Patent Publication Number: US-2002000445-A1

Title: Selectively reinforceable container

Description:
CROSS REFERENCE TO RELATED APPLICATIONS  
     [0001] This application claims the benefit of U.S. Provisional Application No. 60/175,626 filed Jan. 11, 2000. 
    
    
     
       FIELD OF INVENTION  
       [0002] This invention is directed to containers for storage of objects, and more particularly, to containers which are reversibly reinforceable.  
       BACKGROUND OF THE INVENTION  
       [0003] Various containers are known in the art. For example, commonly assigned U.S. Pat. No. 5,379,897 iss. Jan. 10, 1995 to Muckenfuhs et al., incorporated herein by reference, discloses a resiliently deformable package. However, this package does not have auxiliary reinforcement means for use with the container.  
       [0004] U.S. Pat. No. 5,099,939, iss. Apr. 23, 1991 to Goldberg, discloses a vessel comprising a composite of paperboard and polymer film. U.S. Pat. No. 4,801,017, iss. Jan. 31, 1989 to Artusi, discloses a container comprising a tray surrounded by a blank and at least partially joined to the tray. However, selected portions of the blank are not selectively and reversibly attachable to the tray.  
       SUMMARY OF THE INVENTION  
       [0005] The invention comprises a container having a plurality of upstanding sidewalls interconnected by a floor pan. At least one of the sidewalls is reinforceable with an upstanding strut. The strut is removable from the sidewall, without separation from the container in one particular embodiment.  
       [0006] In one embodiment, a pair of the sidewalls may be reinforced with removable struts, the struts being transformable from a first position providing reinforcement to the sidewalls to a second position where the struts do not provide reinforcement to the sidewalls. The struts may be transformable between the first and second positions by articulation.  
       [0007] In another embodiment, the invention comprises a method of assembling a collapsed container. The method of comprising the steps of providing a container having sidewalls interconnected by a floor pan. The container further comprises struts attachable to the sidewalls and removable therefrom optionally without separation from the container. The struts are not attached to the sidewalls. The struts have a proximal end joined to the container at a distal end articulable about the proximal end. The struts are articulated to a position proximate the sidewalls whereby the struts are disposed in a plane substantially parallel to the sidewalls. The struts, and preferably the distal ends thereof, may then be attached to the sidewalls. 
     
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
     [0008]FIG. 1 is a perspective view of a container according to the present invention and illustrating an optional cover.  
     [0009]FIG. 2 is an exploded perspective view of the container of FIG. 1 showing the reinforcement separated from the container.  
     [0010]FIG. 3 is a perspective view of the container of FIG. 1 with the reinforcement attached to the container and in the reinforcing position.  
     [0011]FIG. 4 is a perspective view of the container and reinforcement, the left-hand strut of the reinforcement being in the reinforcing position, the right-hand strut of the reinforcement being removed from the sidewall and not being in a reinforcing position.  
     [0012]FIG. 5 is a bottom plan view of the container showing the reinforcement articulated to a nonreinforcing position. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION  
     [0013]FIG. 1 depicts a preferred embodiment of a container  10  and associated reinforcement  40  according to the present invention. In the embodiment depicted in FIG. 1, the container  10  includes a container  10  body preferably unitarily formed from sheet material. An optional cover  12  may be included and unitarily formed with the container  10 . The container  10  may also include a closure for sealing the cover  12  and container  10 . The cover  12  may be generally flat, as illustrated, or may have a convex inward or convex outward orientation, as desired. If the optional cover  12  and seal  14  are desired, a plug seal  14  may be utilized as is known in the art and illustrated by U.S. Pat. Nos. 3,784,055, iss. Jan. 8, 1974 to Anderson, and 3,967,756, iss. Jul. 19, 1976 to Barish, both of which are incorporated herein by reference. However, it is to be recognized that the cover  12  is an auxiliary feature and does not form part of the claimed invention. For certain embodiments, it is preferred that the cover  12  be substantially flat so that the container  10  is stackable.  
