Abstract:
A portable storage container that both stacks and nests with similar containers includes a plurality of walls extending upwardly from a floor. At least one bail member is moveable between a plurality of positions for supporting the similar containers at varying heights. The bail member includes at least one rib extending radially outward. A similar container stacked on the bail members of the container will interlock with the at least one rib, thereby preventing lateral movement of the upper container relative to the lower container.

Description:
BACKGROUND OF THE INVENTION 
   The present invention relates generally to portable storage containers and more particularly to portable storage containers that provide the ability to select different nesting and stacking depths. 
   Portable storage containers that both stack and nest with similar containers are commonly used for transporting and storing goods. Nesting is typically achieved when an empty container receives a like container therein such that there is at least some overlap between the walls of the containers. The stacking feature is typically used when an occupied container has a like container supported thereon, such that the goods contained in the lower container are preferably not contacted or damaged by the upper container. Many containers use members (known as bail members) to achieve the stacking feature. Bail members may typically be positioned out of the way for purposes of nesting, but then moved to a stacking position for allowing containers to be stacked thereon. 
   The bail members in some containers are movable among three positions: a nesting position, a first stack position and a second stack position. In the nesting position, the bail members are out of the way and the upper container can substantially nest within the lower container. The bail members support containers in the first stack position at a first distance from the floor, where the upper container is not substantially nested within the lower container. The bail members also can be moved to the second stack position to support the upper container at a second distance from the floor, where the upper container is partially nested within the lower container. 
   SUMMARY OF THE INVENTION 
   A portable storage container that both stacks and nests with similar containers includes a plurality of walls extending upwardly from a floor. At least one bail member is moveable between a plurality of positions for supporting the similar containers at varying heights. The bail member includes a support portion pivotably connected to the container by arms at each end. The bail member includes at least one rib extending radially outward from the support portion. A similar container stacked on the bail members of the container will interlock with the at least one rib, thereby preventing lateral movement of the upper container relative to the lower container. 
   The bail member further includes a plurality of microribs on substantially the entire surface of the support portion. This prevents loose stickers, washed from the container, from sticking to the bail members. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     Other advantages of the present invention can be understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein: 
       FIG. 1  is a perspective view of a container according to a first embodiment of the present invention with the bail members in a high nest position and with a similar container nested therein. 
       FIG. 2  shows a sectional view of the lower container of  FIG. 1 , with the bail members in the high nest position. 
       FIG. 2   a  is an enlarged view of the area  2   a  of  FIG. 2 . 
       FIG. 3  is a side view of the containers of  FIG. 1 . 
       FIG. 4  is a sectional view taken through the bail members of the containers of  FIG. 1 . 
       FIG. 5  is a sectional view of the lower container of  FIG. 1  with the bail members in a low nest position. 
       FIG. 6  is a sectional view of the lower container of  FIG. 1  with the bail members in a low stack position. 
       FIG. 7  is a perspective view of the containers of  FIG. 1  with the bail members of the lower container in the low stack position. 
       FIG. 8  is a side view of the containers of  FIG. 7 . 
       FIG. 9  is a sectional view, taken through the bail member of the lower container, of the containers of  FIG. 7 . 
       FIG. 10  is a sectional view of the lower container of  FIG. 1  with the bail members in a high stack position. 
       FIG. 11  is a perspective view of the containers of  FIG. 1  with the bail members of the lower container in the high stack position. 
       FIG. 12  is side view of the containers of  FIG. 11 . 
       FIG. 13  is a sectional view, taken through the bail member of the lower container, of the containers of  FIG. 11 . 
       FIG. 14  is a perspective view of a container according to a second embodiment of the present invention having bail members in a high stack position and a similar container stacked thereon. 
       FIG. 15  shows a sectional view of the lower container of  FIG. 14 , with the bail members in the high stack position. 
       FIG. 16  is a side view of the containers of  FIG. 14 . 
       FIG. 17  is a sectional view taken through the bail member of the lower container of  FIG. 16 . 
       FIG. 18  is a sectional view of the lower container of  FIG. 14  with the bail members in a low stack position. 
       FIG. 19  is a side view of the containers of  FIG. 14  with the bail members of the lower container in the low stack position. 
       FIG. 20  is a sectional view taken through the bail member of the lower container of  FIG. 19 . 
