Patent Publication Number: US-4093101-A

Title: Partitioned plastic case

Description:
BACKGROUND OF THE INVENTION 
     This invention relates to a plastic case for holding beverage containers such as soft drink containers and the like. It relates more particularly to a case of this type having partitions which are removable and replaceable selectively to permit the case to accommodate the various bottle pack configurations presently in use. 
     Plastic cases are used to protectively enclose frangible containers when they are being transported from the bottler to the supermarket or other point of retail sale. Such cases are made of a suitable impact resistent plastic such as high density polyethylene and they are rugged so that they can be returned to the bottler and be reused a number of times. 
     The dimensions of such plastic cases depend upon the size and number of bottles which the particular case is intended to accommodate. A typical case may have room for twelve quart size bottles. Another case might be sized to contain six 2-liter bottles. Although there are some cases that do not have any interior partitioning, it is generally advisable to provide partitioning within the case in order to separate the individual bottles so that they cannot impact against one another during handling. Thus many present day cases have partitioning that divides the case interior into equal-size compartments for accommodating, say, twelve quart bottles or six 2-liter bottles. Usually the partitions are formed integrally with the case during a single molding operation. 
     Such cases do accommodate and protect individual bottles quite nicely. However there has been a growing tendency to merchandise soft drinks in multiple-pack containers. In other words, the bottler might group two 2-liter bottles together in a plastic or fibreboard carton or wrap to form a &#34;two-pack&#34;. Alternatively the bottler may wish to distribute a group of four such bottles as a four pack. Of course, all the while the bottler wants to retain the option of distributing individual bottles. It is apparent then that the merchandizing of beverage containers in different pack configurations raises certain handling and transportation problems. 
     More particularly, the containers must be transported in plastic cases whose interior partitioning is compatible with the pack configuration of the bottles in that case. For example, if the above described six-bottle case is to accommodate two single bottles and one four pack, one transverse partition and two-thirds of the longitudinal partition must be removed from the case in order for it to receive the four pack. On the other hand, in order to accommodate four single bottles and one two-pack, one-third of the longitudinal partition must be omitted. 
     The problem is made more difficult because the bottler never knows which pack configuration will prove popular at any given time in any given area. Resultantly he must maintain an inventory of cases having different interior partitioning configurations to accommodate the various container packs described above. Needless to say, this greatly increases the bottler&#39;s warehousing and distribution costs. To avoid these problems the bottler may opt to provide no partitioning at all in any case. In that event, however, the cases do not adequately protect individual bottles which are now free to impact against one another during handling. 
     Some attempts have been made to provide cases with removable and replaceable partition structure. However, they have not proven to be practical in use. Invariably the partitions are formed separately from the case per se, greatly increasing the molding costs and making the case more expensive to produce. Further, many of these prior cases require special clips and fasteners to reanchor the partitions to the case bottom. These are not only difficult to manipulate but also they are frequently lost. Such prior cases are shown, for example, in U.S. Pat. Nos. 3,200,988, 3,055,531 and 3,353,704. 
     Prior cases are disadvantaged also because they are difficult to arrange in an eye-pleasing array for display and distribution purposes at the point of sale. Consequently the prior practice has been to remove the bottles from the cases and to place them on shelves or racks in the store which practice further increases handling costs and the incidence of breakage. 
     SUMMARY OF THE INVENTION 
     Accordingly the present invention aims to provide a partitioned plastic case which can accommodate a variety of bottle pack configurations. 
     Another object of the invention is to provide a plastic case which protectively encloses individual containers as well as multiple container packs. 
     A further object of the invention is to provide plastic case partitioning which is not only removable, but replaceable in different partition configurations. 
     Yet another object of the invention is to provide a plastic case having removable and replaceable partitioning which is formed in situ with the case in a single molding operation. 
     A further object of the invention is to provide a plastic case with removable and replaceable interior partitioning that can be disconnected and then reconnected to the case bottom wall without any additional fasteners or fixtures. 
     Another object of the invention is to provide a partitioned plastic case which is shaped and arranged to be positioned in a rack for display and dispensing purposes. 
