capable of distributing a load force. 
     A portion of the bottom plate may extend below the lower edge of the side walls and below the lower end of the columns. The bottom plate may have a concave portion. The upper end of each column may include an upper load pad disposed above the upper edge of the side walls. The lower end of each column may include a lower load pad disposed below the lower edge of the side walls. Each side wall may include a handle recess for placement of a hand. 
     Each of the inner and outer arches may include two sides extending downward from an apex to two bottom points. Each inner arch may be concentrically disposed within an outer arch. Each side wall may have an upper central vertical beam, a lower central vertical beam, and two or more lateral rows of outer and inner arches. The upper central vertical beam may extend from the upper edge to a top edge of the handle recess. The lower central vertical beam may extend from a bottom edge of the handle recess to the lower edge of the side wall. Each cross-beam may interconnect the outer arches in each lateral row with other outer arches, upper or lower central vertical beams, a column adjacent to the side wall, or the lateral beams. One lateral beam may define a top of each lateral row and another lateral beam may define a bottom of each lateral row. Another lateral beam may extend through each lateral row interconnecting with the bottom points of the inner arches in the lateral row. Each vertical support beam may interconnect one or more of the lateral beams, the apex of an outer arch, and the apex of an inner arch. The crate may be formed of a light-weight plastic. 
     The present invention is also directed to a light-weight stackable beverage crate capable of bearing load forces. The crate may include a bottom plate, four side walls adjacent the bottom plate forming an interior space for placement of objects, four vertically extending columns interconnecting the side walls and bottom plate, four upper load pads, and four lower load pads. Each side wall may include a pattern of outer arches and inner arches interconnected by a plurality of lateral beams, a plurality of vertical support beams, and a plurality of cross-beams. A lateral beam may define an upper edge of the side wall. Another lateral edge may define a lower edge of the side wall. Each inner arch may be concentrically disposed within an outer arch. Each column may include an upper end and a lower end. Each upper pad may be operatively associated with the upper end of a column. The upper load pads may extend above the upper edge of the side walls. Each lower load pad may be operatively associated with the lower end of a column. The lower load pads may extend below the lower end of the side walls. 
     A portion of the bottom plate may extend below the lower edge of the side walls and below the lower load pads. Each side wall may include a handle recess for placement of a hand. The crate may weigh 1.5 to 2.0 pounds. The crate may be capable of supporting a load of 380 pounds in a stacked configuration. 
     The present invention is also directed to a method of stacking beverage crates. A first and a second crate may each include a bottom plate, four side walls adjacent to the bottom plate forming an interior space for placement of objects, and four vertically extending columns interconnecting the side walls and bottom plate. Each side wall may include a pattern of outer arches and inner arches interconnected by a plurality of lateral beams, a plurality of vertical support beams, and a plurality of cross-beams. A lateral beam may define an upper edge of the side wall, and another lateral beam may define a lower edge of the side wall. Each column may have an upper end that extends above the upper edge of the side walls, and a lower end that that extends below the lower edge of the side walls. A first load may be placed in the first crate&#39;s interior space, and a second load may be placed in the second crate&#39;s interior space. The first crate may be positioned on a bottom surface such that the bottom plate of the first crate contacts the bottom surface. The second crate may be stacked on top of the first crate such that the only load-bearing points of contact between the first and second crates are at the upper ends of the first crate&#39;s columns and the lower ends of the second crate&#39;s columns. 
     The method may further include transferring a weight of the second load through the first crate&#39;s columns to the first crate&#39;s bottom plate. A lower extending portion of the first and second crate&#39;s bottom plate may extend below the lower end of the first and second crate&#39;s columns, respectively. When stacked, the lower extending portion of the second crate&#39;s bottom plate may extend below the upper edge of the first crate&#39;s side wall within the first crate&#39;s interior space. A portion of the bottom plate of each crate may be concave. The upper end of each column of both crates may include an upper load pad disposed above the upper edge of the side walls. The lower end of each column of both crates may include a lower pad disposed below the lower edge of the side walls. The only load-bearing points of contact between the first and second crates may be the first crate&#39;s upper load pads and the second crate&#39;s lower load pads. 
    
    
     
       BRIEF SUMMARY OF THE DRAWINGS 
         FIG. 1  is an isometric view of the crate of the present invention. 
         FIG. 2  is side view of the crate of the present invention. 
         FIG. 3  is a top view of the crate of the present invention. 
         FIG. 4  is a partial top view of the crate of the present invention. 
         FIG. 5  is a partial cross-sectional view taken along lines A-A of  FIG. 3 . 
         FIG. 6  is a partial isometric top view of the crate of the present invention showing an upper bearing pad. 
         FIG. 7  is partial isometric bottom view of the crate of the present invention showing two lower bearing pads. 
