Patent Publication Number: US-9422087-B1

Title: Foldable crate and locking mechanisms therefor

Description:
TECHNICAL FIELD 
     The present invention pertains to containers, in particular foldable crates and locking mechanism therefor. In particular, the invention relates to advances in and elaborations of locking mechanisms for foldable crates. 
     BACKGROUND OF THE INVENTION 
     Foldable crates are widely used these days. There are numerous solutions known in the art for locking mechanisms for foldable crates. The general concept of such locking mechanisms is that a foldable crate can be secured in open conformation, by a locking mechanism, which is releasable by an actuator, typically a tab surrounding the handle of the crate. It is believed that the pertinent state-of-the-art is represented by: U.S. Pat. No. 7,861,878, U.S. Pat. No. 6,290,081, US20100230406, US20120091133 and US20100320202; EP2431283 and EP1655232, as well as by WO2010146190, WO2009100799 and particularly DE10137328. 
     US20120091133 discloses a collapsible box including a plastic structure with a rectangular base, two ends, and two sides which are pivotably coupled to the base. The ends include centered parts combined with latches, which in one position anchor the sides and ends, while in another position the connection between the ends and the sides is released in order to collapse the elements. The collapsible box of US20120091133 is characterized in that the box includes an anchor device consisting of a series of rotary bodies that connect the latches to the centered part via two pairs of resilient parts and which, in the inoperative position thereof, hold the latches outwards, attaching the ends and the sides. When the central part is moved upward, the latches thus release the ends and the sides. 
     U.S. Pat. No. 7,861,878 discloses a fastening device for folding boxes. The folding boxes include a bottom and four lateral walls coupled in jointed fashion to the edges of that bottom, two opposite walls each having a fastening device for ensuring the unfolding of the box. The fastening devices of U.S. Pat. No. 7,861,878 include a vertically displaceable central piece and lateral bolts with horizontal displacement for fastening the lateral walls via their adjacent edges. The fastening device of U.S. Pat. No. 7,861,878 includes elastic spring elements that link the central control piece with pairs of the lateral bolts. The spring elements, in the rest position, maintain the bolts in an engagement and fastening position. The release position of the bolts in U.S. Pat. No. 7,861,878 results when the spring elements pull the bolts against the resistance of the elastic elements. 
     DE10137328 that is considered the most relevant prior art publication discloses an assembly, adapted to open and close side walls of a plastic and reusable box or container, which have a manual locking unit, with at least one projection, which grips over a ratchet hook on the longitudinal wall. The lock operating control is adapted to grip, carry the box or container and also unlock the side walls. 
     SUMMARY OF THE INVENTION 
     The invention relates to advances in and elaborations of locking mechanisms for foldable crates. 
     There is provided in accordance with embodiments of the present invention a foldable crate including a base platform, a pair of longitudinal sidewalls forming a hinged connection with the base platform and a pair of flanking sidewalls forming a hinged connection with the base platform. The flanking sidewalls accommodate a locking mechanism and unlocking mechanism. 
     In accordance with some embodiments of the present invention, the locking mechanism includes a pair of rotary locking elements, pivoting upon axes on flanking sidewalls, as well as a pair of respective protrusions inwardly facing from longitudinal sidewalls. 
     In accordance with some embodiments of the present invention, the unlocking mechanism includes a manual deactivator, configured to exert a rotational torque upon rotary locking elements. 
