Abstract:
A stackable storage crate ( 10 ) comprising side elements ( 13, 14, 15, 16 ) and a base element ( 12 ) wherein at least one of said side elements ( 13, 14, 15, 16 ) is provided with an openable panel ( 30 ) providing access to storage space within said crate ( 10 ).

Description:
[0001]    The present invention relates to crates and, more particularly, to modular storage crates which may be stacked to form a vertically and horizontally aligned array, the contents of each crate accessible from at least one side. 
       BACKGROUND 
       [0002]    Storage crates, typically of a parallelepiped shape open at the top, form convenient storage and transport modules for loose items. Also typically, these storage crates are of unitary construction of injection moulded plastic. 
         [0003]    Such crates are generally sufficiently sturdy to allow stacking of one above the other, but a disadvantage of having the crates in a stack is that, if it is desired to access the contents of any crate lower than the uppermost, the stack must be at least partially dismantled and reassembled. 
         [0004]    A further disadvantage of integrally formed crates is that transport and storage prior to use is expensive due to the volume of space required for each crate. 
         [0005]    It is an object of the present invention to address or at least ameliorate some of the above disadvantages. 
       BRIEF DESCRIPTION OF INVENTION 
       [0006]    Accordingly, in a first broad form of the invention, there is provided a stackable storage crate comprising side elements and a base element wherein at least one of said side elements is provided with an openable panel providing access to storage space within said crate. 
         [0007]    Preferably, said modular elements further include an upper perimeter frame. 
         [0008]    Preferably, said side elements, said base element and said upper perimeter frame are modular components adapted for compaction as a flat pack while in a disassembled state prior to use. 
         [0009]    Preferably, said side elements comprise first and second opposing pairs of side elements. 
         [0010]    Preferably, said base element comprises a base panel and a base perimeter frame. 
         [0011]    Preferably, each of said side elements comprises a side element perimeter frame and side panel; said perimeter frame comprising upper and lower horizontal members and opposing vertical corner members. 
         [0012]    Preferably, at least one said side panel of said first pair of opposing side elements is an opening panel; said opening panel hingedly attached to said side element perimeter frame. 
         [0013]    Preferably, said opening panel is adapted for rotation about said hinge between a vertical closed position and a substantially horizontal open position. 
         [0014]    Preferably, said base perimeter frame comprises a channel section open at an upper side of said channel section; said channel section adapted to receive therein said lower horizontal members and lower ends of said vertical corner members. 
         [0015]    Preferably, said upper and lower horizontal members of said side element perimeter frame of said first opposing pair side elements comprise an “I-beam” section substantially extending the length of each said side element. 
         [0016]    Preferably, said upper and lower horizontal members of said side perimeter frame of said second pair of opposing side elements are provided with apertures adapted for engagement with projecting retaining elements of said base portion. 
         [0017]    Preferably, said channel section of said base element is provided with a plurality of inwardly projecting retaining elements; said retaining elements adapted to engage with lower flanges of said “I-beam” section and said apertures of said lower members as snap-fits when said first pair and said second pair of opposing side elements are assembled to said base element. 
         [0018]    Preferably, said upper perimeter frame comprises an upper channel section open at an underside of said channel; said channel adapted to receive therein said upper horizontal members and upper ends of said vertical corner members. 
         [0019]    Preferably, said upper channel section is provided with a plurality of inwardly projecting retaining elements; said retaining elements adapted to engage with said “I-beam” section and said apertures of said upper horizontal members when said upper perimeter frame is assembled to said first pair of opposing side elements. 
         [0020]    Preferably, said vertical corner members of each of said first opposing pair of side elements are adapted for nesting engagement with corresponding said vertical corner members of said second pair of opposing side elements. 
         [0021]    Preferably, each of said vertical corner members of a first pair of opposing side elements engages with a corresponding vertical corner member of said second pair of opposing side elements by means of notches and projecting lugs. 
         [0022]    Preferably, said opening panel is provided with a forwardly projecting flange at an upper edge of said panel; said flange adapted for engagement within a lower outer edge of said upper channel section of said upper perimeter frame when said opening panel is in said closed position; said engagement retaining said opening panel in a locked condition. 
