Abstract:
The present invention provides a plurality of injection molded plastic panels having integrated connectors which are capable of being packaged and shipped in a knocked-down state and constructed to form an aesthetically pleasing trash container. The integrated connection of the side wall, cover and bottom panel components simplifies trash container construction. The panels are formed of injection molded plastic to interlock with one another without the need for separate metal fasteners or connectors. The system incorporates a minimum number of components by integrally forming the connectors into the injection molded panels which are snapped together to complete the assembly.

Description:
RELATED APPLICATIONS  
       [0001]     This application is relates to U.S. Ser. No. 10/628,636 entitled Secure Trash Container, the contents of which are incorporated herein in their entirety. 
     
    
     FIELD OF THE INVENTION  
       [0002]     This invention relates generally to plastic containers, and more specifically, to a plastic trash container assembly utilizing injection molded structural panels having integrally formed connectors. The trash container assembly is capable of being packaged and shipped in a knocked-down state and assembled into a decorative trash container without tools or additional fasteners.  
       BACKGROUND INFORMATION  
       [0003]     Refuse or trash containers are a necessity for homeowners and business owners alike. Trash containers are preferably positioned in convenient locations for trash collection, which necessitates a decorative exterior if placed in close proximity to employees at businesses or residents in homes. A common form of trash container comprises a rigid one piece body which forms an internal chamber with an access opening provided within a rim at the upper end of the internal chamber. A lid is generally connectable with the rim to close the access opening. When the lid is removed, trash is able to be thrown into and collected within the trash container. Most modern trash containers also house a separate, removable waste receiving receptacle such as a collapsible plastic bag or liner. A common form of trash liner is a flexible plastic bag which is held open by folding an upper edge of the bag over the lip of the container facilitating the ability to place trash into the bag. Once the bag is filled, the top of the bag is tied closed and lifted out of the container.  
         [0004]     For example, U.S. Pat. No. 5,803,300 discloses a rigid one-piece trash container with a bag holding mechanism which firmly supports a flexible walled plastic liner in an open configuration within the container. One drawback associated with this type of container occurs when the filled liner engages the side walls of the container. This engagement often causes difficulty in removing the filled bags from the container.  
         [0005]     U.S. Pat. No. 5,390,818 discloses a trash receptacle for receiving and holding a flexible, collapsible trash liner. More particularly, the trash receptacle device provides a cavity formed in the lower portion of the trash receptacle for use as a foothold for assisting a user in removing a full trash liner from the receptacle, and a handhold to assist the user in transporting the receptacle.  
         [0006]     Typically, the aforementioned one-piece containers are large and incapable of being knocked-down for shipping and storage, adding additional expense to the producer and thus the consumer. In an effort to reduce these problems, one piece containers generally include tapered side walls which allow them to be shipped in a nested arrangement. However, the nested containers are bulky and heavy, offering marginal gains to an end consumer.  
         [0007]     In an attempt to overcome the shipping and storage problems associated with one-piece containers, containers capable of being shipped in a broken down condition have been provided. The top portion of these containers is usually provided with one or more openings, sometimes closed with a swinging door, through which the refuse may pass to be received by the waste receptacle within the container. The swinging doors are generally provided with a weight, spring, or mechanical mechanism which must be pushed open to place trash in the container. Because the top portion is securely attached to the container portion, these devices are generally constructed with access doors in their side to facilitate removing a filled trash liner from the container portion.  
         [0008]     For example, U.S. Pat. No. 6,241,115 discloses a container for housing a waste receptacle. The device includes a base member formed by joining two identical halves. Two interchangeable side walls are attached to the base member and include extensions which form the top of the container. Interchangeable front and back walls are provided, the front wall being hingedly attached and acting as a door. The front and back walls include a spring loaded door for providing access to the waste receptacle. If a waste receptacle in the form of a plastic bag is used, a frame is provided. The frame is moveably mounted on tracks carried by the side walls of the container.  
         [0009]     U.S. Pat. No. 5,348,222 discloses a pedal operated garbage container with improved access to the interior when the lid is opened. In this container, a platform for supporting waste is pivoted to the opposite side walls at its forward edge, and a front wall extends upwardly from the forward edge of the platform. Operation of a pedal pivots the platform upwardly and the front wall outwardly, providing access to the interior. One or more waste receptacles are placed on the platform, and must be lifted out for emptying as needed.  