     It should be understood, however, that the summary above is not intended to limit the invention to the particular forms and examples, rather on the contrary, is to cover all modifications, equivalents, and alternatives falling within the scope of the invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The present invention will be understood and appreciated more comprehensively from the following detailed description taken in conjunction with the appended drawings in which: 
         FIG. 1  an isometric view of an assembled foldable crate in an open conformation and locking/unlocking mechanism therefor, in accordance with an embodiment of the present invention; 
         FIG. 2  is an exploded isometric view of a base platform, a longitudinal sidewall and a flanking sidewall of an embodiment of the foldable crate as well as of a pair of rotary locking elements of the locking mechanism thereof and manual deactivator of the unlocking mechanism thereof; 
         FIG. 3A  is a posterior perspective elevated view of the locking mechanism of the foldable crate; 
         FIG. 3B  is an enlarged posterior perspective elevated view of the locking mechanism of the foldable crate shown in  FIG. 3A ; 
         FIG. 4A  is an elevated frontal cut-away view of the flaking sidewall, showing a terminal portion of a rotary locking element of the locking mechanism of the foldable crate; 
         FIG. 4B  is an enlarged elevated frontal cut-away view of the flaking sidewall, showing a terminal portion of a rotary locking element, shown in  FIG. 5A ; 
         FIG. 5A  is an elevated perspective frontal cut-away view of the flaking sidewall, showing an inwardly facing protrusion on the longitudinal sidewall; 
         FIG. 5B  is an enlarged elevated perspective frontal cut-away view of the flaking sidewall, showing the inwardly facing protrusion on the longitudinal sidewall, shown in  FIG. 5A ; 
         FIG. 6A  is a perspective frontal view of the flaking sidewall, incorporating another embodiment of locking/unlocking mechanism, with a safety catch feature preventing inadvertent opening of the crate; 
         FIG. 6B  is an enlarged frontal view of the flaking sidewall, incorporating another embodiment of locking/unlocking mechanism, with a safety catch feature preventing inadvertent opening of the crate, shown in  FIG. 6A . 
     
    
    
     While the invention is susceptible to various modifications and alternative forms, specific embodiments thereof have been shown merely by way of example in the drawings. The drawings are not necessarily complete and components are not essentially to scale; emphasis instead being placed upon clearly illustrating the principles underlying the present invention. 
     DETAILED DESCRIPTION OF THE INVENTION 
     Illustrative embodiments of the invention are described below. In the interest of clarity, not all features of actual implementation are described in this specification. It will of course be appreciated that in the development of any such actual embodiment, numerous implementation-specific decisions must be made to achieve the developers&#39; specific goals, such as compliance with technology- or business-related constraints, which may vary from one implementation to another. Moreover, it will be appreciated that the effort of such a development might be complex and time-consuming, but would nevertheless be a routine undertaking for those of ordinary skill in the art having the benefit of this disclosure. 
       FIGS. 1 and 2  show components of an embedment of foldable crate  30  as well as locking elements  80  thereof. Foldable crate  30  comprises base platform  32 . Base platform  32  has a plurality of structural recesses  34 , disposed about longitudinal portion  36  of base platform  32  and structural recesses  38  disposed about flanking portion  40  thereof. The superior face of longitudinal portions  36  of base platform  32  are positioned somewhat higher than the superior face of flanking portion  40 . 
     Foldable crate  30  further comprises a pair of longitudinal sidewalls  50  and a pair of flanking sidewalls  60 , of which just a single sidewall from each pair is shown. Longitudinal sidewalls  50  include a plurality of structural elements  52 , disposed about bottom portion  54  of the former, whereas flanking sidewalls  60  include a plurality of structural elements  62 , disposed about bottom portion  64  of sidewalls  60 . Structural elements  52  disposed about bottom portion  54  of longitudinal sidewalls  50  further comprise longitudinal pivots  42  configured to form a hinged connection with structural recesses  34 , disposed about longitudinal portion  36  of base platform  32 ; whereas structural elements  62 , disposed about bottom portion  64  of flanking sidewalls  60  further comprise flanking  44  pivots, configured to form a hinged connection with structural recesses  38  disposed about flanking portion  40  of base platform  32  of foldable crate  30 . Optionally, at least one of pivots  42  or  44  is a single extended rod, typically metallic, threaded respectively throughout the entire length of longitudinal portion  36  or flanking portion  40  of base platform  32 . 
     Structural recesses  34 , disposed about longitudinal portions  36  of base platform  32  as well as with structural recesses  38  disposed about flanking portions  40  of base platform  32  typically include apertures (not shown) configured to receive longitudinal pivots  42  and/or flanking  44  pivots, respectively, thereby forming a hinged connection between longitudinal sidewalls  50  and longitudinal portion  36  as well as flanking sidewalls  60  flanking portions  40  of base platform  32 . Longitudinal portions  36  of base platform  32  embodying structural recesses  34  are positioned somewhat higher than flanking structural recesses  38  disposed about flanking portion  40  of base platform  32  embodying structural recesses  38 , whereas longitudinal pivots  42  are positioned somewhat higher than flanking pivots  44 ; thereby providing for folding flanking sidewalls  60  inwardly towards bottom and then folding longitudinal sidewalls  50  on top of flanking sidewalls  60  in a folded conformation (not shown) foldable crate  30 . 