         [0023]    Preferably, said upper perimeter frame is provided with cut-out portions exposing portions of said forwardly projecting flange when said opening panel is in said closed position; said cut-out portions adapted to allow a user to apply downward pressure on said forwardly projecting flange so as to deflect said flange sufficient to release said flange from said engagement. 
         [0024]    Preferably, said upper perimeter frame and said base perimeter frame are provided with mating engaging elements; said engaging elements adapted to prevent lateral movement between two said crates when one is stacked on another. 
         [0025]    In a further broad form of the invention, there is provided a method for assembly of the modular storage crate of claim  1 ; said storage crate provided with an openable panel in at least one side element of said crate; said method including the steps of:
       (a) snap-fitting together into a nested assembly said vertical corner members of said first and second pair of opposing side elements,   (b) inserting said lower horizontal member of said first and second pair of opposing side element into said channel section of said base element.       
 
         [0028]    Preferably, said method includes the further step of engaging an upper perimeter frame comprising a channel section with upper horizontal members of said perimeter frames of said first and second opposing pairs of side elements. 
         [0029]    Preferably, said openable panel is hingedly attached to a perimeter frame of said at least one of one said pair of opposing side elements. 
         [0030]    In yet a further broad form of the invention, there is provided a method for accessing interiors of a storage crates when a plurality of said storage crates are arranged in a vertical stack; said method including the steps of:
       (a) providing an opening panel in at least one outward facing side element of said storage crates.       
 
         [0032]    Preferably, said storage crate is comprised of a base element, first and second opposing pairs of side elements and an upper perimeter frame. 
     
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
         [0033]    Embodiments of the present invention will now be described with reference to the accompanying drawings wherein: 
           [0034]      FIG. 1  is a perspective view of a stackable crate according to a preferred embodiment of the invention with an opening panel in a closed position, 
           [0035]      FIG. 2  is a perspective view of the stackable crate of  FIG. 1  with an opening panel in an open position, 
           [0036]      FIG. 3  is a perspective view of one of a first pair of opposing side elements of the crate of  FIGS. 1 and 2 , 
           [0037]      FIG. 4  is a perspective view the side element of  FIG. 3  when provided with an opening panel, 
           [0038]      FIG. 5  is a perspective view of one of a second pair of opposing side elements of the crate of  FIGS. 1 and 2 , 
           [0039]      FIG. 5A  is a detailed view of a vertical corner member of an opposing side element of  FIG. 5  showing a snap-fitting lug, 
           [0040]      FIG. 6  is a perspective view of a base element of the crate of  FIGS. 1 and 2 , 
           [0041]      FIG. 7  is a perspective view of an upper perimeter frame of the crate of  FIGS. 1 and 2 , 
           [0042]      FIG. 8  is a sectioned elevation view of a portion of the crate of  FIGS. 1 and 2  showing the arrangement of the opening panel of  FIG. 4 , 
           [0043]      FIG. 9  is a sectioned plan view of a corner portion of the crate of  FIGS. 1 and 2  showing engaged corner members of side elements of  FIGS. 4 and 5 , 
           [0044]      FIG. 10  is an un-sectioned plan view of the corner portion of  FIG. 9 . 
           [0045]      FIG. 11  is a perspective view of a stacked array of the crates of  FIGS. 1 and 2 , showing one crate opened for access. 
       
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
       [0046]    With reference to  FIGS. 1 and 2 , a stackable storage crate  10  comprises a base element  12 , first pair of opposing side elements  13  and  14 , second pair of opposing side elements  15  and  16 , and an upper perimeter frame  18 . 
         [0047]    Each of the side elements  13  to  16  comprises a perimeter frame made up of upper and lower horizontal members and arcuate vertical corner members.  FIG. 3  shows one of the opposing pair of opposite side elements  13  or  14 . The perimeter frame for this configuration of side element comprises upper and lower horizontal frame members  21  and  22  respectively and vertical corner members  23  and  24 . 