     [0014] The container  10  according to the present invention may be relatively small, such that the container  10  may be stored in one&#39;s pocket or purse. Such a container  10  may include the optional cover  12  and be useful for storing pills, capsules, etc. Alternatively, the container  10  may be relatively large such that the container  10  is sized to fit a flat bed semi-truck. Such a container  10  may be useful for carrying construction materials, etc. One contemplated use for the container  10 , particularly when the optional cover  12  and a further optional seal  14  are included, is to store perishable items such as food.  
     [0015] The container  10  comprises a floor pan  22  and sidewalls  20  projecting outwardly from the floor pan  22 . Preferably, in use, the sidewalls  20  project upwardly and terminate at a distal end  46  forming the mouth  26  or opening of the container  10 . The illustrated embodiment has four sidewalls  20 . However, it is to be recognized the invention is not so limited.  
     [0016] The floor pan  22  defines and lies in the first plane. For the embodiment illustrated, the floor pan  22  is defined by the vertices of the four comers of the upstanding sidewalls  20 . The floor pan  22  may be domed convex inwardly to increase strength as is known in the art. Particularly, domed floor pans  22  provide increased strength for loading by the contents of the container  10  in a direction normal to the plane of the floor pan  22 . Alternatively, the floor pan  22  may be disposed convex outwardly, although this may decrease stability when the container  10  rests on a horizontal surface. It is to be recognized that the floor pan  22  may be domed and still define a plane.  
     [0017] Referring to FIG. 2, the container  10  is provided with a reinforcement  40 . Particularly, the reinforcement  40  may comprise struts  42  which support one or more respective sidewalls  20  and preferably a floor pan support  48 . The struts  42  may be utilized to support either self-supporting, reversibly articulable sidewalls  20 , flaccid sidewalls  20 , or combinations thereof.  
     [0018] Further, the struts  42  may be articulable so that they may be applied to and removed from the sidewalls  20  as desired. Preferably, the struts  42  are articulable about a proximal end  44 , the proximal end  44  being juxtaposed with the floor pan  22 . The distal end  46  of the strut  42  may engage the sidewall  20 , a flange circumjacent the mouth  26  of the container  10 , or any other point near the top or opening of the container  10  which is convenient and provides structural support to resist collapse of the container  10 .  
     [0019] Further, the reinforcement  40  preferably further comprises one or more floor pan supports  48 . The floor pan supports  48  extend partially, or preferably completely across the length, and optionally across the width of the floor pan  22 . If the floor pan  22  has an aspect ratio greater than one, preferably the floor pan support  48  extends throughout and in the direction of the major axis.  
     [0020] Referring to FIGS.  2 - 3 , preferably, the struts  42  and floor pan support  48  comprise a single, unitary and integral piece of material as illustrated. The reinforcement  40 , thus comprises a contiguous planar member which in turn comprises one or more struts  42  and the floor pan support  48 . This arrangement provides the benefit that the reinforcement  40  may be manufactured as a single element. Further, attachment of the reinforcement  40  to the container  10  is simplified. For example, in the embodiment illustrated, the floor pan support  48  may be joined to the bottom of the floor pan  22  of the container  10 . Joining may be accomplished using any suitable means such as heat sealing, although ultrasonic welding, adhesive, etc., may be used.  
     [0021] Referring to FIGS.  3 - 4 , the struts  42  which reinforce the sidewalls  20  may be transformable between the first and second positions using a number of known means. For example, the struts  42  may slidably engage the sidewalls  20  by translation relative thereto. Alternatively and preferably, the strut  42  may be articulably joined to its respective sidewall  20  at the proximal end  44  of the strut  42 . More preferably, the proximal end  44  of the strut  42  is joined to the container  10  at a hinge juxtaposed with the floor pan  22 . This arrangements allows the strut  42  to support the entire length of the sidewall  20  between the floor pan  22  and the opening  26  at the top of the container  10 . By supporting the entire length, the full depth of the sidewall  20  is reinforced. This arrangement becomes more important when the container  10  is reversibly collapsible and erectable as described hereinbelow.  