         FIG. 8  is a side view of two stacked crates of the present invention. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       FIG. 1  shows crate  10 . Crate  10  may be made formed as an integrally molded single piece by heat-injected plastic molding. Crate  10  may be molded from a plastic material such as a high density polyethylene or other plastic material having similar qualities. Crate  10  has a substantially square configuration with side walls  12  and bottom plate  14 . Vertical columns  16  are positioned in each corner of crate  10 . Columns  16  interconnect sidewalls  12  and bottom plate  14 . Openings  18  are provided in side walls  12  and accommodate the hand of a person gripping crate  10  as may be done when crate  10  is physically moved by a person. 
     With reference to  FIG. 2 , each side wall  12  includes a series of lateral supporting beams  20 ,  22 ,  24 ,  26 ,  28 ,  30 ,  32 , and  34 . Lateral beams  20  serve as an upper rim for crate  10 . Interconnected between lateral beams  20 ,  22 ,  24  and  26  are a series of outer arches  36  and partial outer arches  36   a .  FIG. 2  shows two outer arches  36  and two partial outer arches  36   a  although less than two or more than two outer arches  36  and partial outer arches  36   a  may be used. Interconnected between lateral beams  22  and  24  are a series of inner arches  38  positioned with outer arches  36 .  FIG. 2  shows two inner arches  38  although less than or more than two inner arches  38  may be used. Cross-arches  40  interconnect lateral beam  20  and outer arches  36  and interconnect lateral beam  20  and partial outer arches  36   a . Cross-beams  42  interconnect columns  16  to outer arches  36 . Vertical support beam  44  is centrally positioned and interconnects lateral beam  20  and lateral beam  22 . Vertical support beams  46  interconnect lateral beam  20 , outer arches  36 , lateral beam  22 , and inner arches  36   a . Vertical support beams  46  also interconnect lateral beam  20 , partial outer arches  36   a  and lateral beam  22 . Cross-beams  48  interconnect outer arches  36  and partial outer arches  36   a.    
     Again with reference to  FIG. 2 , interconnected between lateral beams  24 ,  26 ,  28  and  30  are a series of outer arches  36 .  FIG. 2  shows four outer arches  36  although less than four or more than two outer arches  36  may be used. Inner arches  38  are positioned within and are interconnected to respective outer arches  36 .  FIG. 2  shows four inner arches  38  although less than or more than four inner arches  38  may be used. Cross-beams  42  interconnect columns  16  to outer arches  36 . Central support beam  52  is centrally positioned and interconnects lateral beams  24 ,  26 ,  28 ,  30 ,  32 , and  34 . Vertical support beams  46  interconnect lateral beams  24  and  26 , outer arches  36 , and inner arches  36   a . Cross-beams  48  interconnect outer arches  36 . Cross-beams  50  interconnect lateral beam  26  and outer arches  36 . Cross-beams  54  interconnect central support beam  52  and outer arches  36 . 
       FIG. 2  also illustrates that interconnected between lateral beams  28 ,  30 ,  32  and  34  are a series of outer arches  36 .  FIG. 2  shows four outer arches  36  although less than or more than four outer arches may be used. Inner arches  38  are positioned within and are interconnected to respective outer arches  36 .  FIG. 2  shows four inner arches  38  although less than or more than four inner arches may be used. Cross-beams  42  interconnect columns  16  to outer arches  36 . Vertical support beams  46  interconnect lateral beams  28  and  30 , outer arches  36 , and inner arches  36   a . Cross-beams  48  interconnect outer arches  36 . Cross-beams  50  interconnect lateral beam  30  and outer arches  36 . Cross-beams  54  interconnect central support beam  52  and outer arches  36 . Vertical braces  56  interconnect lateral beam  32  and lateral beam  34 . Bottom lip  58  is positioned outwardly from lateral beam  34  and extends around the entirety of crate  10 . Bottom lip  58  serves as a mating guide and accommodates the upper rim of another crate when crate  10  is stacked on top of another crate. In stacking arrangement, the upper rim (e.g., lateral beams  20 ) of the lower crate would be situated within receiving area  60  of crate  10 . 
       FIGS. 3 and 4  show the configuration of bottom plate  14 . Bottom plate  14  includes central support beam  62  and central support beam  64  that interconnect opposing lateral beams  34  and intersect at central portion  66 . Primary cross-beams  68 ,  70  each traverse bottom plate  14  from column  16  to opposing column  16  and interconnect at central portion  66  of central support beams  62 ,  64 . Secondary cross-beams  72  traverse between distal ends  74  of central supports beams  62 ,  64  where they interconnect with central support beams  62 ,  64 . Secondary cross-beams  72  intersect with primary cross-beams  68 ,  70  at point  76 . Lateral beams  78  extend from opposite sides of bottom plate  14  and interconnect with central support beams  62 ,  64 , primary cross-beams  68 ,  70  and secondary cross-beams  72 . Lateral supports  80  interconnect lateral beam  34 , at least one lateral beam  78 , and primary cross-beams  68  or  70 . Lateral supports  82  interconnect central support beams  62 ,  64 , at least one lateral beam  78  and primary cross-beams  68  or  70 . 