     Other objects will, in part, be obvious and will, in part, appear hereinafter. The invention accordingly comprises the features of construction, combination of elements and arrangement of parts as exemplified in the following detailed description and the scope of the invention will be indicated in the claims. 
     Briefly my case is generally rectangular and is made of a suitably rugged, impact resistent plastic such as high density polyethylene. The space inside the case is subdivided by longitudinal and transverse partitions and these partitions are formed in situ with the case in a single molding operation. The specific dimensions of the case and the number and placement of the partitions depend upon the size and number of containers to be placed in the case. For example, there are cases which hold twenty-four 61/2 to 16-ounce bottles. In most cases, the partitions are arranged to form four rows of six compartments each. There are other cases designed to hold twelve quart bottles, their partitions being positioned to form three rows of four compartments each. Still other cases have interior partitions arranged to form two rows of three compartments each, sized to contain six 2-liter bottles. 
     The case has the usual rectangular side and end walls joined together at the corners of the case and interconnected by an integral grid-like bottom wall that is customarily used in such cases to save material and assure adequate drainage from the case. Also, appropriate handles are formed in the end walls of the case to facilitate carrying the case and its contents. Further, integral, upstanding box girders are molded into the corners of the case to strengthen the case and make it more resistent to racking. The lower ends of the box girders are spaced above the bottom of the case and are open so that the case can be retained in a special beverage display and dispensing rack to be described in detail later. 
     The subject case has unusual versatility in that its interior partitions can be removed selectively and even replaced selectively so that the case can accommodate beverage containers arranged singly or in the various different pack configurations in use. For illustrative purposes we will describe the invention in the context of a case capable of accommodating six 2-liter bottles arranged in two rows of three bottles each. In other words, the case has a single longitudinal partition and a pair of spaced-apart transverse partitions dividing the case into six equal compartments. It is customary for bottlers to distribute bottles of this size individually, as well as in a pack consisting of two such bottles retained side by side by a plastic or fibreboard carton or wrap. They may also distribute 2-liter bottles in a four pack consisting of two rows of two bottles each. 
     The present case, as a result of its special, removable and replaceable partitioning, is able to accommodate any combination of individual bottles or packs totalling six bottles. In other words, the partitions in the present case can be arranged so that the case can hold six individual bottles or two individual bottles and a four pack or four individual bottles and a two pack or one four pack and one two pack, etc. As a consequence, a single case is able to satisfy the entire needs of the bottler distributing 2-liter containers; he need no longer maintain inventories of different cases that are only capable of accommodating a single container pack arrangement. Yet the present partitioned case can be molded in one piece in a single molding operation. Therefore the cost of making the case is kept to a minimum. 
     The partitions are able to be molded integrally with the remainder of the case, yet are removable and replaceable without requiring any special fasteners or fixtures because of the special structure connecting the bottom edges of the partitions to the case bottom wall during the molding operation. More particularly, each connection between a partition and the bottom wall is comprised of a narrow tab projecting down from the bottom of the partition through an opening in the case bottom wall. The lower end of the tab is connected to opposite side edges of that opening by way of upwardly-outwardly oriented webs. In cross-section then, the tab and webs are shaped more or less like a downwardly pointing arrow. Directly below the points of connection of the webs to the bottom wall are formed a pair of flat coplanar projecting surfaces for reasons to be described presently. 
     During the molding operation, the partitions are also formed with connections to the case side and end walls and to each other near the tops of the partitions. Each connection of a partition to the case comprises a laterally extending tab having a pair of closely spaced-apart, vertically oriented, elongated ribs adjacent the case wall. The connections between the longitudinal partition and the transverse partitions comprise lateral tabs molded integrally with the longitudinal partition on each side of a transverse partition with each tab having a similar rib spaced slightly away from the corresponding transverse partition. 
