Abstract:
The present invention provides a container for holding product therein during shipment, storage, or display and being returned for reuse. The container has a base and perpendicular side walls. The side walls are not attached to each other. The base and side walls are adapted, individually or in combination, to flex so that a second container can be nested within a first container. When the second container is placed within the first container, a portion of the base and the side walls of the first container form an obtuse angle. The base and the side walls are biased to form a right angle before the second container is nested within the first and after the second container is unstacked from the first container.

Description:
FIELD OF THE INVENTION  
       [0001]     The present invention relates to containers for use in shipping, storing, and/or displaying product, and more particularly, to containers or trays that can be nestably stacked together.  
       BACKGROUND OF THE INVENTION  
       [0002]     A large number of different container structures are utilized by manufacturers to ship a variety of different products to end users, which may be wholesale or retail customers. These containers may also be used to store and/or display products. Many of these boxes, trays, or like container carriers have perpendicular side walls in order to efficiently and effectively utilize the internal volume of the container for storing or displaying a product while at the same time minimizing the space needed to store or transport the containers. Additionally, many of these containers are made out of a rigid or semi-rigid material such as plastic to further the transport, support, or display of a product. However, these containers, even those with an open top, e.g., tray-like containers, have the disadvantage of not being able to be compactly stored when not in use. Empty containers that cannot be compactly stored for reuse take up valuable warehouse or storage space and also increase shipping costs as they require more space in a vehicle while being returned for reuse.  
         [0003]     One style of container that does allow for compact storage when not in use is one that has its side walls obtusely angled out from its bottom or base wall. This style of a container allows empty containers to be nested or stacked together in a relatively compact fashion. However, for some products, these style of containers have the disadvantage of wasting internal space within the container and not allowing for the effective display or storage of products. For example, for some products, space within the container, particularly near the top of the container, is wasted due to the angling out of the side walls. Additionally, when these style containers are placed next to one another for shipping or storage, space between the containers, particularly at the bottom of the container is wasted due again to the angling out of the side walls. Hence, shipping and storage costs are increased.  
         [0004]     Another style of containers have employed a collapsible method for achieving compact storage when not in use, but these types of boxes have the disadvantage of being required to be assembled or de-assembled before or after use, and may also lack other advantageous properties such as the rigidity of a plastic-like material which may be lacking in a cardboard-style container.  
         [0005]     Accordingly, there is a need for a container with generally perpendicular side walls for shipping, storing, and/or displaying a product that also allows for the compact storing or nesting of the containers or trays when not in use. There is further a need for a method to produce such a stackable container.  
       SUMMARY OF THE INVENTION  
       [0006]     The present invention provides a container or tray for holding product therein during shipment, storage, and/or display and being returned for reuse. Specifically, the container has a generally rectangular base and side walls which are normally perpendicular to the base. The side walls are not attached to each other so that the corners formed between the side walls are cutaway or open. A portion of the base is adapted to flex or pivot so that a second container can be stackably nested within a first container, thereby saving space for shipping or storage purposes. When the second container is placed within the first container, a central portion of the base and the side walls of the first container form an obtuse angle which allows the second container to be nested within the first. Moreover, the base and the side walls are biased, independently or in combination, to form a right angle between the base and the side walls both before the second container is nested within the first and after the second container is unstacked from the first container. In a preferred embodiment, the container is made out of a thermoplastic material which may be a polypropylene foam or any other suitable material. However, the material from which the container is made may vary. It is the inherent properties of the material from which the container is made which enable the side walls to spring back or return to their original positions after one or more inner trays or containers is/are removed from the interior of the outside container.  
         [0007]     In one embodiment, the base of the container or tray has a plurality of aligned openings therethrough positioned near the intersection of the side walls and the base, i.e., near the right angle formed between an outer portion of the base and the side walls. These openings, which may be any desired shape or configuration, facilitate the flexing or pivoting of the container side walls to allow multiple containers to be nested and stacked together.  