       FIG. 21  is a sectional view of the lower container of  FIG. 14  with the bail members in a low nest position. 
       FIG. 22  is a side view of the container of  FIG. 21 . 
       FIG. 23  is a perspective view of the container of  FIGS. 4-22  stacked on the container of  FIGS. 1-13 , with the bail members of the lower container in the high nest position. 
       FIG. 24  is a side view of the containers of  FIG. 23 . 
       FIG. 25  is a sectional view of the containers of  FIG. 24  taken through a bail member of the lower container. 
       FIG. 26  is a perspective view of the containers of  FIG. 23 , with the bail members of the lower container in the high stack position. 
       FIG. 27  is a side view of the containers of  FIG. 26 . 
       FIG. 28  is a sectional view of the containers of  FIG. 27  taken through a bail member of the lower container. 
       FIG. 29  is a perspective view of the containers of  FIG. 23 , with the bail members of the lower container in the low stack position. 
       FIG. 30  is a side view of the containers of  FIG. 29 . 
       FIG. 31  is a sectional view of the containers of  FIG. 30  taken through a bail member of the lower container. 
   

   DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
   Two like containers  10 ,  10 ′ according to the present invention are shown stacked in  FIG. 1 . Generally, the description will be with reference to the lower container  10 , although in the example shown in  FIG. 1 , the description would be equally applicable to the upper container  10 ′. The container  10  includes a floor  12  and a pair of opposed side walls  14  and a pair of opposed end walls  16 . A pair of notches  17  are formed at the bottom of the end walls  16  and the floor  12 . The notches  17  each define a channel which extends one end wall  16  to the other. 
   Two bail members  18  are each mounted to each end wall  16 . While they may take a variety of shapes, bail members  18  are shown as molded plastic having a generally cylindrical support portion  19  that extends across the length of the container  10 . Each bail member  18  includes a pair of arms  21  extending transversely from the support portion  19 . As shown in  FIG. 2 , each arm  21  includes an inward, lateral projection  38  that provides additional weight to the bail member  18 , increases stiffness and resistance to twisting and increases stability. 
   Each bail member  18  includes a plurality of circumferential molded micro-ribs  22  on the support portion  19  providing alternating recesses and protrusions all along substantially the entire surface of the support portion  19 . The microribs  22  are substantially smaller than the diameter of the support portion  19  of the bail member  18 , e.g. less than five percent. The microribs  22  are also tightly spaced axially along the support portion  19 , such that the spaces between the microribs  22  are not wider than the microribs  22  themselves. In the example shown, the width of the spaces between the microribs  22  is approximately equal to the width of the microribs  22 . The microribs  22  help prevent stickers, washed from the container  10 , from sticking to the bail members  18  when washing the container  10  by reducing the available surface area of the support portion  19 . 
   The end walls  16  each include an upper wall portion that has an outer wall portion  20  spaced from an inner wall portion  23 . A lower wall portion  24  is generally aligned below the inner wall portion  23 , such that the outer wall portion  20  forms a support or ledge  25  along the end wall  16 . The side walls  14  similarly include ledges  26  protruding outwardly from the side walls  14  at a height even with the ledges  25  on the end walls  16 . The ledges  26  on the side walls  14  include lower concave recesses  28  formed along their length. 
   The inner wall portion  23  includes an upper support rest  36  at a height above the floor  12  for supporting the bail member  18  at an upper stack position. Each upper support rest  36  includes an upwardly open concave recess  37 , which is a notch formed in the inner wall portion  23 . The inner wall portion  23  further includes a lower support rest  42 , which is closer to the floor than the upper support rest  36 , for supporting the bail member  18  at a lower stack position. 
   Elongated pin openings  30  are formed in each outer wall portion  20  to trap pins  32  at the outer ends of the bail members  18 . The pins  32  are slidable and pivotable within the pin openings  30 , such that the bail members  18  can be moved to a plurality of positions and orientations. 
   In  FIGS. 1-4 , the bail members  18  are in a high nest position. The pins  32  of the bail members  18  are slid to an outer end of the pin opening  30  and the bail members  18  are pivoted to an upright position, as shown. In the high nest position, the support portions  19  of the bail members  18  are spaced above uppermost edges of the side walls  14  and end walls  16 . 