     [0022] The distal end  46  of the strut  42  may be attachable to the container  10  using any of or combinations of several known means, such as frictional engagement, adhesive attachment, cohesive attachment, hook and loop fasteners, tab-slot arrangements, etc. Any means for removably attaching the distal end  46  of the strut  42  to the container  10  is suitable. Preferably, attachment of the strut  42  to the container  10  causes one or more sensory indicia to occur to the user. The sensory indicia may be visual, audible or tactile. Sensory indicia occur when the strut  42  is joined to the container  10  using any mechanical engagement, such as tab-slot arrangements.  
     [0023] The container  10  may have a circumjacent flange. The flange may be usable for providing a sealing means if the optional cover  12  is provided with the container  10 . Alternatively, the flange, either with or without the optional cover  12 , may be usable for gripping the container  10 , opening and closing the optional cover  12 , etc. It is to be recognized the strut  42  may be attachable to the container  10  at locations intermediate the proximal and distal ends  46  of the strut  42 . However, attachment of the strut  42  at the distal end  46  is convenient and provides fixed points spaced apart so that the strut  42  does not comprise a cantilevered support geometry.  
     [0024] Referring to FIGS.  4 - 5 , the struts  42  may be articulated to a position which does not provide reinforcement  40  to the sidewall  20 , and even be releasably attached to the floor pan  22  or to the floor pan support  48 . Particularly, the struts  42  are preferably removably attachable to the outer surface of the container  10 , although arrangements having the struts  42  removably attachable to the inner surface of the container  10  are contemplated as described below. This arrangement allows for storage of the container  10  without interference from the struts  42  when not in use.  
     [0025] The strut  42  may be disposed in the form of a panel. The strut  42  is considered to comprise a panel if the strut  42  has a width at least 75% of the width of the respective sidewall  20  which the strut  42  reinforces. If so, such a panel is optionally substantially coextensive of and attachable to the sidewall  20  of the container  10 . This arrangement provides a strut  42  which provides support throughout the entire width of the upstanding sidewall  20 . It is to be recognized that, however, the stiffness of the strut  42  is a linear function of its width and a cubic function of its thickness for bending moments perpendicular to the strut  42 . Accordingly, the strut  42  may be optionally reinforced as described hereinbelow.  
     [0026] It is to be recognized that the container  10  may have a rectangular footprint and/or rectangular sidewalls  20 . If so, the height may be greater than the width of the sidewalls  20 , or vice versa, as desired for the particular geometry under consideration. Further, the strut  42  may be perforate. A perforate strut  42  provides the benefit that, when used in conjunction with a transparent container  10 , the user may more easily view contents of the container  10  disposed behind the strut  42 .  
     [0027] Referring to FIGS. 2, 3,  4 , and  5 , the reinforcement  40  preferably further comprises a floor pan support  48 , for reinforcing the floor pan  22  as described above. If so, preferably the strut  42  or struts  42  and floor pan support  48  are contiguous and comprised of an integral piece of material as described above. The container  10 , as illustrated, may have a major axis and minor axis opposed thereto, although any geometry and configuration may be utilized without deviation from the claimed invention. If the container  10  has a major axis and minor axis, preferably the floor pan support  48  heterogeneously reinforces the floor pan  22  in a direction substantially parallel to the major axis. The heterogeneous support along the major axis is preferred because it reinforces the longest unsupported span of the floor pan  22 .  
     [0028] Likewise, the struts  42  may heterogeneously support the container  10  in a direction having a vector component normal to, and preferably identically normal to the floor pan  22 . This arrangement provides resistance to bending and unintended collapse when the container  10  is in use. Suitable materials for reinforcing the container  10  include single-face and double-face fluted cardboard, polymeric materials similar or identical to that used for the container  10 , etc. If cardboard, paperboard, or other cellulosic materials are selected for the struts  42  and/or floor pan support  48 , such material may be sized or provided with a hydrophobic coating to prevent degradation due to moisture, washing, etc.  
     [0029] In a preferred embodiment, the container  10  comprises a first material and the reinforcement  40  comprises a second material, the first and second materials being dissimilar. Each is tailored to its specific function. For example, the container  10  may comprise a material which is impermeable and prevents evaporation or spoilage of liquid contents contained therein. The struts  42  may comprise a heterogeneous reinforcing material suited for articulation about a hinge line  30 . Thus, using the claimed arrangement, each material may be tailored to the specific properties which will be helpful at the point of use.  