         [0008]     In another embodiment, the base of the container or tray has a plurality of aligned tabs formed by C-shaped cuts therethrough positioned near the intersection of the side walls and the base, i.e., near the right angle formed between an outer portion of the base and the side walls. These tabs, which may be any desired shape or configuration, facilitate the flexing or pivoting of the container sidewalls relative to a central portion of the base to allow multiple containers to be nested and stacked together.  
         [0009]     The present invention also provides for a stack of containers nestably stacked inside each other, each having a base and a plurality of side walls, which are not attached to each other, but which are integral with the base. The base and the side walls of at least one outer container form an obtuse angle allowing additional containers to be nested inside the outer container or containers. The base and the side walls, individually or in combination, are biased so that the container side walls form right angles with a central portion of the base before another container is nested inside the container and also after the containers are separated.  
         [0010]     The nestably stackable containers of the present invention can be formed by providing a blank and a heat source, heating the blank with the heat source along fold lines, bending the blank along the fold lines whereby side walls are formed perpendicular to the base and extending upwardly from the base. The base and side walls are then allowed to cool in their preferred orientation or position. In a preferred embodiment, a thermoplastic material is used to form the container which enables the container to return to its original position after being emptied of other containers. Additionally, a plurality of openings may be created in the base by removing material from select locations of the blank. Alternatively, a plurality of tabs may be created in the base by cutting the blank at select locations in predetermined shapes or configurations. The openings or tabs create hinges or pivot points about which the side walls hinge or pivot when another like container is nestably stacked therein.  
         [0011]     The present invention provides a box, container or tray which has side walls which are sturdy or strong enough to keep objects therein and which is also nestably stackable. The above and other objects and advantages of the present invention shall be made apparent from the accompanying drawings and the description thereof. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0012]     The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with a general description of the invention given above and the detailed description of the embodiments given below, serve to explain the principles of the invention.  
         [0013]      FIG. 1  is a perspective view of a preferred embodiment of the container of the present invention;  
         [0014]      FIG. 1A  is a cross-sectional view taken of line  1 A- 1 A of  FIG. 1 ;  
         [0015]      FIG. 1B  is a cross-sectional view of a portion of a stack of containers shown in  FIGS. 1 and 1 A;  
         [0016]      FIG. 2  is a perspective view of another embodiment of container in accordance with the present invention;  
         [0017]      FIG. 2A  is a cross-sectional view taken of line  2 A- 2 A of  FIG. 2 .;  
         [0018]      FIG. 2B  is a cross-sectional view of a portion of the container shown in  FIGS. 2 and 2 A being flexed when additional like containers are nested within it;  
         [0019]      FIG. 3  is a perspective view of another embodiment of container in accordance with the present invention;  
         [0020]      FIG. 3A  is a cross-sectional view taken of line  3 A- 3 A of  FIG. 3 ;  
         [0021]      FIG. 3B  is a cross-sectional view of a portion of the container shown in  FIGS. 3 and 3 A being flexed when additional like containers are nested within it;  
         [0022]      FIG. 4  is a perspective view of a flat blank used to form the container shown in  FIGS. 2 and 2 A before the side walls are bent into position;  
         [0023]      FIG. 4A  is a perspective view of another blank used to form the container shown in  FIGS. 2 and 2 A before its side walls are bent into position;  
         [0024]      FIG. 4B  is a perspective view of another blank used to form the container shown in  FIGS. 3 and 3 A before its side walls are bent into position;  
         [0025]      FIG. 5  is a perspective view showing the blank shown in  FIG. 4  positioned over a heat source; and  
         [0026]      FIG. 6  is a perspective view of the tray shown in  FIGS. 1 and 1 A, showing a first side wall being bent into position.  