         [0010]     These types of containers suffer from numerous drawbacks for consumers. One such drawback relates to assembly of the container. These containers are often difficult to assemble, requiring tools and a substantial number of fasteners to align the panels and doors for proper operation. In addition, such containers may require internal linkages for operation of the lid.  
         [0011]     Other advances in the art are aimed at making filled trash liners easier to remove from the receptacle. For example, U.S. Pat. No. 4,923,080 discloses a trash receptacle that opens on the side so that a filled liner need not be lifted out of the receptacle.  
         [0012]     U.S. Pat. No. 5,984,134 discloses a trash container formed with an open fronted housing having a pivotally mounted front wall movable between a closed position and an open position to allow a filled liner to be removed from the housing. A releasable locking device locks the front wall into the closed position.  
         [0013]     Typically, the structure of such devices are complex, requiring numerous small metal and/or plastic fasteners and connector members to maintain a structurally sound container. Due to the complexity of these devices they are generally only offered to consumers fully assembled and not in a knocked-down condition, and therefore require large shipping containers or crates, thereby increasing the final cost of the product to the consumer.  
         [0014]     Such prior art devices, while working well, have not met all of the needs of manufacturers to provide a product that can be easily manufactured, packaged and shipped to the consumer in a knocked-down state. Nor have they met the needs of consumers requiring structural integrity combined with a pleasing aesthetic appearance and ease of assembly without the need for tools and small fasteners for assembly.  
         [0015]     Paramount among such needs is a trash container panel system which creates a trash container having walls which resist panel separation, buckling, racking and weather infiltration. Structural integrity is a further consideration; the container formed by the panels must tie into the cover and bottom in such a way as to unify the entire enclosure. Also, from a safety standpoint, a cover should be present which can be easily latched and which provides dependable pivoting access to the lineable container.  
         [0016]     There are also commercial considerations that must be satisfied by any viable trash container assembly; considerations which are not entirely satisfied by state of the art products. The trash container must be formed of relatively few component parts that are inexpensive to manufacture by conventional techniques. The trash container must also be capable of being packaged and shipped in a knocked-down state for assembly on a desired site.  
         [0017]     Finally, there are ergonomic needs that a trash container assembly must satisfy in order to achieve acceptance by the end user. The trash container must be easily and quickly assembled using minimal hardware and requiring a minimal number or no tools. Further, the trash container must not require excessive strength to assemble or include heavy component parts. Moreover, the trash container must assemble together in such a way so as not to detract from the internal storage volume of the resulting trash container.  
       BRIEF DESCRIPTION OF THE INVENTION  
       [0018]     The present invention provides a plurality of injection molded plastic panels having integrated connectors which are capable of being packaged and shipped in a knocked-down state and constructed to form an aesthetically pleasing trash container. The integrated connection of the side wall, cover and bottom panel components simplifies trash container construction. The panels are formed of injection molded plastic to interlock with one another without the need for separate metal fasteners or connectors.  
         [0019]     The system incorporates a minimum number of components by integrally forming the connectors into the injection molded panels which are snapped together without tools to complete the assembly. This construction eliminates the need for separate extruded or molded connectors or fasteners to assemble the trash container. Injection molding allows the panels to be formed with a single wall having integral cross-bracing, ribs and gussets for increased rigidity when compared to blow molded or rotationally molded containers. The same side wall and bottom panel components can be used to create a variety of trash containers, and the assembly of the trash container requires minimal hardware and a minimum number of hand tools. The bottom, front and back wall panels have integrally formed outwardly projecting bosses for interlocking cooperative engagement with the left and right side wall panels. The left and right side wall panels are constructed with integrally formed inwardly contoured sockets for interlocking cooperative engagement with the bosses on the edges of the base, front and back side wall panels. The engagement between the bosses and the sockets serve to rigidly connect the components together into a weather resistant trash container.  
         [0020]     The system further includes a one-piece latching cover which is hingedly connected and latched into place after the front, back, side and bottom panels have been fully assembled. Each of the side panels include a removably attached retainer-ramp. The retainer-ramps are constructed and arranged to cooperate with the side panels to support a conventional plastic trash liner without the need for metal frames, arms or fasteners. In addition, the retainer-ramps permit the flexible liner to be retained completely inside of the trash container in contrast with the prior art which folds the liner over the rim of the container or over a metal frame to retain the liner in an open position. Still yet, the ramp portion of the retainer-ramps permit a filled liner to be easily pulled upwardly through the container opening without snagging or catching.  
