Patent Description:
Totes and other types of containers that use optional divider panels are a primary packaging product used in the industry to distribute a wide array of products. Such containers are typically provided in a returnable loop system (e.g., an ASRS system - automatic storage and retrieval system) where they are used to fulfill orders from inventory. The containers quite often contain and transport multiple SKU's (i.e., code assigned to a particular product) of different products.

To keep the different products inside the container from mixing, divider panels are provided to separate and compartmentalize the products into distinct locations in the container. The container can include one or more panels that can be inserted to extend from a first end of the container to the second end, as well as one or more panels that can be inserted to extend from one side of the container to the other side (e.g., perpendicular to the end to end panels). Slots are provided in the various panels that enable each panel to engage with the other panels where they intersect.

The panels divide the container into separate areas for each of the products loaded in the container. In some instances, the products can be heavy and can become a shifting load during transport. This shifting of the load can create pressure on the upper and lower portions of the divider panels causing the panels to flex, bend or bulge under such side loading conditions. This can damage the panels and lead to mixing of products from different portions of the container.

<CIT> discloses a container having a series of interlocking removable partitions that divides the container into a series of separate compartments.

The present invention provides a container with divider panels that lock together at intersecting edges to prevent flexing or bulging of the panels during transport.

The present invention is generally directed to a tote with locking divider features. The locking features keep the upper and lower walls of the divider in position, and prevents flexing or bending of these walls during load transport. Specifically, the dividers are provided with locking grooves or channels that trap the upper or lower end of a divider wall the length of the intersection with another divider extending perpendicular thereto. The grooves or channels also help guide the dividers during assembly, ensuring proper fit and location.

The tote with dividers having locking features according to the present invention is a tote according to claim <NUM>.

The first projection and the second projection can have a generally T-shaped cross-sectional shape with the rest of the first divider, or other useful shape.

The first channel on the first divider is formed from a first rib extending outward from the first side of the first divider and a second rib extending outward from the first side of the first divider and spaced from the first rib. Similarly, the second channel on the first divider is formed from a first rib extending outward from the second side of the first divider and a second rib extending outward from the second side of the first divider and spaced from the first rib on the second side of the first divider.

Also, the first channel on the second divider is formed from a first rib extending outward from the first side of the second divider and a second rib extending outward from the first side of the second divider and spaced from the first rib. The second channel on the second divider is formed from a first rib extending outward from the second side of the second divider and a second rib extending outward from the second side of the second divider and spaced from the first rib on the second side of the second divider.

The first divider can also have a second slot spaced from the first slot and extending from the top edge of the first divider downward part way toward the bottom edge of the first divider. A third channel is aligned with the second slot and extends downward from a bottom of the second slot on the first side of the first divider and a fourth channel is also aligned with the second slot and extends downward from the bottom of the second slot on the second side of the divider.

Additionally, the container can include a third divider extending between the first side wall and the second side wall. The third divider can have a first slot extending from a bottom edge of the third divider upward part way toward a top edge of the third divider. The first slot of the third divider includes a first edge configured to engage the third channel of the first divider and a second edge configured to engage the fourth channel on the first divider to prevent flexing of the lower portions of the third divider. Additional dividers and/or slots with the channel structures can be utilized in the container depending on the size of the container, the size of the products to be transported, desired number of compartments, etc..

The first divider can include a first locking tab on a first end of the first divider for locking the first divider to the first end wall and a second locking tab on a second end of the first divider for locking the first divider to the second end wall. Similarly, the second divider can include a first locking tab on a first end of the second divider for locking the second divider to the first side wall and a second locking tab on a second end of the second divider for locking the second divider to the second side wall. Alternatively, the container can include grooves or channels on the interior of the end walls and side walls for locking the edges of the dividers.

Preferably, the first slot in the first divider extends about halfway between the top edge and the bottom edge of the first divider. Similarly, the first slot of the second divider extends about halfway between the top edge and the bottom edge of the second divider.

The container and the dividers are formed from plastic. Other similar or suitable materials can also be used.

Other features and advantages of the invention will be apparent from the following specification taken in conjunction with the following Figures.