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0027]     Referring to  FIG. 1 , there is illustrated a container or tray  10  according to one embodiment of the present invention. The container  10  comprises a base  12  and a plurality of side walls  14 ,  16 ,  18  and  20 , all extending upwardly from the perimeter of the base  12  and being perpendicular to the base  12 . The base  12  and side walls  14 ,  16 ,  18  and  20  define an interior  21  of the container  10  for storing or displaying products or items (not shown). The side walls  14 ,  16 ,  18 ,  20  each are illustrated with at least one aperture or hole  22  which may be used as handles for transporting the container  10 . If desired, the handles may be omitted on one or more side walls. Alternatively, any number of handles of any shape or configuration may be incorporated into the container  10 .  
         [0028]     As shown in  FIG. 1A , the side walls,  14 ,  16 ,  18  and  20  are not attached to each other. Hence, the container  10  has open or cutaway corners  24 . Although one configuration or shape of openings at the corners  24  is illustrated, the open corners  24  may be other sizes or shapes. The side walls  14 ,  16 ,  18  and  20  are connected to the base  12  at a fold line  27  and form a right angle  28  with the base member  12 . See  FIGS. 1 and 1 A. The side walls  14 ,  16 ,  18  and  20  have upper edges  30 ,  32 ,  34  and  36 , respectively. Although the upper edges of the side walls are illustrated as being co-planar due to the side walls being the same height, the side walls may be different heights if desired, in which case the upper edges of the side walls would not be co-planar. This may be the case in any of the embodiments described herein.  
         [0029]     As shown in  FIG. 1B , when a second container  11  like the container  10 , having a base  13  and sidewalls  15  is nested inside the interior  21  of the outer container  10 , the side walls  14 ,  16 ,  18  and  20  of the outer container  10  flex outward about a flex or pivot point  26  located along base  12 . See  FIG. 1B .  FIG. 1B  also shows a third tray or container  17  having a base  19  and sidewalls  23  nested or nestably stacked within the second container  11 . The second and third containers  11  and  17  are shown in  FIG. 1B  in dashed lines. Due, at least in part to the inherent nature of the thermoplastic material from which the container  10  is made, the side walls  14 ,  16 ,  18 ,  20  of the container  10  return to their position shown in  FIG. 1A  after the containers  11  and  17  are taken out or removed from the interior  21  of the container  10 . Although two containers  11  and  17  are shown nestably stacked inside container  10 , any number of containers may be nestably stacked together to save space during shipping and/or storage.  
         [0030]      FIG. 2  shows an alternative embodiment of the present invention. In this embodiment, like parts will be described with like numbers to those described above but with an “a” designation after the number. In this embodiment, container  10   a  comprises a base  12   a  and a plurality of side walls  14   a ,  16   a ,  18   a  and  20   a , all extending upwardly from the perimeter of the base  12   a  and being perpendicular to the base  12   a . The base  12   a  and side walls  14   a ,  16   a ,  18   a  and  20   a  define an interior  21   a  of the container  10   a  for storing or displaying products or items (not shown). The side walls  14   a ,  16   a ,  18   a ,  20   a  each are illustrated with at least one aperture or hole  22   a  used as handles for transporting the container  10   a . If desired, the handles may be omitted on one or more side walls. Alternatively, any number of handles of any shape or configuration may be incorporated into the container  10   a.    
         [0031]     As shown in  FIG. 2 , the side walls  14   a ,  16   a ,  18   a  and  20   a  are not attached to each other. Hence, the container  10   a  has open or cutaway corners  24   a . Although one configuration or shape of openings at the corners  24   a  is illustrated, the open corners  24   a  may be other sizes or shapes. The side walls  14   a ,  16   a ,  18   a , and  20   a  are connected to the base  12   a  along a fold line  27   a  and each side wall forms a right angle  28   a  with the base  12   a . See  FIGS. 2 and 2 A. The side walls  14   a ,  16   a ,  18   a  and  20   a  have upper edges  30   a ,  32   a ,  34   a  and  36   a , respectively.  