       FIGS. 3 and 4  also show upper load pads  84  positioned and affixed to columns  16  at corners  86  of crate  10 . Upper loads pads  84  receive loads forces when in stacked arrangement with other crates and distribute such forces through columns  16  (to bottom plate  14 ) and away from the central portions of side walls  12  of crate  10 , particularly the immediate areas adjacent to opening  18  in the handle portion of crate  10 . By distributing the load forces away from the handle area, crate  10  achieves optimal structural integrity and is capable of withstanding forces well in excess of forces customarily generated when crates are stacked eight high, housing contents such as milk containers. 
       FIG. 5  shows that bottom plate  14  is concave so that when in stacked arrangement and with a full load of contents, bottom plate  14  will not deform in an outwardly direction to the point where the surface of bottom plate  14  will come into contact with the contents of the lower crate. Such contact is not desired because it may degrade the containers housed in the lower crate or abrade the packaging to such an extent that manufacture identification and other markings may be removed or become unidentifiable. 
       FIG. 6  shows the positioning of upper load pads  84  in corner  86  of crate  10 . Pads  86  may be integrally formed with column  16 . Pads  84  may be variable in configuration and size so long as they are capable of directing load forces through columns  16  (to bottom plate  14 ) and away from the handle area of crate  10 . Pads  84  function by providing the contact point between crate  10  and an upper crate stacked on crate  10 . Pads  84  bear the load forces created by the weight of the upper crate and any additional crates stacked thereon, including the weight of the contents of the crate or crates. Pads  84  distribute the forces through columns  16  (to bottom plate  14 ) and away from the central areas of side walls  12  particularly away from the handle area surrounding opening  18 . Crate  10  is able to bear load forces in excess of conventional beverage crates while being lighter in weight as a result of less material being used to form crate  10 . 
       FIG. 7  reveals that bottom pads  88  may be placed or formed in bottom corners  90  of columns  16 . Pads  88  are designed to mate with pads  84  when crate  10  is in stacking arrangement with a second crate  10  or with a conventional crate. Pads  88  further serve to distribute stacking loads through columns  16  and away from the central areas of crate  10 , particularly the area surrounding the opening  18 . Pads  88  may be variable in configuration and size so long as they are capable of directing load forces away from the central areas of side walls  12 . 
       FIG. 8  shows crates  10  in stacking arrangement. Pads  84  provide the contact point between crate  10  and upper crate  10   a  stacked on crate  10 . Pads  84  bear the load forces created by the weight of upper crate  10   a  and any additional crates stacked thereon, including the weight of the contents of crate  10   a  and other stacked crates. Pads  84  distribute the forces through columns  16  (to bottom plate  14 ) and away from the central areas of side walls  12  particularly away from the handle area surrounding opening  18 . 
     Crate  10  provides increased air circulation within area  92  (shown in  FIG. 1 ) where contents are stored for transport. The increased air circulation results from less material being used to form side walls  12  and bottom plate  14 . With less material, crate  10  has a greater unobstructed surface area that enables more air to circulate from outside the crate to within area  92  and around the contents of crate  10 . Increased air circulation is important particularly for refrigerated contents housed within crate  10  such as milk. The contents are able to be kept at a more consistent temperature to thereby provide longer shelf life. 
     Crate  10  weighs between 1½ lbs. to 2 lbs. The lighter weight (as compared to conventional crates weighing 2½ lbs. to 3 lbs.) is the result of less material being used in the formation of crate  10 . For example, less material is needed as a result of the arch patterns of side walls  12  and the pattern of bottom plate  14 . While less material is used, crate  10  exhibits superior stability and strength. Because crate  10  weighs less than conventional beverage crates, crate  10  is easier to manipulate by persons transporting the contents of crate  10 . In stacked arrangement, crates  10  are more easily hauled on and off a transport truck by delivery personnel using a hand-truck. Less effort and assertion is required to physically lift and move individual crates  10 . Crates  10  also achieve fuel savings. Because they weigh less, crates  10  when stacked and transported in a delivery vehicle cause the vehicle to weigh less than if loaded with conventional crates. Less fuel is used to transport crates  10  and their contents due to the lighter weight of the load. 
     Crate  10  is also capable of bearing torque or perimeter loads in excess of those loads commonly generated when transporting conventional beverage crates. Crate  10  is also able to withstand impact forces that would be generated if crate  10  were dropped from a height of 30 inches with a standard content. 
     Crates  10  are also interchangeable with conventional beverage crates. Accordingly, crate  10  may be stacked onto a conventional beverage crate or receive a conventional beverage crate in stacked arrangement. 
     The structural stability and strength of crate  10  is the result of the symmetry of the support structures forming crate  10 , particularly the arch patterns. 
     While preferred embodiments of the present invention have been described, it is to be understood that the embodiments described are illustrative only and that the scope of the invention is to be defined solely by the appended claims when accorded a full range of equivalents, many variations and modifications naturally occurring to those skilled in the art from a perusal hereof.