         [0021]     The lid panel is hingedly connected to removable and replaceable hinge inserts to provide an opening to place trash in the container. The lid is provided with a latch means constructed and arranged to allow the lid to be latched in a closed position to prevent wind or animals from opening the container. The removable and replaceable hinge inserts permit interchangeability in the event that a hinge should become damaged.  
         [0022]     In addition to the integrally formed bosses constructed to cooperate with the side panels, the lower surface of the base panel includes integrally formed bosses constructed and arranged to cooperate with casters to allow easy movement of a loaded or unloaded trash container. The upper surface of the base panel includes a vent allowing filled trash liners to be easily removed by eliminating the vacuum caused within a container when a filled liner engages the side walls.  
         [0023]     Accordingly, it is an objective of the present invention to provide a trash container assembly having panels with integrated connectors.  
         [0024]     A further objective is to provide a trash container having panels with integrated connectors which accommodate injection molding plastic formation of the panel components for increased structural integrity.  
         [0025]     Yet a further objective is to provide a trash container assembly in which the side walls, cover, and bottom panels are integrally interlocked without separate fasteners or connectors.  
         [0026]     Another objective is to provide a trash container assembly constructed of modular panels having an aesthetically pleasing appearance.  
         [0027]     Yet another objective is to provide a trash container assembly that is capable of being packaged and shipped in a knocked-down state and constructed into a secure enclosure upon a desired site.  
         [0028]     Yet another objective is to provide a trash container assembly that includes removable and replaceable hinge components.  
         [0029]     Still yet another objective is to provide a trash container assembly that retains a flexible liner completely inside of the container without requiring separate frames or fasteners for improved aesthetic appearance.  
         [0030]     Other objectives and advantages of this invention will become apparent from the following description taken in conjunction with the accompanying drawings wherein are set forth, by way of illustration and example, certain embodiments of this invention. The drawings constitute a part of this specification and include exemplary embodiments of the present invention and illustrate various objects and features thereof.  
     
    
     BRIEF DESCRIPTION OF THE FIGURES  
       [0031]      FIG. 1  is a perspective view of the trash container of the instant invention;  
         [0032]      FIG. 2  is an exploded view of the trash container shown in  FIG. 1 ;  
         [0033]      FIG. 3  is a perspective view of the trash container embodiment shown in  FIG. 1  with a liner in place and the cover panel in the open position;  
         [0034]      FIG. 4  is a front view of the trash container embodiment shown in  FIG. 1 ;  
         [0035]      FIG. 5  is a section view taken along line  1 - 1  of the embodiment shown in  FIG. 4  illustrating the cooperative engagement of the base, side, and cover panels;  
         [0036]      FIG. 6  is a partial section view taken along line  2 - 2  of the embodiment shown in  FIG. 5  illustrating the cooperative engagement of the cover latch and the front panel;  
         [0037]      FIG. 7  is a bottom view of the base panel utilized in the trash container embodiment shown in  FIG. 1 .  
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0038]     While the present invention is susceptible of embodiment in various forms, there is shown in the drawings and will hereinafter be described a presently preferred embodiment with the understanding that the present disclosure is to be considered an exemplification of the invention and is not intended to limit the invention to the specific embodiments illustrated.  
         [0039]      FIGS. 1-2  which are now referenced illustrate perspective and exploded views of the trash container assembly, generally referenced as  10 , according to a preferred embodiment of the present invention. The trash container is made up of a base panel  100 , left side wall panel  200 , right side wall panel  300 , back wall panel  400 , front wall panel  500  and cover panel  600 . In the preferred embodiment the panels comprising the assembly are formed of but not limited to a suitable plastic such as polystyrene, polypropylene or polyethylene, through the process of injection molding. The result is that the panels comprising the trash container  10  are formed as unitary single wall panels with integral connectors and cross bracing. Strengthening ribs  202  and gussets  204  are formed within the inner surfaces of the wall panels, cover panel, and base panel in order to enhance rigidity of the panels while leaving the external surface in a generally smooth condition for aesthetic purposes, as shown in  FIG. 2 . The base panel  100  has a top surface  104 , bottom surface  106  ( FIG. 7 ), front edge  108 , back edge  110 , left edge  112 , and right edge  114 . Integrally formed along the left and right base panel edges is a plurality of bosses  116  for attaching the base panel to the left  200  and right  300  wall panels. The bosses  116  extend outwardly from each edge to cooperate with sockets  210  extending inwardly along the bottom portions  206 ,  306  of the left and right wall panels respectively. The bosses  116  and sockets  210  are constructed and arranged so that the bosses  116  enter and mateably engage the sockets  210 , securing the panels together in an inter-fitting engagement and perpendicular arrangement. Detent or spring-lock fasteners, such as those illustrated at  118  cooperate with apertures  208 , to secure the bosses  116  to the sockets  210 . Those skilled in the art will appreciate that the spring-lock fasteners  118  can be used throughout the trash container  10  to mount or secure components to one another, and to facilitate ready assembly of the trash container if it is provided in an unassembled or broken-down condition. The overlapping boss  116  and socket  210  arrangement increases the structural integrity of the trash container  10  by preventing the panels  200 ,  300 ,  400 ,  500  from bowing or bending inwardly or outwardly, and thus, adversely affecting the appearance or operation of the trash container  10 .  