     Longitudinal sidewalls  50  include tabs  56 , adapted to serve as gripping handles. Longitudinal sidewalls  50  include flanking facets  58  extending essentially perpendicularly along a portion of the vertical edges of longitudinal sidewalls  50 . It is further noted that flanking facets  58  of longitudinal sidewalls  50  preferably form enclosed channels  59  within longitudinal sidewalls  50 . 
     Flanking sidewalls  60  include tab  66 , adapted to serve as a gripping handle. It is noted that flanking sidewalls  60  include side recesses  68 , forming an opening sidewalls  60  allowing passage of protrusion  78  of longitudinal sidewalls  50  upon opening and folding crate  30 . Flanking sidewalls  60  include flanking struts  72 , forming a channel which is in continuum with enclosed channels  59  formed by flanking facets  58  within longitudinal sidewalls  50 . 
     Flanking sidewalls  60  comprise structured centric recess  70 , essentially surrounding tab  66 . Structured centric recess  70 , of flanking sidewall  60 , is adapted to accommodate unlocking element  82 . Structured centric recess  70  in flanking sidewalls  60  comprises a couple of grooves  76  along a portion of the sides thereof, adapted to accommodate ridges or extensions (not shown) of unlocking element  82  and sustain vertical displacement of the latter within the former. 
     Referring now to  FIG. 3A to 5B  which show rotary locking elements  80  in greater details. Rotary locking elements  80  are pivoted on pivots  84  positioned typically somewhat offset structured centric recess  70 , in flanking sidewall  60 . Rotary locking elements  80  further comprise or embody leaf-springs  88 , extending from the top face upwards and towards the terminal portion  86  of rotary locking elements  80 . 
     Locking elements  80  are threaded into channels  59  in flanking sidewalls  60 , underneath flanking struts  72 . It is noted that the channels formed underneath flanking struts  72  are somewhat wider than locking elements  80 ; thereby sustaining radial displacement of the latter within the former. Locking elements  80  are furnished with pivots, which are threaded into apertures  84 , at the top portion of flanking sidewalls  60 . Locking elements  80  are rotatable upon pivots threaded into apertures  84 , in flanking sidewalls  60 ; thereby sustaining radial displacement of the terminal portion of locking elements  80  within channels formed underneath flanking struts  72  in flanking sidewalls  60 . 
     Longitudinal sidewalls  50  comprise structured protrusions  78 , extending inwardly from the inner faces of longitudinal sidewalls  50 . U-shaped cut  69  is formed essentially surrounding protrusions  78 , thereby rendering protrusions  78  outwardly displaceable, upon pushing onto protrusions  78  in an outward direction, against the biasing force exerted upon deformation of the material at the basis of U-shaped cut  69 . Structured protrusions  78  of longitudinal sidewalls  50  comprise upwardly oriented back upper face  71  and essentially vertically oriented back upper face  73 , slightly upwardly inclined backwards. 
     Underneath flanking struts  72 , flanking sidewalls  60  comprise recesses  68  defining an opening towards the interior of crate  30 . Recesses  68  in flanking sidewalls  60  allow structured protrusions  78  of longitudinal sidewalls  50  to surpass the terminal portions of locking elements  80 , while unfolding crate  30  into open conformation, shown in  FIG. 1 . Terminal portions of locking elements  80  preferably comprise chamfered or beveled terminal front face  86 . Chamfered or beveled terminal front face  86  of locking elements  80  is to some extent inwardly slanted, facing somewhat towards the corner of crate  30 . 
     To unfold crate  30  into open conformation, shown in  FIG. 1 , initially longitudinal sidewalls  50  are elevated and consequently rotated upwardly and away from base platform  32 , until the former are erected essentially perpendicularly to the latter. Then flanking sidewalls  60  are elevated and consequently rotated upwardly and away from base platform  32 , until terminal portions of locking elements  80  collide from behind with structured protrusions  78 . 