         [0048]    Each of vertical corner members  23  and  24  is provided with upper and lower corner extension portions  23 A,  23 B and  24 A,  24 B respectively. These extension portions are of similar arcuate form as that of the central portion of the corner members, but are inwardly offset. Vertical corner members  24  and  25  are further provided with notches  27  arranged for snap-fitting to projecting lugs  57  of opposite side elements  15  and  16  (see  FIG. 5A ), as will be explained below. 
         [0049]    The dimensions of the arcuate corner members  23  and  24  of the first pair of opposing side elements  13  and  14  are smaller than the arcuate corner members  52  and  53  of the second pair of opposing side elements  15  and  16  (shown in  FIG. 5 ), such that adjoining corner members assemble together as a snap-fit, with projecting lugs  57  of vertical corner member  52  engaged with notches  27  of vertical corner member  23  as may be seen in  FIG. 9 . 
         [0050]    Again with reference to  FIGS. 3 and 4 , each of upper and lower horizontal frame members  21  and  22  comprises an elongate “I-beam” section terminating at each end at vertical element  25  of corner members  23  and  24  respectively. At least one of side elements  13  and  14  is provided with cut-out portions  26 . Upper horizontal frame member  21  is further provided with notched web elements  31  projecting outwardly at intervals from either side of the central web  19  of the “I-beam” section. 
         [0051]    Referring now to  FIG. 4 , at least one of side element  13  and  14  is provided with an opening panel  30 , hingedly attached to lower horizontal frame member  22  by a flexible element  32  (as best seen in  FIG. 8 ). 
         [0052]    Opening panel  30  rotates about flexible element  32  from a vertical closed position (as shown in  FIGS. 1 and 8 ) to a substantially horizontal fully open position (as shown in  FIG. 2 ). It will be seen from  FIG. 8  that lower horizontal member  22  and flexible element  32  may be so arranged relative to base element  12 , that when opening panel  30  is in the fully open position, its inner surface  34  (then horizontal) is flush with the upper surface  36  of base element  12 . 
         [0053]    Again with reference to  FIGS. 4 and 8 , opening panel  30  is provided with at least an outwardly projecting upper flange  38  and optionally with strengthening side flanges  39 . When panel  30  is in its closed position, upper flange  38  lies just below the lower flange  40  of the “I-beam” section of upper horizontal member  21 . Thus portions of upper flange  38  of opening panel  30  are accessible through cut-out portions  26 . The purpose of these cut-out portions will be explained below. 
         [0054]    The configuration of the second pair of opposing side elements  15  and  16  is shown in  FIG. 5 . Each of side elements  15  and  16  comprises a perimeter frame made up of upper and lower horizontal members  50  and  51  and arcuate vertical corner members  52  and  53 . Vertical corner members  52  and  53  are provided with extension portions  52 A,  52 B and  53 A,  53 B respectively. These extension portions are of similar arcuate form as the central portions of the corner members, but are inwardly offset. An infill panel  54  is affixed to the inner periphery of the perimeter frame. 
         [0055]    The vertical flanges of both upper and lower horizontal members  50  and  51  are provided with apertures  55  for snap-in engagement with retaining elements  67  provided in base element  12  and retaining elements  73  of upper perimeter frame  18  respectively (as shown in  FIGS. 6 and 7 ). Vertical corner members  52  and  53  are further provided with projecting lugs  57  (as seen in  FIG. 5A ) for snap-fitting engagement with the notches  27  of vertical corner members  23  and  24  of side elements  13  and  14 . 
         [0056]    As shown in  FIGS. 6 and 8 , base portion  12  is comprised of a central panel  60  surrounded by a channel section  62  open at its upper side. Channel section  62  is dimensioned such that each of lower horizontal members  22  and  51  of the first and second opposing side elements  13  to  16  may be inserted into the channel section  62  as a close sliding fit. As shown in  FIG. 6  the front and rear portions  63  and  64  respectively of the channel section  62  are provided on the opposing inside surfaces with retaining elements  66  adapted to engage the lower flange  68  of the “I-beam” section of lower horizontal member  22 . This retaining arrangement at the front portion  63  may be seen assembled in  FIG. 8 . Side channel sections  80  and  81  are provided with retaining elements  65  for snap-fit engagement with the apertures  55  of upper horizontal frame members of side elements  15  and  16  (see  FIG. 5 ). 