     [0030] The first and second materials may be of identical composition but dissimilar geometries, for example, the container  10  may be comprised of a polymeric material having a first gauge. The struts  42  and/or floor pan support  48  may be comprised of a polymeric material having a second gauge. The second gauge may be greater than the first gauge. This arrangement allows the container  10  to be formed of a thinner gauge material for material savings. Concomitantly, the reinforcing struts  42  and/or floor pan support  48  may comprise a thicker gauge material for strength.  
     [0031] If desired, the strut  42  may further comprise notches  34 , undulations, tabs, or handles for gripping and manipulation of the strut  42 . This arrangement provides the benefit that the strut  42  may be more easily manipulated and, hence, more easily transformed between the first and second positions. If desired, the strut  42  may be of variable cross section. For example, the strut  42  may have a cross section which provides a greater bending modulus at the proximal end  44  of the strut  42  than at the distal end  46 . Likewise, the container  10  may comprise variable wall thicknesses to provide additional rigidity, as desired.  
     [0032] The reinforcement  40  may be joined to the inner surface of the container  10 , to prevent the reinforcement  40  from inadvertently becoming entangled with nearby objects. Preferably, the reinforcement  40  is joined to the outer surface of the container  10 , so that the contents of the container  10  may be easily removed and the container  10  easily cleaned. The container  10  may optionally be reversibly collapsible and erectable, If so, the container  10  has a first volume associated with its collapsed condition. The container  10  further has a second volume associated with its erected condition. The second volume is greater than the first. The container  10  may be collapsed in stages as the contents are depleted. This provides the benefits of requiring less storage space and removing oxygen from the container  10  if perishable contents are stored therein.  
     [0033] The container  10  may be optionally reversible transformable between collapsed and erected conditions in any number of manners. In a preferred embodiment, at least one, and preferably each sidewall  20  has a hinge line  30  disposed substantially parallel to the plane of the floor. The hinge line  30  divides the sidewall  20  into upper and lower portions, each of which is articulable about the hinge lines  30  when the container  10  is transformed between the collapsed and erected conditions. Alternatively, the container  10  may be transformable between collapsed and erected conditions, as illustrated by commonly assigned U.S. Pat. No. 5,996,882, iss. Dec. 7, 1999 to Randall, and incorporated herein by reference.  
     [0034] In an alternative embodiment, the strut  42  may be totally separable from the container  10 . In such an embodiment, the strut  42  has separate attachment means at both the proximal end  44  and distal end  46  of the strut  42 . Additionally, the strut  42  may be attached to the container  10  at positions intermediate the proximal and distal ends  44 ,  46 . Attachment at the proximal end  44 , distal end  46 , and intermediate position may be accomplished using any of the aforementioned and known means. If desired, the struts  42  may be articulated until they contact, and even be joined, to the outwardly facing surface of the floor pan support  48 , as illustrated in FIG. 5.  
     [0035] While the illustrated embodiments disclose two sidewalls  20  which are reinforced with the struts  42 , one of ordinary skill will recognize that one sidewall  20 , all sidewalls  20 , or any combination therebetween may be reinforced by the struts  42 . Additionally, the container  10  may be provided with two floor pan supports  48 . If the floor pan supports  48  heterogeneously reinforce the floor pan  22 , the heterogeneous reinforcement may be applied in mutually orthogonal directions, to provide more consistent support across the floor pan  22 . Of course, as noted above, the invention is not limited to containers  10  having four sidewalls  20 .  
     [0036] In a further variation, it is not necessary that the proximal end  44  of the strut  42  be juxtaposed with the floor pan  22 . The strut  42  may be articulated about the top or a position juxtaposed with the aperture  26  of the container  10 . Alternatively, the container  10  may have a plurality of struts  42 . Some of the struts may be articulated about a proximal end  44  juxtaposed with the floor pan  22 , while other struts  42  articulate about a proximal end  44  juxtaposed with the top of the container  10 , and still other struts  42  articulate about an intermediate position. All such variations are contemplated and within the scope of the appended claims.