     Altering the fully partitioned, six compartment case to accommodate different pack configurations involves breaking the connections between the partitions themselves and between partitions and the case walls. More particularly, the connections to the case side and end walls are broken by vertically sawing or cutting the tab connecting those parts at a location between the ribs. Likewise, the connections between the partitions are severed by sawing or cutting their connecting tabs at a location between the rib and the adjacent transverse partition. Finally, the partitions are separated from the case bottom wall by cutting and sawing the connector webs right at the boundary or junction of those webs with the case bottom wall. Thus by severing the appropriate tabs and webs, one may remove one-third of the longitudinal partition so that the case can contain four individual bottles and one two-pack. Alternatively, two-thirds of the longitudinal partition and one transverse partition can be removed so that the case can accommodate one four pack and two individual bottles. As a further example, all of the partitions can be removed so that the case can accommodate one four-pack and one two-pack or three two-packs. 
     Under certain circumstances, it may be desirable to replace some or all of the previously removed partitions to enable the case to accommodate more individual bottles. In this event, one or more of the partitions are replaced in the case at their original locations. The oblique webs, still attached to the tabs at the bottoms of the partitions, are forced downwards until their ends engage under the projecting surfaces just below the original connection of the webs to the case bottom wall. The webs are somewhat resilient so that they tend to resume their original orientation and actually pull the replaced partitions down against the case bottom wall and thus firmly anchor them in place. 
     Reconnection of the ends of the partitions to each other and to the case side and end walls may be accomplished, if desired, by means of metal or plastic clips engaging over the ribs still present at the ends of the severed partition structure and at the original connecting locations on the case walls and the remaining transverse partition. Actually, the reconnection of the partitions to the case bottom wall is all that is required to firmly reanchor the partitions. The reconnection to the case side and end walls is only done to preserve the vertical orientation of the partitions. 
     Of course once the partition structure has been replaced, the case can be modified further to accommodate different pack arrangements by removing or replacing appropriate partitions in the same manner described above. 
     Thus the ability to mold the partitions and case walls together using a single pair of male and female dies in a single molding operation minimizes the cost of making the subject case. Further, the fact that the partition structure can be removed and then subsequently reconnected to the case bottom wall without using any special fasteners or fixtures means that the same case can be modified readily to accommodate a variety of different container pack configurations. This results in further economies for the bottler who is not longer required to inventory a number of differently-partitioned cases to suit his changing marketing requirements. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     For a fuller understanding of the nature and objects of the invention, reference should be had to the following detailed description taken in connection with the accompanying drawings, in which 
     FIG. 1 is a perspective view of a plastic case having removable, replaceable partitions, made in accordance with this invention; 
     FIGS. 2A to 2C are top plan views of the FIG. 1 case on a smaller scale illustrating different possible partition arrangements; 
     FIG. 3 is a fragmentary sectional view on a much larger scale illustrating the partition-connecting structure in greater detail; 
     FIG. 3A is a sectional view of a partition section along line 3a--3a of FIG. 3 on a still larger scale; 
     FIG. 3B is a similar view of the same partition section after removal and replacement of that section; 
     FIG. 4 is a perspective view of a rack designed to retain a plurality of the FIG. 1 cases for display and dispensing purposes, and 
     FIG. 5 is a diagrammatic view showing a modified connection between the partitions and the case side walls. 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Turning now to FIG. 1 of the drawings, the subject partitioned case shown generally at 10 is generally rectangular, being molded in a single molding operation of a suitable strong, impact resistent material. The case includes a generally rectangular outer shell shown generally at 11 consisting of a pair of identical side walls 12 and a pair of identical end walls 14 and a grid-like bottom wall 16 extending between the side and end walls. 
     Four identical box grinders 18 are formed at the corners of shell 11. Each box girder 18 is hollow as indicated in FIG. 1 and its lower end 18a is open. Box girders 18 strengthen the case and facilitate retaining it in a rack to be described later. A horizontal rib 22 extends between the box girders 18 at each end of the box which serves as a handle for the case. An appropriately shaped opening 24 is provided at each end wall 14 just below rib 22 to accommodate the fingers of the person carrying the case. Each end wall 14 also has a lip 14a extending all along its upper edge between box girders 18. Similar lips 12a extend along the top edges of the side walls 12. These lips 12a and 14a connected by the box girders 18 form a continuous rectangular hoop which rigidifies and strengthens the case and together with the box girders make it more resistent to racking. 
     Formed integrally with shell 11 during the same molding operation is an internal partition structure shown generally at 26. In the illustrated case embodiment, the structure divides the case into six equal compartments arranged in two rows of three compartments each. This is a typical partition configuration used when the case is designed to accommodate six individual 2-liter beverage containers. A case intended to hold a different number of or differently sized containers would have, of course, a different internal partition configuration. 
     The beverage containers project above the top of the case as illustrated in FIG. 4 so that one case can be stacked upon the crowns of the containers in an underlying case as is commonly done in the industry. 
     The partition structure 26 comprises a single longitudinal partition 28 that extends between the case end walls 14 midway across the case. The longitudinal partition is divided into three sections 28a, 28b and 28c by two transverse partitions 32 that extend between the case side walls 12 at equally spaced locations from the case end walls 14. Each of these partitions is composed of sections 32a and 32b on opposite sides of partition 28. The partitions 28 and 32 are all molded in situ within shell 11 at the same time the shell 11 is formed so that they are integral with each other and with the walls of shell 11. 
     When the plastic in the newly formed case sets following the actual molding operation, it may undergo some shrinkage. The partitions 28 and 32 being relatively thin tend to set first. Then when the shell 11 cools and contracts, it tends to cause the partitions 28 and 32 to become bowed or warped. To avoid this problem, a series of relatively small, vertical slots 34 may be formed at the tops of the partitions 28 and 32 near where those partitions intersect to permit lengthwise compression of the partitions when shell 11 contracts. 
     Referring now for a moment to FIG. 4, the cases 10 are particularly adapted to be retained in a storage and display rack indicated generally at 40. Rack 40 comprises four upstanding standards 42 in the form of angle irons which project up from a rectangular base 44. The tops of standards 42 are interconnected by sheet metal straps 46 to form a generally rectangular parallelopiped. 
     A series of vertically spaced pairs of rails 48 and 52 extend between the front and rear standards 42 at opposite sides of rack 40. The ends of the rails 48 and 52 are connected to the standards by any suitable means such as by welds or bolts. Rails 48 and 52 are also angle irons and they are oriented so as to have legs 48a, 52a projecting inward from standards 42 to form a pair of tracks. The rear end portion of each of these legs is cut or separated from its adjacent vertical leg and is bent upwardly forming an upstanding tab 54. Each pair of rails 48 and 52 is intended to support a single case 10 horizontally or inclined relative to the ground. 
     To place a case 10 in the rack, the case is set on the rails so that the rail legs 48a and 52a engage under the lower ends of the box girders 18 on the case. The case is slid rearwardly on the rails until the rearmost and wall 14 engages tabs 54. Then the rear end of the case is lifted up slightly and shifted back so that the tabs 54 project into the lower ends of the box girders 18 at the rear of the rack. There is sufficient clearance between the edge of each tab 54 and the adjacent vertical rail leg to accommodate the thickness of the box girder wall. The engagement of the case over the tabs prevents the case from being inadvertently knocked or pulled out of the rack 40. 
     The illustrated rack 40 is able to accommodate three cases 10. Obviously the same principles can be utilized to build taller racks or side-by-side racks to accommodate a large number of cases. Adequate space should be left between the adjacent pairs of rails 48 and 52 to permit the contents of the cases to be seen and be removed easily by the purchasers. Of course when a case is emptied, it is easily removed from the rack and replaced by disengaging it from tabs 54 and sliding it forwardly on the rails. 
     In accordance with this invention, the partition structure 26 in the FIG. 1 case, which is designed to accommodate six individual bottles, can be altered as in FIG. 2A so that the case can accommodate four individual bottles and a two-pack or as in FIG. 2B to permit the case to hold one four-pack and one two-pack or as shown in FIG. 2C to allow the case to hold two individual bottles and one four-pack, or so the case can accommodate other pack configurations totalling six bottles. Furthermore, this can be accomplished without requiring any special fixtures or fasteners to reconnect the partitions to the case bottom wall. 
     Referring to FIG. 3, each partition section is anchored to the case bottom wall 16 by a specially-shaped, molded in situ connection shown generally at 70. More particularly, each such connection 70 includes a relatively narrow rectangular tab 72 projecting from the bottom edge of the partition section, e.g. section 28a in FIG. 3. The tab 72 extends down through a rectangular opening 74 forward in the grid-like case bottom wall 16. The lower edge of tab 72 is connected to the spaced-apart, parallel bottom wall ribs 16a and 16b defining opening 74 by means of a pair of similar webs 76a and 76b extending in opposite directions from the lower edge of tab 72 upwardly and outwardly to the top edges of ribs 16a, 16b respectively. Thus the tab 72 and webs 76a, 76b in cross-section have the general shape of a downwardly pointing arrow as best seen in 3A. 
     Still referring to FIG. 3A, the bottom wall ribs 16a and 16b are also formed with flat horizontal surfaces 78a and 78b projecting toward one another just below the boundaries or junctions 77 between the webs 76a, 76b and their respective ribs. These projecting surfaces 78a and 78b cooperate with the webs to reconnect the partition sections to the case bottom wall as will be described later. There may also be other connections between the partitions and the case bottom wall that may be permanently severed when a partition is removed. It is important to appreciate at this point, however, that the connections between the partitions and the case bottom wall are specifically designed so that the entire partitioned case can be formed with a single pair of male and female dies in a single molding operation and so that the molded case can be removed easily from the dies. In other words, tab 72 and webs 76a and 76b and the case bottom wall ribs 16a and 16b are all formed at the same time by a male die portion projecting into a female die portion and these die portions can be separated easily after the plastic sets leaving the finished partition-case bottom wall connection 70. 
     Referring now to FIGS. 1 and 3, all the partition sections except section 28b are also connected at 80 to the case side and end walls 12, 14. These connections are substantially identical. FIG. 3 shows the connection 80 between section 32a and side wall 12 in detail. It comprises a laterally extending tab 82 that projects from the side edge of the partition section 32a near the top thereof and is joined to the inner face of the case wall 12. Each tab 82 is formed with a pair of vertical, spaced-apart elongated ribs 84 and 86 on each side of the tab adjacent the junction of the tab and the case wall. These ribs facilitate resecurement of the partition sections to the case walls as will be described later. 
     There are additional connections seen generally at 90 between the partition sections themselves. More particularly, the longitudinal partition sections 28a and 28b have laterally extending tabs 92 projecting toward and joined to the transverse partitions 32 at the tops thereof. One such connection 90 is detailed in FIG. 3. Each tab 92 is formed with a pair of vertically oriented elongated ribs 96 spaced somewhat from the adjacent transverse partition 32. These ribs also facilitate reconnection of the partition sections. 
     When it is desired to remove a partition section or an entire partition, this is accomplished by cutting one or another of the tabs 86, 92 and one or another of the pairs of webs 76a and 76b. Thus, for example, if it is desired to modify the partition structure in the FIGS. 1 and 3 case as in FIG. 2A to permit it to accommodate four single containers and a two-pack, the longitudinal partition section 28a is removed. This is accomplished by cutting or sawing tab 86 connecting section 28a to end wall 14. The cut is made between bosses 84 and 86 which provide a certain amount of guidance for the cut. Next, the tab 92 connecting section 28a to the transverse partition 32 is cut along a line between the transverse partition 32 and the adjacent pair of ribs 96. Finally, the webs 76a and 76b joining partition section 28a to the case bottom wall 16 are cut at junctions 77 of those webs with the bottom wall ribs 16a and 16b as best seen in FIG. 3A. Any other connections between 28a and wall 16 are also severed. Now the partition section 28a can be removed from the case shell 11 permitting a two pack to be inserted at the left hand end of case 10. 
     If for some reason it is now desired to replace the partition section 28a so that the same case can again accommodate six individual bottles, the partition section 28a is placed in its original position with its tab 72 projecting down into opening 74 in the case bottom wall. Then the webs 76a and 76b are pressed downward so that their free ends engage under the projecting surfaces 78a and 78b on ribs 16a and 16b respectively as shown in FIG. 3B. These webs are resilient so that they tend to resume their normal unstressed positions illustrated in FIG. 3A. Consequently they pull downward on tab 72 thereby securely reanchoring the partition section 28a to the case bottom wall 16. 
     This connection is quite sufficient to retain the partition section in the case shell 11. However to assure that the section is oriented properly within the case, the tabs 82 and 92 may, if desired, be reconnected to the case end wall 14 and transverse partition 32 respectively. This is accomplished by means of a metal or plastic clip 98 shown in FIG. 3 which is pressed down over the edge of the partition section and engages around bosses 84 and 86 to rejoin the tab 82 to the case end wall. FIG. 3 specifically shows the connection between the partition section 32a and the case side wall 12. However, the end wall connection is substantially the same. 
     A similar clip 98 is pressed down onto the tab 92 adjacent partition 32. The clip engages around the ribs 96 on opposite sides of partition 32 thereby reconnecting the partition section 28a at partition 32. It should be understood that while it is desirable to use the clips 98 to reconnect the sides of the partition sections, this is not absolutely necessary because the connections between the partitions sections and the case bottom wall suffice to securely anchor the sections to the bottom wall. 
     In the event that it again becomes necessary to remove the partition section 28a, the clips 98 can be removed and the webs 76a and 76b squeezed together as the partition section 28a is pressed toward the bottom of the case. This permits the ends of the webs 76a and 76b to be disengaged from under the projecting surfaces 78a and 78b, freeing the partition section. 
     A modified connection between the partitions and the case side wall is illustrated in FIG. 5. As shown there, a transverse partition section 32b is molded in situ between longitudinal partition 28 and the case side wall 12, the connection point to the inside of the wall being at 102. Flexible and resilient arms 104 and 106 molded as part of section 32b extend laterally from opposite sides of that section toward wall 12. These arms may be curved as shown or straight and their ends terminate in flexible and resilient barbs 104a and 106a respectively. Section 32b can be separated from the case wall 12 by a saw cut that separates the partition end 108 from connection point 102. Moreover, the partition section 32b can be reconnected to the side wall 12 by pressing the arms 104 and 106 together and forcing the barbs 104a and 106a into slots 110 and 112 formed in the wall 12 on opposite sides of connection point 102. The slots are made slightly undersized so that the barbs have to be flexed somewhat toward their respective arms in order to be squeezed through the slots. 
     Upon passing through the slots 110 and 112, the barbs 104a and 106a spring back to their unstressed positions thereby locking the arms in the wall 12. The tension in the arms thereupon draws the partition section end 108 against point 102 and holds it in that position even though the case is handled roughly in use. 
     It will thus be seen from the foregoing that various ones or all of the partition sections 28a, 28b and 28c and one or both of the transverse partitions 32 can be removed and replaced as desired to permit the case 10 to accommodate individual bottles, two-packs or a four-pack in any combination that will place a total of six bottles in the case. Accordingly the same case can be used in different areas requiring different container pack configurations. Furthermore, the various partition sections can be reanchored to the case bottom wall without requiring any special fixtures or fasteners that could become lost and are difficult to install. Yet the entire partitioned case can be formed in a single molding operation so that manufacturing costs are kept to a minimum. 
     It will thus be seen that the objects set forth above, among those made apparent from the preceding description, are efficiently attained and certain changes may be made in the above construction without departing from the scope of the invention. For example, the retaining tabs 54 in FIG. 3 can be located at the front ends of the rails 52 and engage in the box girders 18 at the front of the case. Also the rack 40 can be made two or three cases deep. Then inclining the rails relative to the ground would not only make the contents of the cases move visible, but also would make it easier to pull cases at each level of the rack forward as product is emptied out of the forwardmost case at each level. Further, the clips 98 (FIG. 3) can be modified so that they connect between the ribs 96 on the replaced partition section 28a and the partition 32 itself instead of the ribs 96 on the opposite side of that partition. Thus, it is intended that all matter contained in the above description or as shown in the accompanying drawings be interpreted as illustrative and not in a limiting sense. 
     It is also to be understood that the following claims are intended to cover all of the generic and specific features of the invention herein described.