         [0032]     The base  12   a  of the container  10   a  shown in  FIGS. 2, 2A  and  2 B has a plurality of aligned tabs  40  formed by C-shaped cuts  42  through the base  12   a . The tabs  40  are located generally near the intersection between the base  12   a  and the side walls  14   a ,  16   a ,  18   a  and  20   a . Although the tabs  40  are illustrated as being in a generally C-shape and a particular size, the shape and size of the tabs  40  may be different than as is shown. These tabs  40 , as shown in  FIG. 2B , provide a pivot point, further facilitate the flexing of the side walls of the container  10   a  to allow multiple containers to be nested and stacked together.  
         [0033]     As shown in  FIG. 2B , when a second container  11   a  like the container  10   a , having a base  13   a  and sidewalls  15   a  is nested inside the interior  21   a  of the outer container  10   a , the side walls  14   a ,  16   a ,  18   a  and  20   a  of the outer container  10   a  flex outward about a flex or pivot point  26   a  along the base  12   a . See  FIG. 2B . Due, at least in part due to the position of the tabs  40 , an outer portion  44  of the base  12   a , along with the side walls flexes or pivots about a pivot point  19   a .  FIG. 2B  also shows a third tray or container  17   a  having a base  19   a  and sidewalls  23   a  nested or nestably stacked within the second container  11   a . The second and third containers  11   a  and  17   a  are shown in  FIG. 2B  in dashed lines. Due, at least in part to the inherent nature of the thermoplastic material from which the container  10  is made, the side walls  14   a ,  16   a ,  18   a  and  20   a  of the container  10   a  return to their position shown in  FIG. 2A  after the containers  11   a  and  17   a  are taken out or removed from the interior  21   a  of the container  10   a . Although two containers  11   a  and  17   a  are shown nestably stacked inside container  10   a , any number of containers may be nestably stacked together to save space during shipping and/or storage.  
         [0034]      FIG. 3  shows yet another embodiment of the present invention. In this embodiment, like parts will be described with like numbers to those described above but with an “b” designation after the number. In this embodiment, container  10   b  comprises a base  12   b  and a plurality of side walls  14   b ,  16   b ,  18   b  and  20   b , all extending upwardly from the perimeter of the base  12   b  and being perpendicular to the base  12   b . The base  12   b  and side walls  14   b ,  16   b ,  18   b  and  20   b  define an interior  21   b  of the container  10   b  for storing or displaying products or items (not shown). The side walls  14   b ,  16   b ,  18   b ,  20   b  each are illustrated with at least one aperture or hole  22   b  used as handles for transporting the container  10   b . Of course, the handles may be omitted on any side wall, if desired. Alternatively, any number of handles of any shape or configuration may be incorporated into the container  10   b.    
         [0035]     As shown in  FIG. 3 , the side walls  14   b ,  16   b ,  18   b  and  20   b  are not attached to each other. Hence, the container  10   b  has open or cutaway corners  24   b . Although one configuration or shape of openings at the corners  24   b  is illustrated, the open corners  24   b  may be other sizes or shapes. The side walls  14   b ,  16   b ,  18   b , and  20   b  are connected to the base  12   b  along a fold line  27   b  and each side wall forms a right angle  28   b  with the base  12   b . See  FIGS. 3 and 3 A. The side walls  14   b ,  16   b ,  18   b  and  20   b  have upper edges  30   b ,  32   b ,  34   b  and  36   b , respectively.  
         [0036]     The base  12   b  of the container  10   b  shown in  FIGS. 3, 3A  and  3 B has a plurality of aligned generally rectangular openings  46  created by removing material from the base  12   b . The openings  46  are located generally near the intersection between the base  12   a  and the side walls  14   a ,  16   a ,  18   a  and  20   a . Although the openings  46  are illustrated as being a particular shape and a particular size, the shape and size of the openings  46  may be different than as is shown. These openings  46 , as shown in  FIG. 3B , provide a pivot point, further facilitate the flexing of the side walls of the container  10   a  to allow multiple containers to be nested and stacked together.  
         [0037]     As shown in  FIG. 3B , when a second container  11   b  like the container  10   b , having a base  13   b  and sidewalls  15   b  is nested inside the interior  21   b  of the outer container  10   b , the side walls  14   b ,  16   b ,  18   b  and  20   b  of the outer container  10   b  flex outward about a flex or pivot point  19   b  along the base  12   b . See  FIG. 3B . Due, at least in part due to the position of the openings  46 , an outer portion  48  of the base  12   b , along with the side walls flexes or pivots about a pivot point  26   b .  FIG. 3B  also shows a third tray or container  17   b  having a base  19   b  and sidewalls  23   b  nested or nestably stacked within the second container  11   b . The second and third containers  11   b  and  17   b  are shown in  FIG. 3B  in dashed lines. Due, at least in part to the inherent nature of the thermoplastic material from which the container  10   b  is made, the side walls  14   b ,  16   b ,  18   b  and  20   b  of the container  10   b  return to their position shown in  FIG. 3A  after the containers  11   b  and  17   b  are taken out or removed from the interior  21   b  of the container  10   b . Although two containers  11   b  and  17   b  are shown nestably stacked inside container  10   b , any number of containers may be nestably stacked together to save space during shipping and/or storage.  
         [0038]      FIGS. 4-6  illustrate the method of making container  10 . The first step in the method is providing a blank  50  die cut or otherwise formed from a flat piece of stock. Handles  22  may be cut from the blank  50 , if desired. In a preferred embodiment, the blank  50  is made of polypropylene foam. However, any like thermoplastic material could be used with the claimed process. Polyethylene is advantageous because it is a thermoplastic material which allows it to be heated, bent, and then retains its new shape when cooled. Polyethylene is a non-brittle thermoplastic which allows the container to have greater flexibility when multiple containers are nested together and it also has a surface temperature which is appropriate for many container applications.  
         [0039]     As shown in  FIG. 5 , the blank  50  is positioned over a heat source  52  which may be a wire, light source, or other like heating mechanism.  FIG. 5  illustrates a pair of heated wires  54  as the heat source  52 . The blank  50  and the heat source  52  are positioned so that the heat source  52  will heat the blank  50  along desired fold lines. Once the blank  50  is sufficiently heated, as shown in  FIG. 5 , the side wall  14  is bent upward along the fold line  27  thereby creating a side wall  14  perpendicular to the base  12 . After the blank  50  is bent into shape, it is allowed to cool. Once it cools, it will retain its new shape. The process can then be repeated for each of the other side walls  16 ,  18  and  20  until a container or tray is completely formed.  
         [0040]     As shown in  FIG. 4A , the method may include a step of creating a plurality of tabs  42  in the blank  50  and more particularly in the central portion of the blank  50  which becomes the base  12  when the container  10   a  is formed. As shown in  FIG. 4A , a cutting tool  56  may be moved relative to a stationary blank  50  or alternatively, the blank  50  may be moved relative to a stationary cutting tool  54  to cut the blank  50  at the desired locations to form the tabs  40 .  
         [0041]     As shown in  FIG. 4B , the method may include a step of creating a plurality of openings  42  in the blank  50  and more particularly in the central portion of the blank  50  which becomes the base  12  when the container  10   b  is formed. As shown in  FIG. 4B , a cutting tool  58  may be moved relative to a stationary blank  50  or alternatively, the blank  50  may be moved relative to a stationary cutting tool  58  to cut the blank  50  at the desired locations to form the openings  46 .  
         [0042]     While various embodiments of the present invention have been illustrated and described in considerable detail, it is not the intention of the applicant to restrict or in any way limit the scope of the claims to such detail. Additional advantages and modifications will readily appear to those skilled in the art. The invention in its broader aspect is, therefore, not limited to the specific details, representative system, apparatus, and method, and illustrative example shown and described. Accordingly, departures may be made from such details without departing from the spirit or scope of the applicant&#39;s general inventive concept.