         [0040]     The left wall panel  200  is configured having a first edge  212  and a second edge  214 . Both edges  212 ,  214  include integrally formed elongated and contoured sockets  210  extending inwardly in a linear fashion along each edge. The sockets  210  are generally constructed and arranged to cooperate with the bosses  116  provided along either edge of the back panel  400  and front panel  500 .  
         [0041]     The right wall panel  300  is configured having a first edge  312  and a second edge  314 . Both edges  312 ,  314  include integrally formed elongated and contoured sockets  210  extending inwardly in a linear fashion along each edge. The sockets  210  are generally constructed and arranged to cooperate with bosses  116  provided along either edge of the back panel  400  and front panel  500 .  
         [0042]     The outer surface of the panels  200 ,  300 ,  400 ,  500  are constructed generally smooth having a plurality of inwardly bowed grooves  230  for added strength and aesthetic appearance. The inside of the panels  200 ,  300 ,  400 ,  500  are constructed with a plurality of strengthening ribs  202  extending along the panels with a portion of the ribs  202  being provided with a plurality of gussets  204  to further strengthen the panels. The ribs  202  and gussets  204  increase the structural integrity of the trash container  10  by preventing the panels  200 ,  300 ,  400 ,  500  from bowing or bending inwardly or outwardly, and thus, adversely affecting the appearance or operation of the trash container  10 . The integrally formed ribs  202  and gussets  204  are facilitated by injection molding. Injection molding offers significant strength and stability advantages over blow-molding or rotational molding as utilized in the prior art. In this manner the container of the instant invention is capable of handling a significant amount of weight as compared to prior art plastic trash containers.  
         [0043]     The left and right side panels  200 ,  300  are attached to the base panel  100  by inserting the contoured bosses  116  into the sockets  210  until the spring tabs  118  engage the apertures  208  in the sockets  210  of the left  200  and right  300  panels.  
         [0044]     The front and back panels  400 ,  500  are attached to the left  200  and right  300  panels by inserting the elongated and contoured bosses  116  into sockets  210  until the spring tabs  118  integrally formed into the contoured bosses  116  engage the apertures  208  in the sockets of the left and right panels  400 ,  500 . It will be appreciated that the purpose of the contoured and elongated bosses  116  are to align two panels in a perpendicular relationship and to facilitate their mechanical connection. The perpendicular panels are brought into an overlapping relationship wherein the contoured bosses  116  enter the corresponding sockets  210  in the left, and right panels  200 ,  300  respectively. The result is a mechanically secure connection between the panels. The overlapping edges between the panels as described above provides a secure connection and offers several advantages. First, the design allows the panels to be connected without the need for separate connectors. Second, the design creates a positive lock that prevents separation of the panels. Third, the design maintains alignment of the panels in the same plane and prevents bowing or bending of either panel relative to one another. The resultant trash container created by the combination of the interlocking panels benefits from high structural integrity and reliable operation.  