   The bail member  18  in the high nest position supports a similar container  10 ′, such that the floor  12 ′ of the upper container  10 ′ is suspended at a distance above the floor  12  of the lower container  10 . The floor  12 ′ of the upper container  10 ′ is not in contact with the support portion  19  of the bail member  18  of the lower container  10 . In this position, the upper container  10 ′ is supported by the support portions  19  of the bail members  18  of the lower container  10 , with the support portions  19  received in the concave recesses  28 ′ formed in the ledges  26 ′ on the side walls  14 ′. This position provides a small storage space between the floors  12 ,  12 ′ of the containers. 
   The support portions  19  of the bail members  18  each include a pair of inner radially-protruding interlocking projections  44   a  and a pair of outer radially-protruding interlocking projections  44   b . The inner and outer interlocking projections  44   a - b  extend partially about the circumference of the support portion  19  and are at least several times greater in size than the microribs  22 , for example, the inner and outer interlocking projections  44   a - b  are approximately ten times greater in radial thickness than the microribs  22 . In the example shown, as can be seen in  FIG. 2   a , the inner and outer interlocking projections  44   a - b  (only outer interlocking projections  44   b  visible in  FIG. 2   a ) extend halfway around the circumference of the support portion  19 , tapering into the support portions at the ends of the interlocking projections  44   a - b . A portion of one of the microribs  22  is also shown in  FIG. 2   a . Each microrib  22  is approximately 0.0075″ in radial height and has a half-circle cross-section. 
   The inner and outer interlocking projections  44   a - b  are positioned such that they project upwardly from the support portion  19  only in certain rotational positions of the bail member  18 . For example, in the high nest position as shown in  FIGS. 1-4 , it can be seen in  FIGS. 2-4  that the inner and outer interlocking projections  44   a - b  do not extend upwardly from the upper surface of the support portion  19 , but project outwardly of the container  10 . However, as can be seen in  FIG. 3 , the concave ledges  26 ′ are positioned inwardly of the outer interlocking projections  44   b  and in contact with the outer interlocking projections  44   b  because they are concave and extend downwardly on the outer surface of the support portion  19  of the bail member  18  in the high nest position. The outer interlocking projections  44   b  thus prevent lateral movement of the upper container  10 ′ relative to the lower container  10  in the high nest position. 
     FIG. 5  is a sectional view of the lower container  10  of  FIG. 1  with the bail members in a low nest position. In this position, a similar container  10 ′ (not shown in  FIG. 5 ) can fully nest in the lower container  10  to the point where the ledges  25 ′,  26 ′ rest on the end walls  16  and side walls  14 , respectively, of the lower container  10 . 
     FIG. 6  is a sectional view of the lower container of  FIG. 1  with the bail members  18  in a low stack position on the lower support rests  42  on the inner wall portions  23 . The lower support rests  42  are notches formed in the inner wall portion  23  to impede movement of the bail member  18  out of the selected position. The lateral projections  38  are also interlocked within a recess  52  between the inner and outer wall portions  23 ,  20  to increase stability of the bail member  18 .  FIGS. 7-9  show the containers of  FIG. 1  with the bail members  18  of the lower container  10  in the low stack position. The upper container  10 ′ is supported above the floor  12  by the bail member  18  in the notch  17 ′ of the upper container  10 ′ to create a middle-sized storage area between the floors  12 ,  12 ′ that is larger than that provided by the high and low nest positions, but smaller than that provided by the high stack position. The arms  21  of the bail members  18  are received between the inner wall portions  23  and outer wall portions  20 . The inner and outer wall portions  23 ,  20  prevent contact with the arm  21  by users or by other containers or objects, which prevents the pin  32  from being knocked out of the pin opening  30  when the bail members  18  are in the lower stack position. 
   Referring to  FIG. 9 , the floor  12 ′ and bottom edges of end walls  16  rest on the bail members  18  between the outer interlocking projections  44   b  on the support portion  19  of the bail members  18 . The inner interlocking projections  44   a  on the support portion  19  are received in small recesses  46 ′ formed in the bottom of the floor  12 ′. The interlocking of the inner and outer interlocking projections  44   a - b  with the floor  12 ′, end walls  16 ′ and recesses  46 ′ prevent lateral movement of the upper container  10 ′ when stacked on the bail members  18  of the lower container  10  when the bail members  18  are in certain of the multiple positions. Alternatively, the interlocking members, i.e. the recesses  46 ′ and the interlocking projections  44   a - b  could be switched, such that the recesses  46 ′ are on the bail members  18  and the interlocking projections  44   a - b  are on the bottom of the floor  12 . 