To understand the present invention, it will now be described by way of example, with reference to the accompanying <FIG>. <FIG>, which are not part of the invention, refer to a prior art tote.

While this invention is susceptible of embodiments in many different forms, there is shown in the drawings and will herein be described in detail preferred embodiments of the invention with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the broad aspect of the invention to the embodiments illustrated.

<FIG> illustrates a known container <NUM> having a body formed from a first end wall <NUM>, an opposing second end wall <NUM>, a first side wall <NUM> and an opposing second side wall <NUM>, all of which are extending upward from a bottom wall <NUM>. The container <NUM> - typically referred to in the industry as a tote - is also shown having a plurality of divider panels <NUM>, <NUM> separating the interior of the container <NUM> into a plurality of sections or compartments <NUM>. The container <NUM> and divider panels <NUM>, <NUM> are typically formed from plastic or other similar or suitable materials.

The divider panels <NUM>, <NUM> are optionally added to the interior of the container body when it is desired to create the sections or compartments <NUM> for shipping items that need to be separated. As shown in <FIG>, the panels <NUM>, <NUM> include a first end to end divider panel <NUM> that extends from the first end wall <NUM> to the second end wall <NUM>, and two side to side divider panels <NUM> that extend from the first side wall <NUM> to the second side wall <NUM>. As illustrated in <FIG>, the first end to end divider panel <NUM> is provided with slots <NUM> that extend about half way down the panel <NUM> from an upper edge, and the side to side divider panels <NUM> include slots <NUM> that extend half way up the panel <NUM> from a lower edge. The slots <NUM>, <NUM> are positioned and configured to interact with each other where the divider panels <NUM>, <NUM> intersect.

The slots <NUM>, <NUM> break up the upper or lower portions of the panels <NUM>, <NUM> into sections (sometimes referred to as "pedals") which can be prone to flexing, bulging or breaking when transporting a load in one or more of the compartments <NUM>. <FIG> illustrates an upper wall portion <NUM> flexing out of a planar alignment with the rest of the divider panel <NUM>. Similarly, <FIG> shows a lower wall portion <NUM> bulging from the planar alignment.

The present invention provides structure between the edges of the slots on one panel and the body of an intersecting panel to lock the upper or lower wall portions <NUM>, <NUM> in place and prevent any flexing or bulging of the wall portions.

<FIG>, <FIG>, <FIG> and <FIG> show a container <NUM> in accordance with the present invention. The container <NUM> includes a first end wall <NUM>, an opposing second end wall <NUM>, a first side wall <NUM> and a second side wall <NUM>. All of the end walls <NUM>, <NUM> and side walls <NUM>, <NUM> extend upward from a bottom wall <NUM>.

A first end to end divider panel <NUM> is shown extending between the end walls <NUM>, <NUM> and having three, spaced apart slots <NUM> extending from an upper edge of the panel <NUM> downward to about midway toward a bottom edge of the panel <NUM> (as used herein, directional or positional words like upper, lower, top etc. are made with respect to the structures as shown in the drawings and as normally positioned during use, and are not meant to limit the invention to being in such positions). A first side to side divider panel <NUM> and a second side to side divider panel <NUM> are shown extending from the first side wall <NUM> to the second side wall <NUM>. Each of the side to side divider panels <NUM>, <NUM> include a slot <NUM> extending from a bottom edge of the panel upward to approximately midway toward a top edge of the panel <NUM>, <NUM>.

Similar to the known containers with dividers, the slots of the end to end divider panel and the side to side divider panels are positioned to align so that the panels can intersect each other. However, unlike the known containers, the portions of each of the panels between the slots is not allowed to freely flex or move. Instead, such portions are held in place by structures in the cross panel.

