Patent CA-3024777-A1 (CA)
Inventor: WILCOX DONALD E
IPC: B65D6/18
Filed: 2014-04-22
Abstract: Blank. Technica/ Field: Containers that can be reused and that are suitable for the storage and transportation of produce. In this specification where a document, act or item of knowledge is referred to or discussed, this reference or discussion is not an admission that the document, act or item of knowledge or any combination thereof was at the priority date, publicly available, known to the public, part of common general knowledge, or otherwise constitutes prior art under the applicable statutory provisions; or is known to be relevant to an attempt to solve any problem with which this specification is concerned. Bananas are harvested in the tropical regions of Central and South America for consumption in North America, North American retailers of bananas specify the shipment of bananas on standard GMA (Grocery Manufacturers Association) pallets with a nominal footprint of 48" x 40". Retailers further specify that bananas be packaged in increments of 40 lbs. net product weight delivered to retail distribution centers. Bananas are typically shipped in refrigerated intermodal containers (Containers) via container ships from ports in South and Central America to ports on the east, central and west coast of the USA, then over the road to distributions centers. Standard 40-foot reefer containers can accommodate a total door loading height of about 83". GMA pallets have a nominal height of 5.5", allowing a net packaged product height of about 77.5". It is desirable to minimize the cost and environmental impact of shipping bananas by maximizing the quantity of bananas in 40 lb. package increments in a 48" x 40" x 77.5" rectangular prism, while also maximizing the delivered quality of the fruit. [0005] Prior to this invention, the industry-standard method for packaging bananas for shipment to North American retailers has been to pack in corrugated cardboard boxes that have been tailored to this application. Corrugated boxes for bananas are a 2-piece construction with outside dimensions of about 19.7" (50 cm) x 15.75" (40 cm) x 9.69" (24.6 cm) in height weighing 3 lbs. each. These boxes maximize the available space by fitting 2 boxes across the 40" dimension of the pallet and 3 boxes across the 48" dimension of the pallet for a total of 6 boxes per layer stacked 8 layers high on the pallet. The 2-piece box consists of a bottom box and a top cover that telescopes the full height of the box to contribute to stacking strength with double wall construction. In order to deliver 40 lbs. net weight of bananas, corrugated boxes are packed with about 41.5 lbs. of green fruit at the farms. Corrugated boxes weigh approximately 3 lbs. each, resulting in container loads that approach both the weight limit and the cubic space or cube limit of containers. [0006] Bananas are cut from stems into clusters of 4 to 9 banana fingers; each cluster having 2 rows of bananas referred to as the inner whirl on the concave side of the cluster and the outer whirl on the convex side of the cluster. Boxes are typically packed with 15 to 17 clusters per box to meet the net weight specification for major North American retailers. These clusters are packed in 4 lines or rows of fruit, crowns and inner whirl down, with each line containing 4 to 5 clusters across the longer 19.7" dimension of the box. The first 2 lines are packed overlapping in the center of the box with the 2 additional lines of fruit packed left and right overlapping the first two lines. such that the bananas are stacked up to 3 clusters or 6 banana fingers high in the box and with the 2nd line completely surrounded by bananas in the 1st, 3rd and 4th lines. The 4-line pack used in the traditional corrugated boxes generally results in the height of the fruit exceeding the height of the box at the time of packing, or high pack. The telescoping lid facilitates this high pack while still permitting boxes to be stacked on pallets. 41.5 lbs. of green fruit also cause flexible boxes to bulge in all directions. Due to the initial high pack situation with 4 lines of fruit combined with the tendency forring back to engage the stop 22 on the sidewall 12. [00039]     In an exemplary embodiment, the edges of each endwall 11 and sidewall 12 include a series of vertically-spaced "L" or "L"-shaped hooks 50 that allow an endwall 11 to interlock with a sidewall 12 when both are upright and overlap when the container is in the "erected" position. This further promotes close coupling of the endwalls 11 to the sidewalls 12, promoting the structural integrity of the container 10 in the "erected"  configuration and thereby reducing damage to the contents of the container.   [00040]    While many conventional RPCs are collapsible by folding, they are often designed to take on their set-up configuration by latching of their end walls.  Such endwall latching can result in inadvertent disengagement of the latches (and resulting collapse of the RPC) during carrying and stacking due to the exertion of lateral forces against the handles or end walls. This can result in damage to the contents of the container.As indicated above, an exemplary embodiment of the container has a unique design that employs latching of the sidewalls 12, which reduces inadvertent disengagement, since lateral force against the handles and end walls during carrying and stacking will not disengage the latches. In addition, the use of "L" hooks 50 to couple each sidewall 12 to each endwall 11 will further counteract any lateral forces on the handles and endwalls. FIG. 8 depicts a cross section of a sidewall 12 and endwall 11 when coupled through the use of "L" hooks 50. [00041]    In an exemplary embodiment, one or more of the sidewalls 12 or endwalls 11 will have an opening within which a door 40 is mounted in such a way that does not cut through the perimeter of the sidewall 12 or endwall 11. Such door 40, which can be constructed from the same material as the sidewall 12 or endwall 11, can be hingeably mounted or attached to the opening to allow the door 40 to pivot and be opened and closed. Opening the door 40 permits visual inspection and/or sampling of the product in the container 10, even when the container is within a stack of other containers on a pallet. The door 40 can be closed again, renewing the protective barrier that the endwall 11 or sidewall 12 provides to the contents of the container 10 in storage or transport. Preferably, when the door 40 is in the closed position, the door 40 is coupled or attached to the sidewall 12 or endwall 11 by a clip 41 that prevents the door 40 from opening without user action. [00042]    FIG. 7 and FIG. 7a depict an exemplary embodiment with the opening and door 40 in the sidewall, and the clip 41 having the form of a spring tang.  