         [0057]    With reference to  FIGS. 7 and 8 , upper perimeter frame  18  (shown inverted in  FIG. 7 ) is formed of a channel section  70  of similar form and dimensions to the surrounding channel section  62  of base portion  12 . The front and rear portions  71  and  72  of channel section  70  are also provided with retaining elements  74  on opposing internal surfaces adapted to engage with the previously described webs  31  of side elements  13  and  14 . This retaining arrangement also is shown in  FIG. 8 . Side channel sections  77  and  78  are provided with retaining elements  73  for snap-fitting engagements with apertures  55  in lower horizontal frame members  51  of side elements  15  and  16  (see  FIG. 5 ). 
         [0058]    Front portion  71  is further provided with recesses  75  which, on assembly of upper perimeter frame  18  with side elements  13  and  14  coincide with cut-out portions  26 . 
         [0059]    The channel sections  70  and  62  respectively of upper perimeter frame  18  and base element  12 , are provided with mating elements adapted to interlock when the base of one crate is resting on the upper perimeter frame of another so as to prevent lateral movement between the two crates. A preferred arrangement may be seen in  FIG. 8  where the channel of the base element  12  is provided with a groove  90  and the channel of the perimeter frame  18  is provided with a ridge  92 . 
         [0060]    Prior to assembly, the elements comprising stackable storage crate  10  may be bundled into a flat pack held together by suitable packaging material. To assemble the elements into a storage crate, a user would proceed as follows:
       (a) the vertical corner members of the first and second pair of opposing side elements  13 ,  14 ,  15  and  16  are snap-fitted together,   (b) the assembly of the four side elements are then inserted into the channel sections of base element  12 ,   (c) the upper perimeter frame  18  is placed over the upper horizontal members of each of the side elements  13  to  16  and pressed downwardly until the retaining elements  74  engage the notched webs  31  of the upper horizontal members  21 , and retaining elements  73  engage with apertures  55  of upper horizontal members  50 .       
 
         [0064]    It will be seen from  FIG. 8  that the vertical sides of the channel section  70  of the upper perimeter frame  18 , extend below the underside  84  of upper horizontal member  21 . This allows the outwardly projecting upper flange  38  of opening panel  30  to engage with the inside surface of front vertical side  85  of channel section  70 , thereby maintaining opening panel  30  in its vertical closed position. 
         [0065]    Recesses  75  provided in the front vertical side  85  of perimeter frame  18  coincide, when assembled to side elements  13  and  14 , with cut-out portions  26  of upper horizontal member  21  of side element  13  as best seen in  FIG. 10 . This allows the fingers of a user to apply downward pressure to flange  38  of opening panel  30  so as to deflect flange  38  sufficient to lower its leading edge below the level of the lower edge of vertical side  85 , thereby allowing panel  30  to swing outwardly to its open position. 
         [0066]    When assembled, the inner surfaces of the panels of all four side elements  13 ,  14 ,  15  and  16  together with the upper surface of base element  12  intersect at their respective edges to form an unobstructed space. 
         [0067]    All elements of the stackable storage crate of the present invention may be made by injection moulding of a suitable polymer, for example polypropylene. The fixed and openable panels are preferably clear with the frame elements having a frosted finish. 
         [0068]    In use, a number of the stackable storage crates may be stacked into a column and a number of columns placed side by side to form a row of columns, as shown in  FIG. 11 . It will be clear that the arrangement of opening panel  30  may be applied to both first opposing sides  13  and  14  so that the contents of the storage crate  10  may be accessed from both sides of a stack of crates such as shown in  FIG. 11 . 
         [0069]    The above describes only some embodiments of the present invention and modifications, obvious to those skilled in the art, can be made thereto without departing from the scope and spirit of the present invention.