     FIG. 10  is a sectional view of the lower container  10  of  FIG. 1  with the bail members  18  in a high stack position.  FIGS. 11-13  show the containers  10 ,  10 ′ of  FIG. 1  with the bail members  18  of the lower container  10  in the high stack position. The support portion  19  of the bail member  18  of the lower container  10  is received in the notches  17 ′ of the upper container  10 ′ such that the floor  12 ′ of the upper container  10 ′ is supported by the bail members  18 . This position provides the maximum storage capacity in the container  10  and transfers load to the bail members  18 , thus keeping the weight of the upper container  10 ′ off the contents of the lower container  10 . As shown in  FIG. 13 , the floor  12 ′ and bottom edges of end walls  16  rest on the bail members  18  between the outer interlocking projections  44   b  on the support portion  19  of the bail members  18 . The inner interlocking projections  44   a  on the support portion  19  are received in small recesses  46 ′ formed in the bottom of the floor  12 ′. The interlocking of the inner and outer interlocking projections  44   a - b  with the floor  12 ′, end walls  16 ′ and recesses  46 ′ prevent lateral movement of the upper container  10 ′ when stacked on the bail members  18  of the lower container  10  when the bail members  18  are in this high stack position. 
   Two containers  110 ,  110 ′ according to a second embodiment of the present invention is shown in  FIGS. 14-22 . Components corresponding to those in the first embodiment are given a similar reference numeral, preappended with the numeral “1.” Corresponding components of the upper container  110 ′ are designated with the prime notation. The container  110  includes side walls  114  and end walls  116  extending upwardly from a floor  112 . End walls  116  include outer wall portions  120  and inner wall portions  123 . Pin openings  130  are formed in the outer wall portions  123  and receive the pins  132  of the bail members  118 . The side walls  114  include ledges  126  protruding outwardly from the side walls  114  at a height even with the ledges  125  on the end walls  116 . The ledges  126  on the side walls  114  include concave lower recesses  128  formed along their length. The support portions  119  of the bail members  118  have a single pair of interlocking projections  144  spaced proximate outer ends of the support portion  119 . Each bail member  118  includes a plurality of circumferential molded micro-ribs  122  on the support portion  119 . 
   In  FIGS. 14-17 , the bail members  118 ,  118 ′ are shown in the upper stack position with the support portions  119  of the bail members  118  supported on support rests  136 . In this position, the floor  112 ′ of a similar container  110 ′ is supported in notches  117 ′ on the bail members  118  at a maximum height above the floor  112 , as shown in  FIG. 17 . The floor  112 ′ and bottom edges of end walls  116 ′ rest on the bail members  18  between the outer interlocking projections  44   b  on the support portion  119  of the bail members  118 . The interlocking projections  144  on the support portion  119  are received in small recesses  146 ′ formed in the bottom of the floor  112 ′. The interlocking of interlocking projections  144  with the floor  112 ′, end walls  116 ′ and recesses  146 ′ prevent lateral movement of the upper container  110 ′ when stacked on the bail members  118  of the lower container  110  when the bail members  118  are in this high stack position. 
   Referring to  FIG. 15 , the arms  119  of the bail members  118  include a pair of lateral projections  138   a - b  that interlock within recesses and contours between the inner and outer wall portions  123 ,  120  in the various positions of the bail members  118  to increase stability of the bail members  118 . 
   In  FIGS. 18-20 , the bail members  118  are shown in the low stack position with the support portions  119  of the bail members  118  supported on the support rests  142 . In this position, the floor  112 ′ of a similar container  110 ′ is supported on the bail members  118  above the floor  112 , and the upper container  110 ′ partially nests within the container  110  without putting contacting the contents of the container  110 . As shown in  FIG. 19 , the floor  112 ′ and bottom edges of end walls  116 ′ rest on the bail members  18  between the interlocking projections  44  on the support portion  119  of the bail members  118 . The interlocking of the interlocking projections  144  with the floor  112 ′ and end walls  116 ′ prevents lateral movement of the upper container  110 ′ when stacked on the bail members  118  of the lower container  110  when the bail members  118  are in this low stack position. 