     Upon collision of structured protrusions  78  with terminal portions of locking elements  80  and particularly with chamfered or beveled terminal front face  86  thereof, structured protrusions  78  are displaced in an outward direction, while the material at the basis of U-shaped cut  69  is somewhat bent or deformed, forming a biasing force urging structured protrusions  78  in an inward direction. Alternatively or additionally, upon collision of terminal portions of locking elements  80  with structured protrusions  78 , terminal portions of locking elements  80  are displaced in an upward direction, while being contiguously translated upon the surface of upwardly oriented back upper face  71  of structured protrusions  78  on longitudinal sidewalls  50 . 
     Ultimately, upon elevating flanking sidewalls  60  and consequently rotating the same upwardly and away from base platform  32 , until the former are erected essentially perpendicularly to the latter, terminal portions of locking elements  80  surpass structured protrusions  78 . Upon surpassing terminal portions of locking elements  80 , structured protrusions  78  are spontaneously displaced in an inward direction, due to the biasing force formed by the deformed or bent material at the basis of U-shaped cut  69  spontaneously urging structured protrusions  78  in an inward direction. Alternatively or additionally upon surpassing structured protrusions  78 , terminal portions of locking elements  80  are spontaneously displaced in a downward direction, due to the biasing force exerted by leaf-springs  88  of locking elements  80 , bouncing against inner top face of the top portion of flanking sidewalls  60 . 
     Upon surpassing structured protrusions  78 , terminal portions of locking elements  80  become locked in front of structured protrusions  78  of longitudinal sidewalls  50 , whereby flanking sidewalls  60  become locked in a perpendicular orientation relatively to base platform  32 , rendering crate  30  locked in open conformation, shown in  FIG. 1 . 
     Unlocking element  82  is slidable in structured centric recess  70 , of flanking sidewalls  60 . Ridges or extensions (not shown) of unlocking element  82  are threaded into grooves  76  of about structured centric recess  70  and slidable therein. Vertical translation of unlocking element  82  upwards is restricted by the length of grooves  76 . Leaf-springs  88  spontaneously drive unlocking element  82  in a downward direction, by bouncing against inner top face of the top portion of flanking sidewalls  60 . 
     Upon forceful manual elevation of unlocking element  82  in an upward direction, terminal portions of unlocking element  82  exert rotational torque onto locking elements  80 , causing locking elements  80  to rotate upon pivots threaded into apertures  84 , in flanking sidewalls  60 , so that the terminal portions of locking elements  80  are radially displaced in an upward direction and assume a higher position within channels formed underneath flanking struts  72  in flanking sidewalls  60 ; thereby rendering crate  30  readily foldable into folded conformation (not shown). 
     Enclosed channels  59  formed by flanking facets  58  within longitudinal sidewalls  50  preferably comprise separation bumper elements  63 , extending into the channels underneath flanking struts  72  in flanking sidewalls  60 . Separation bumper elements  63  typically include an outwardly slanted bottom face (not shown), facing essentially inwardly and downwardly. Upon forceful manual elevation of unlocking element  82  in an upward direction, the top faces of terminal portions of unlocking element  82  collide with separation bumper elements  63 , preferably with an outwardly slanted bottom face thereof, thereby a normal force is exerted onto terminal portions of unlocking element  82  and in turn onto flanking sidewalls  60  essentially inwardly and downwardly, forming a rotational torque onto flanking sidewalls  60 , causing flanking sidewalls  60  to commence rotating upon flanking pivots  44 , towards base platform  32 , thus initiating the folding of crate  30  into folded conformation (not shown). 
     It is noted that deepened bottom portion in structured centric recess  70  is used for manual access to unlocking element  82  from underneath. It is further noted that the top face of the central portion of unlocking element  82  is preferably disposed not higher than the bottom face of tab  66  in flanking sidewalls  60 , when unlocking element  82  is in a released position, shown in  FIG. 1 ; whereas when unlocking element  82  is in an elevated position (not shown), the top face of the central portion of unlocking element  82  partially obstructs tab  66  in flanking sidewalls  60 ; thereby preventing inadvertent usage of crate  30 , while unlocking element  82  is in an elevated position (not shown). 