<FIG> provides an enlarged view of an intersection of an upper portion of one of the side to side divider panels <NUM>, <NUM> with an upper portion of the end to end divider panel <NUM>. As shown, the side to side divider panel includes a first groove or channel <NUM> on a first side <NUM> of the panel and a second groove or channel <NUM> on a second side <NUM> of the panel which enclose the edges <NUM>, <NUM> of one of the slots <NUM> of the end to end panel <NUM>. The first channel <NUM> is formed from a first rib <NUM> extending outward from the first side <NUM> and a second rib <NUM> spaced from the first rib, extending outward from the first side <NUM>. Similarly, the second channel <NUM> is formed from a first rib <NUM> and a second rib <NUM> extending outward from the second side <NUM>. The edges <NUM>, <NUM> of the slot <NUM> of the end to end divider panel are shown having projecting ribs giving the edges <NUM>, <NUM> a generally T-shaped cross-sectional appearance.

The channels <NUM>, <NUM> hold the upper portions of the end to end divider <NUM> in place and prevent flexing at this location. Each of the side to side panels is provided with similar channels to lock in the upper portions of the end to end divider panel <NUM> at each slot <NUM> location. While the edges <NUM>, <NUM> of the slots <NUM> are shown having a T-shaped cross-section, other shapes (including more complex ones) can be used as desired or necessary to maintain the upper portions in a locked configuration depending on the size of the container or load or other factors relating to the use of the container. Additionally, the channels can be continuous along the entire length of the slots, or can be intermittent along this length.

Similar to the channels formed on the upper portions of the side to side divider panels <NUM>, <NUM>, the end to end divider panel <NUM> includes a first groove or channel <NUM> formed from a first rib <NUM> and second rib <NUM> on a first side <NUM> of the divider panel <NUM>, and a second groove or channel <NUM> formed from a first rib <NUM> and second rib <NUM> on a second side <NUM> of the divider panel <NUM>. The channels <NUM>, <NUM> cooperate with the edges <NUM>, <NUM> of the slots <NUM> of the side to side divider panels to hold the lower portions of such panels in place to prevent flexing or bulging.

Similar to the divider panels, the end walls and side walls of the container can include interior facing grooves or channels for receiving the side edges of the panels, or other structures for securing such side edges.

While one end to end divider panel and two side to side panels are shown, additional (or fewer - for the side to side panels) divider panels can be provided with the slot edge locking structures described herein. Moreover, while the end to end divider panel is shown slots extending from a top edge, and the side to side divider panels have slots extending from a bottom edge, this can be reversed.

Claim 1:
A tote with dividers having locking features comprising:
a container (<NUM>) having a first side wall (<NUM>), an opposing second side wall (<NUM>), a first end wall (<NUM>), an opposing second end wall (<NUM>) and a bottom (<NUM>) extending between the first and second side walls and the first and second end walls;
a first divider (<NUM>) extending between the first end wall and the second end wall of the container, the first divider having a first slot (<NUM>) extending from a top edge of the first divider downward part way toward a bottom edge of the first divider, a first channel (<NUM>) aligned with the first slot and extending downward from a bottom of the first slot on a first side (<NUM>) of the first divider and a second channel (<NUM>) aligned with the first slot and extending downward from the bottom of the first slot on a second side (<NUM>) of the first divider; and,
a second divider (<NUM>) extending between the first side wall and the second side wall, the second divider having a first slot (<NUM>) extending from a bottom edge of the second divider upward part way toward a top edge of the second divider, wherein the first slot of the second divider includes a first edge (<NUM>) configured to engage the first channel (<NUM>) of the first divider and a second edge (<NUM>) configured to engage the second channel (<NUM>) on the first divider to prevent flexing of the lower portions of the second divider,
wherein the second divider further includes a first channel (<NUM>) aligned with the first slot of the second divider and extending upward from a top of the first slot on a first side (<NUM>) of the second divider and a second channel (<NUM>) aligned with the first slot and extending upward from the top of the first slot on a second side (<NUM>) of the second divider, wherein a first edge (<NUM>) of the first slot of the first divider is configured to engage the first channel on the second divider and a second edge (<NUM>) of the first slot of the first divider is configured to engage the second channel on the second divider, and wherein the first edge (<NUM>) of the first slot of the first divider includes a first projection that fits in the first channel of the second divider and the second edge (<NUM>) of the first slot of the first divider includes a second projection that fits in the second channel of the second divider.