         [0045]     Referring to  FIGS. 3-6 , perspective and section views of the trash container are shown illustrating the pivotal operation of the cover panel  600  and latch assembly. Also illustrated is the construction and arrangement of the separable and replaceable hinge assemblies. The hinge assemblies generally include a pair of hinge inserts  650  ( FIG. 2 ), each having a pair of hinge pins  652 . The hinge pins are constructed and arranged to cooperate with a plurality of hinge pin receivers  602 . The hinge pin receivers  602  are generally a pair of outwardly depending supports  603  located adjacent to the back edge  610  of the cover panel  600  and are constructed and arranged to cooperate with a hinge pin  652  to allow pivotal movement of the cover panel  600  between an open position illustrated in  FIG. 3  and a closed position illustrated in  FIG. 1 . The hinge pins  652  are each integrally formed onto the upper portion of the hinge inserts  650 . The hinge pins  652  cooperate with their respective hinge pin receivers  602  to allow pivotal movement of the cover panel  600  and also allow the cover  600  to be removed when in the open position by lifting the cover upward and sliding the hinge pin receiver  602  outward from the pins  652 . The cover panel  600  is releasably secured in the closed position by pivoting the cover panel downward until the cover latch  622  pivotally mounted into the front panel  500  engages at least one corresponding indentation  620  formed in the front portion of the cover panel  600 . The result is a positive mechanical connection. To open the cover panel  600 , the cover latch  622  is pulled outward until the catch  624  is released from the indentation  620  and the cover panel is pivoted upwards. The result is a positive mechanical connection between the side walls of the container and the cover panel  600  that resists opening by winds or animals, and yet provides easy access for placing trash into the container.  
         [0046]     It should be appreciated that the hinge assemblies allow the cover panel  600  to be installed and/or removed when the cover  600  is in the open position and yet the cover and lid are secure and non-removable when in the closed position. It should also be appreciated that the hinge inserts are removable and replaceable in the event that one or both should become damaged.  
         [0047]     Referring to  FIGS. 2-6  the retainer-ramps  450  are illustrated. The retainer-ramps include an upper portion  452  that is constructed and arranged to retain a flexible liner  700  in an open position within the trash container and a lower portion  454  constructed and arranged to permit a filled liner to be easily removed from the trash container without catching or snagging. The upper portion of the retainer-ramp includes a depending lip  456  over which the flexible liner may be folded over for retention thereof. The lowermost portion of retainer-ramp is constructed and arranged to fit against the inner surface of each respective panel and taper inwardly away from the inner surface as the retainer-ramp extends toward the container opening. In this manner the retainer-ramps function as a guide to aid in the removal of a filled liner from the container. The inner surface of the retainer-ramp  458  includes an attachment means integrally formed thereto for attaching the retainer-ramp to the inner surface of the front, back, left and right panels. The attachment means is illustrated herein as a pair of snap-lock connectors  460 . The snap-lock connectors each include an inner portion  462  and an outer portion  464 ; both portions are integrally formed onto their respective panels. For assembly the inner portion is pressed into the outer portion until the components are engaged. In addition to the retainer-ramps the base panel is provided with a vent aperture  120  to aid in the removal of filled liners.  
         [0048]     Referring to  FIGS. 2 and 7 , the casters  120  and caster bosses  122  are illustrated. The casters  120  include a stem  124  that is constructed and arranged to cooperate with an aperture  126  integrally formed onto the lower surface  106  of the base panel  100 . For assembly the stem is inserted into the boss aperture until retainer ring  128  snaps into a corresponding groove formed into the aperture, the result is a mechanically secure connection. The casters may also include a releasable lock  130  to prevent the trash container from unwanted movement on hills and the like.  
         [0049]     All patents and publications mentioned in this specification are indicative of the levels of those skilled in the art to which the invention pertains. All patents and publications are herein incorporated by reference to the same extent as if each individual publication was specifically and individually indicated to be incorporated by reference.  
         [0050]     It is to be understood that while a certain form of the invention is illustrated, it is not to be limited to the specific form or arrangement herein described and shown. It will be apparent to those skilled in the art that various changes may be made without departing from the scope of the invention and the invention is not to be considered limited to what is shown and described in the specification.  
         [0051]     One skilled in the art will readily appreciate that the present invention is well adapted to carry out the objectives and obtain the ends and advantages mentioned, as well as those inherent therein. The embodiments, methods, procedures and techniques described herein are presently representative of the preferred embodiments, are intended to be exemplary and are not intended as limitations on the scope. Changes therein and other uses will occur to those skilled in the art which are encompassed within the spirit of the invention and are defined by the scope of the appended claims. Although the invention has been described in connection with specific preferred embodiments, it should be understood that the invention as claimed should not be unduly limited to such specific embodiments. Indeed, various modifications of the described modes for carrying out the invention which are obvious to those skilled in the art are intended to be within the scope of the following claims.