     Upon release of forceful elevation of unlocking element  82  in an upward direction, leaf-springs  88  of locking elements  80 , spontaneously drive locking elements  80  in a downward direction which in turn drive unlocking element  82  in a downward direction as well. Upon spontaneous translation of unlocking element  82  in a downward direction, locking elements  80  are capable to assume a lower position within channels formed underneath flanking struts  72  in flanking sidewalls  60 ; thereby rendering crate  30  readily transformable into open conformation, shown in  FIG. 1 . 
     It is noted that due to the modularity of crate  30 , unlocking element  82  as well as locking elements  80  are readily replaceable in individual manner. Moreover even without or with dysfunctional unlocking element  82 , crate  30  still can be assembled into open conformation shown in  FIG. 1  and used for its purpose. 
     It is further noted that due to geometrical proportions of unlocking element  82  relatively to locking elements  80 , a translational lever is formed wherein the terminal portion of unlocking element  82  exerts a force onto a centric portion of locking elements  80 , whereby the terminal portion of locking elements  80  is consequently elevated a greater distance than the terminal portion of unlocking element  82 . Consequently upon effecting a relatively minor vertical translation of unlocking element  82 , a relatively major vertical translation of the terminal portion of locking elements  80  is achieved; rendering crate  30  more easily and readily foldable into a folded configuration (not shown). 
     In accordance with some preferred embodiments of the present invention, reference is now made to  FIGS. 6A and 6B  showing flaking sidewall  60 , employing safety catch mechanism  190  preventing inadvertent opening of rotary locking element  180 . Rotary locking element  180  is pivoted on pivot  184  positioned typically somewhat offset the structured centric recess, in flanking sidewall  60 . Rotary locking element  180  further comprises or embodies leaf-spring  188 , extending from the top face upwards and towards pivot  184  of rotary locking element  180 . 
     Rotary locking element  180  is threaded into channel in flanking sidewall  60 , underneath flanking strut  72 . It is noted that the channel formed underneath flanking struts  72  is somewhat wider than terminal portion  186  of locking element  180 ; thereby sustaining radial displacement of the latter within the former. Locking element  180  is rotatable upon pivot  184 , in flanking sidewalls  60 ; thereby sustaining radial displacement of terminal portion  186  of locking elements  180  within channel formed underneath flanking strut  72  in flanking sidewalls  60 . 
     Flanking sidewall  60  shown in  FIGS. 6A and 6B  further comprises exemplary safety catch mechanism  190  preventing inadvertent elevation rotation of rotary locking element  180 , within channel formed underneath flanking strut  72  in flanking sidewalls  60 . Rotary locking element  180  comprises exemplary extended protrusion  194 . The terminal portion of extended protrusion  194  is configured to be bent, folded or otherwise displaced in an upward direction, towards rotary locking element  180 , upon a force exerted from underneath, by the terminal portion of exemplary unlocking element  182 . 
     Upon forceful elevation of unlocking element  182  in an upward direction, top terminal portion of unlocking element  182  exerts a force onto the terminal portion of extended protrusion  194 ; whereby the terminal portion of extended protrusion  194  is displaced in an upward direction, towards rotary locking element  180 . Thereafter rotary locking element  180  is capable to perform rotation upon pivot  184 , upon further elevation of unlocking element  182  in an upward direction, thereby sustaining radial displacement of terminal portion  186  of locking elements  180  within channel formed underneath flanking strut  72  in flanking sidewalls  60 . 
     However if no forceful elevation in an upward direction is applied to unlocking element  182 , locking element  180  is locked in place and rotation of rotary locking element  180  upon pivot  184  is precluded, because the terminal face of extended protrusion  194  is pushed against detent  192 , whereby radial displacement of terminal portion  186  of locking elements  180  within channel formed underneath flanking strut  72  in flanking sidewalls  60  is prevented. Consequently if an attempt to rotate locking element  180  in an upward direction is made, for instance upon opening of the foldable crate, safety catch mechanism  190  prevents rotation of rotary locking element  180  upon pivot  184 , because the terminal face of extended protrusion  194  is pushed against detent  192 ; whereby inadvertent folding of the foldable crate is prevented. 
     It will be appreciated by persons skilled in the art that the present invention is not limited by what has been particularly shown and described herein above. Rather the scope of the invention is defined by the claims which follow: