Patent Publication Number: US-9403622-B2

Title: Multi-level stacking container

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application claims benefit of U.S. provisional application Ser. No. 61/901,824, filed on Nov. 8, 2013. All documents above are incorporated herein in their entirety by reference. 
    
    
     SUMMARY OF THE INVENTION 
     More specifically, in accordance with the present invention, there is provided a container comprising a base; a first and a second pairs of opposite sidewalls extending from the base to a lip, the lip running around the perimeter of the container and delimiting an upper collar, the upper collar having a height h from the lip to an upper rim of the container; a pair of bars operatively coupled to and extending across the first pair of opposite sidewalls; wherein each one of the first pair of opposite sidewalls comprises an outer wall and an inner wall separated by a recess; the inner wall comprises an upper supporting surface, a lower supporting surface and a nesting surface; the outer wall comprises a first opening located below the lip, and a second opening located between the upper rim of the container and the lip; wherein each bar comprises an elongated member and first and second lateral arms at each end of the elongated member at a generally perpendicular angle from the elongated member and forming an elbow, each arm comprising a pivot end opposite the elbow, the pivot end being received in the second opening; and wherein, the bars are movable between: i) a lower stacking bar position in which the lateral arms of the bar are rotated down in the recess between the outer wall and the inner wall, and the elbows rest on the lower supporting surface, ii) an upper stacking bar position in which the lateral arms are rotated up in the recess between the outer wall and the inner wall and the elbows rest on the upper supporting surface, and iii) a nesting position in which the lateral arms are rotated up in the recess between the outer wall and the inner wall and the elbows rest on the nesting surface. 
     There is further provided a method of manufacturing a container, comprising injection-molding a base, a first and a second pairs of opposite sidewalls extending from the base to a lip delimiting an upper collar having a height h from the lip to an upper rim of the container; each one of the first pair of opposite sidewalls comprising an outer wall and an inner wall separated by a recess; the inner wall comprising an upper supporting surface, a lower supporting surface and a nesting surface; the outer wall comprising a first opening located below the lip, and a second opening located between the upper rim of the container and the lip; providing a pair of bars, each comprising comprises an elongated member and first and second lateral arms at each end of the elongated member at a generally perpendicular angle from the elongated member and forming an elbow, each arm comprising a pivot end opposite the elbow; and positioning the bars across the first pair of opposite sidewalls, each pivot end of a bar being received in the second opening across the first pair of opposite sidewalls; wherein, the bars are movable between: i) a lower stacking bar position in which the lateral arms of the bar are rotated down in the recess between the outer wall and the inner wall, and the elbows rest on the lower supporting surface, ii) an upper stacking bar position in which the lateral arms are rotated up in the recess between the outer wall and the inner wall and the elbows rest on the upper supporting surface, iii) and a nesting position in which the lateral arms are rotated up in the recess between the outer wall and the inner wall and the elbows rest on the nesting surface. 
     Other objects, advantages and features of the present invention will become more apparent upon reading of the following non-restrictive description of specific embodiments thereof, given by way of example only with reference to the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       In the appended drawings: 
         FIG. 1  is a perspective view of a container according to an embodiment of an aspect of the present invention; 
         FIG. 2  is a detail of an inside view of the container of  FIG. 1  with a support bar in a lower position; 
         FIG. 3  is a detail of an outside view of the container of  FIG. 1  with the support bar in tan lower position; 
         FIG. 4  is a detail of an inside view of the container of  FIG. 1  with the support bar in an upper position; 
         FIG. 5  is a detail of an outside view of the container of  FIG. 1  with the support bar in an upper position; 
         FIG. 6  is a perspective view of a support bar according to an embodiment of an aspect of the present invention; 
         FIG. 7  shows nested containers; and 
         FIG. 8  is a detail of an inside view of a container according to an embodiment of an aspect of the present invention, showing the support bar in the lower position, in the upper position and in the nesting position. 
     
    
    
     DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS 
     The present invention is illustrated in further details by the following non-limiting examples. 
     As illustrated in  FIG. 1 , a container  10  according to an embodiment of an aspect of the present invention comprises a base  12 , a pair of opposed sidewalls  1416  and  1820  extending from the base  12 , and a pair of moveable support bars  22 ,  24  operatively coupled to and extending across the pair of opposed sidewalls  1416  for example, each support bar  22 ,  24  being moveable between two stacking positions such that the container  10  is stackable in two positions (see positions S supper  and S lower  in  FIG. 8 ), according to the volume content of the container, with a second, like or compatible, container (see  FIG. 7 ) when the containers are full; as well as a nesting position (see position S nesting  in  FIG. 8 ) for stacking empty containers, as will be described hereinbelow. 
     Each one of the sidewalls  14 ,  16 ,  18 ,  20  projects from the edges of the base  12  at an obtuse angle (see angle α,  FIG. 7  for example). Such geometry permits nesting a first container  10  into a similar (like or compatible) second container when the second-bottom-container is empty. 
     The base  12  and the sidewalls  14 ,  16 ,  18 ,  20  may be injection-molded in high-density polyethylene or polypropylene for example. The support bars  22 ,  24  may be made in metal, such as stainless steel for example, in plastic, such as thermoplastic for example, or they may be hybrid, such as metallic with plastic molded pivot ends for example. 
     As best seen in  FIG. 1 , each one of sidewalls  14 ,  16  comprises a first outer notch  36 , proximal a lateral edge  28  thereof, and a first inner notch  38 , laterally spaced from the first outer notch  36  away from the lateral edge  28 , and a second outer notch  40  proximal the opposite lateral edge  30  and a second inner notch  42  laterally spaced from the second outer notch  40  away from the lateral edge  30 , on the basal edge  32  of the sidewall  14 ,  16 . These notches  38 ,  36  and  40 ,  42  receive the support bars  22 ,  24  respectively of a second similar container when stacked as known in the art. The outer notches  36 ,  40  are used for stacking containers with the bars in the upper position (see position S upper  in  FIG. 8 ), while the inner notches  38 ,  42  are used for stacking containers with the bars in the lower position (see position S lower  in  FIG. 8 ). 
     A nesting lip  46  runs around the perimeter of the container  10 , delimiting an upper collar  460  of a height h from the upper edge of the container  10 , as best seen in  FIG. 3 . The lip  46  extends peripherally from the outer surface of the sidewalls  14 ,  16 ,  18 , and  20  substantially parallel to their respective upper rim along the length of the sidewalls. This lip  46  rests or is supported on the upper rims of a second, empty, bottom container when the container  10  is nested therein. 
     As best seen in  FIGS. 2 and 4 , each sidewall  14 ,  16 , at a region close to the junction with the sidewalls  18 ,  20 , is formed of an outer wall  260  and an inner well  300  separated by an empty space or recess. The outer wall  260  is of the same height as the height of the sidewall  14 ,  16  from the base  12  to the upper rim  34  of the sidewall  14 ,  16 , whereas the inner well  300  has a lower, varying height from the base  12 , thereby forming an inner rim  340  comprising an upper supporting surface  342 , a lower supporting surface  344  and a nesting surface  345 , allowing respectively the positions S upper , S lower  and S nesting  of the support bars  22 ,  24  as shown in phantom lines  FIG. 8 ). 
     The inner wall  300  is reinforced with a structure of structural ribs  360 , which is selected for a loaded bar  22 ,  24 , as will be described hereinbelow in relation to  FIGS. 4 and 5 . 
     A best seen in  FIGS. 3 and 5 , the outer wall  260  comprises a first opening  50  located below the lip  46 , and a second opening  60  located between the upper rim  34  and the lip  46 . The perimeter of the first opening  50  is reinforced with ribs  110  to support the bar  22 ,  24  in the lower position as will be described hereinbelow in relation to  FIGS. 2 and 3 . The inner wall  300  is reinforced by the internal ribs  360  structure under the second opening  60  described hereinabove, and best seen on  FIG. 2 . 
     Such combination allows that the nesting collar  460  has a reduced height h, for example of 1.7″, as opposed to a height H of 2¼″ or 2½″ as known in the art (see  FIG. 7 ). Moreover, the nesting collar  460  has a constant height h around the perimeter of the container  10 , and is devoid of grooves which result in weakening the load resistance of standard containers (C) when stacked (see groove (G) in collar of standard container (C) in  FIG. 7 ). 
     In  FIG. 6 , the bar  22 ,  24  is shown as an elongated member  210 , with first and second lateral arms  220 ,  240  at each end of the elongated member  210  at a generally perpendicular angle from the elongated member  210 , forming elbows  222 ,  224 . Each arm  220 ,  240  comprises a pivot end  226 ,  228  opposite the elbows  222 ,  224 . As shown for example in  FIGS. 6 and 8 , stops  223  protruding from the elongated member  210  may be provided to prevent translations of stacked containers along the direction of the bars. 
     The pivot ends  226 ,  228  are received in the opening  60  located between the upper rim  34  and the lip  46  of respective opposite was  14 ,  16  shown in  FIG. 3  for example. 
     In a lower stacking bar position as shown in  FIG. 2, 3 or 8 , the arms  220 ,  240  of the bar  22 ,  24  are rotated down in the recess between the outer wall  260  and the inner wall  300 , and the elbows  222 ,  224  of the support bar  22 ,  24  are received by the first opening  50  and rest on the lower supporting surface  344  of the inner rim  340 . The load of containers stacked above is thus distributed on the upper surface of the bars and on the lower supporting surface  344 . 
     In an upper stacking bar position shown in  FIG. 4, 5 or 8 , the arms  220 ,  240  of the bar  22 ,  24  are rotated up in the recess between the outer wall  260  and the inner wall  300  and the elbows  222 ,  224  rest on the upper supporting surface  342  of the inner rim  340 . In this upper stacking bar position, the load of containers stacked above is thus distributed on the upper surface of the bars, on the upper supporting surface  342  and on the internal ribs  360  structure below and about the opening  60 , resulting in an increased load resistance. 
     The double wall structure  260 ,  300  thus provides an increased load resistance as compared to containers (C) as show for example in  FIG. 7 . 
     The double wall structure  260 ,  300  allows accommodating the lateral arms of the bars so that the lateral arms and the elbows of the bars do not protrude on the outside of the containers as opposed to bar (B) of container (C) (see  FIG. 7 ). Moreover, the double wall structure provides an increased resistance to load, the pivot end  226 ,  228  partially supporting the load when containers are stacked in the upper position. 
     As shown in  FIG. 7  (nesting positions), the present container allows a more efficient nesting than standard containers (C), by providing a shorter nesting collar  460  (h lower than H): the shorter nesting collar  460  allows a lower nesting height when empty containers are stacked. 
     The scope of the claims should not be limited by the embodiments set forth in the examples, but should be given the broadest interpretation consistent with the description as a whole.