This embodiment of the curved fruit sampling door 40 incorporates a clip 41 that, when engaged, holds the door 40 closed and when disengaged allows the door 40 to open to provide access to the contents of the container 10. Preferably, the clip 41 is a "low profile spring tang" mechanism which fits within the thickness of the sidewall 12 or endwall 11, not extending inside the curved surface of the sidewall 12 or endwall 11 or outside the plane as defined by the outside surface of the sidewall 12 or endwall 11.  The mechanism of the clip 41 is reusable, allowing for repeated opening and closing of the sample door 40. The clip 41 is rotated outward to disengage the clip 41 and allow the door 40 to open. The door 40 and clip 41 are rotated inward with slight pressure to engage the clip 41 and the latch bracket 42. Because of the door's 40 material, its hinged connection 47 and the use of the clip 41 to secure it, the door 40 can be opened and closed repeatedly throughout the life of the container 10 without affecting the structural integrity of the container, the protection of the product in the container, or the life of the container. [00043]     In a preferred embodiment, the dimensions of the container 10 are optimized for use in a particular product market or supply chain. It is desirable to have the maximum possible length of a container 10 without overhanging the pallets on which a container or multiple containers are placed. in the case of an exemplary embodiment of the container for use with bananas, where 40-inch by 48-inch pallets are customarily used, the optimum exterior length for a container 10 is about 24 inches (about 60.9 cm) and the optimum exterior width is about 13,33 inches (about 33.9 cm). With these dimensions, the container 10 could be placed on pallets in a six-down configuration, a pallet loading pattern with three (3) containers across the approximately 40-inch dimension of the pallet and two (2) containers across the approximately 48-inch dimension. See FIG. 2 and FIG. 3 for illustrations of a "six-down"  configuration. [00044]     ln the North American retail supply chain, containers are likely to be mixed with conventional RPCs that are only about 23.5 inches (about 60 cm) in exterior length.  Accordingly, it is desirable for the container 10 to be about 24 inches long when erected and filled with bananas, but only about 23.5 inches long when folded down to facilitate mixing of empty folded crates on pallets. The novel design approach accomplishes the increased length when erected, but does so without increasing the height of folded containers 10 to optimize the number of containers 10 that can be packed on pallets for return. FIG. 10a depicts the profile of one end of the container when in the "collapsed"  configuration. Fig. 10b depicts the profile of the same end of the container when in the "erected" configuration, showing the additional length of the container in the "erected"  configuration when compared to the length of the container in the "collapsed"  configuration. The approximately 24-inch length when erected maximizes banana capacity and eliminates pallet underhang that exists with other RPCs, These dimensions also close gaps between pallets for better transport stability and airflow.  This brings the added benefit that corner boards can be properly used to prevent the flow of air between pallet loads in ripening rooms, so that ripening can be more precisely controlled. [00045]     In a preferred embodiment, a container 10 with an exterior measuring approximately 24 inches long by approximately 13.33 inches wide results in interior dimensions that facilitate packing of three (3) longer lines of curved fruit (e.g., bananas) per container. Three (3) lines don't pile as tall as the four-line arrangement commonly used in conventional banana containers, and this lower packing height results in less "high pack" damage to the banana in the container. FIG. 9a depicts the first line of packing of bananas. FIG. 9b depicts the second line of bananas packed over the first line, partially overlapping it. Finally, FIG. 9c depicts the third line of bananas packed, which also partially overlaps the first line. A preferred embodiment also includes added height to the container 10 to prevent "high pack" damage, with the preferred exterior height for a container for bananas being approximately 9,66 inches. [00046]     In a preferred embodiment, the container 10 includes some extra material 60 in its dimensions to promote easier stacking without the need for perfect alignment.   In an exemplary ernbodiment, this lead-in material 60 includes about 1/8 inch to 1/2 inch lead-in in both the length and width dimensions for easier stacking. Exemplary containers can also be slid in and out of place for easier stacking and de-stacking as a result of this lead-in material. [00047]     In another embodiment, the endwalls 12 and sidewalls 11 are optimized for the storage of transportation of pineapples, specifically through the use of wall shaping and recessed areas designed to protect the barrels and crowns of pineapples, and the ability to adjust the height of the container 10 at the time of packing to closely fit the pineapples in the container. [00048]     While the application has been described in terms of various specific and preferred embodiments, the skilled artisan will appreciate that various modifications, substitutions, omissions, and changes may be made without departing from the spirit thereof. Accordingly, it is intended that the scope of the present application be limited solely by the scope of the following claims, including equivalents thereof.