     FIG. 21  is a sectional view of the lower container  110  of  FIG. 14 , with the bail members  118  in the low nest position, with the support portion  119  of the bail members  118  vertically aligned outwardly of the floor  112 . This permits the full nesting of the upper container  110 ′ (not shown in  FIG. 21 ) to the point where the ledges  125 ′,  126 ′ rest on the end walls  116  and side walls  114 , respectively, of the lower container  110 .  FIG. 22  is a side view of the container  110 . 
   In both embodiments, the walls and floor of the container  10 ,  110  are integrally molded as a single unitary structure from a plastic material such as polypropylene or may also be HDPE, or other suitable materials, via an injection molding or other suitable process. The bail members  18 ,  118  may be formed of any suitable material, but are preferably injection molded from 50% glass-filled nylon or other composite material, but could also be steel. The container  10  of  FIGS. 1-13  and the container  110  of  FIGS. 14-22  are also designed to be stacked together as shown in  FIGS. 23-31 . In the embodiments shown, the container  10  is 24 inches by 20 inches, while the container  110  is 24 inches by 16 inches. Of course, other sizes would be within the scope of the present invention, but these sizes are used for purposes of illustration below. 
   In  FIGS. 23-25 , the bail member  18  of the lower container  10  is in the high nest position, such that the support portion  19  of the bail member  18  is spaced above the uppermost edges of the side walls  14  and end walls  16 . The support portion  19  is received within the recess  128  on the ledge  126  of the upper container  110  to support the container  110  partially nested within the container  10 , thereby protecting the contents of the lower container  10  between floors  12 ,  112  while efficiently stacking the containers  10 ,  110 . It should be noted that, in embodiments having the dimensions stated above, there will be approximately a 2-inch gap between the end walls  116  of the upper container  110  and the end walls  16  of the lower container  10 . It can be seen in  FIGS. 24 and 25  that the inner and outer interlocking projections  44   a - b  do not extend upwardly from the upper surface of the support portion  19  when rotated to the high nest position, but project outwardly of the container  10 . It can also be seen that the inner interlocking projections  44   a  would interfere with the placement of the ledge  126  onto the support portion  19  if they did extend upwardly in this position. However, as can be seen in  FIG. 24 , the concave ledges  126  are positioned inwardly of the inner interlocking projections  44   a  and in contact with the inner interlocking projections  44   a  because they are concave and extend downwardly on the outer surface of the support portion  19  of the bail member  18  in the high nest position. The inner interlocking projections  44   a  thus prevent lateral movement of the upper container  110  relative to the lower container  10  in the high nest position. 
     FIGS. 26-28  illustrate the container  110  stacked on the container  10  while the bail members  18  are in the upper stack position. As shown, the notch  117  of the upper container  110  aligns with the bail member  18  in the upper stack position. As shown in  FIGS. 27-28 , the floor  112  and bottom edges of end walls  116  rest on the bail members  18  between the inner interlocking projections  44   a  on the support portion  19  of the bail members  18 . The interlocking of the inner interlocking projections  44   a  with the floor  112  and end walls  116  prevent lateral movement of the upper container  110  when stacked on the bail members  18  of the lower container  10  when the bail members  18  are in certain of the multiple positions. 
     FIGS. 29-31  illustrate the container  110  stacked on the container  10  while the bail members  18  are in the low stack position. As shown, the notch  117  of the upper container  110  aligns with the bail member  18  in the low stack position. As shown in  FIG. 31 , the floor  112  and bottom edges of end walls  116  rest on the bail members  18  between the inner interlocking projections  44   a  on the support portion  19  of the bail members  18 . The interlocking of the inner interlocking projections  44   a  with the floor  112  and end walls  116  prevent lateral movement of the upper container  110  when stacked on the bail members  18  of the lower container  10  when the bail members  18  are in certain of the multiple positions, including the low nest position. 
   While embodiments of the invention have been illustrated and described, it is not intended that these embodiments illustrate and describe all possible forms of the invention. 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 invention. There are different designs of containers that would benefit from the present invention.