Patent ID: 12258175

DETAILED DESCRIPTION OF THE ILLUSTRATIVE EMBODIMENTS

Referring toFIG.1, an assembled container10is disclosed. The container10, in all disclosed embodiments, comprises three principal parts, a molded plastic bottom pallet12compatible with forklift handling, a foldable four-sided sleeve14of corrugated organic material or the like, and a molded plastic top cover16. Two sides of the sleeve have cutouts18extending to opposite top edges while the other two sides are solid. These cutouts are optional; i.e., all four sides of the sleeve may be solid. The pallet12and cover16can be vacuum-assist thermoformed of polyethylene or other suitable polymer while the sleeve14can be constructed of corrugated paperboard, preferably treated for waterproofing, or any other suitable material with fold joints20at the four vertical corners between side panels. The material thickness is chosen such that the side panels exhibit a degree of flexibility and may be die cut to form slots22and24adjacent the top and bottom edges, respectively, as shown inFIGS.3and5. Additional slots or openings25may be formed in the sleeve14for handling purposes as desired.

Detailed Description of the First Embodiment

The first embodiment is shown inFIGS.2,3,4,4A,5-11Aand corresponds essentially to what is shown inFIG.1as far as the three major components are concerned. It includes passive locks comprising tabs26in locations that correspond to the locations of slots24that are cut into the side walls of the sleeve14. As a result, the tabs26fit into the slots24to secure the sleeve14to the pallet12simply by pushing the properly configured sleeve bottom edge into a groove28formed around the periphery of the pallet12inside of a surrounding rim30. A similar arrangement is provided at the top of the combination to secure the cover16to the top edge of the sleeve14. This includes the slots22in the solid sides of the sleeve and tabs36molded into the interior wall of a groove38inside of a rim40extending around the outside of the cover16as shown inFIGS.11and11A. Here, tabs36are formed on only two sides of the cover because there are no slots in the sleeve on two of the sides. However, in a container having a sleeve with no cutouts18, slots and tabs can be provided on all four sides. Again, the locations of the tabs36and slots22are chosen to coincide so the tabs fit into the slots when the cover16is pushed down on the top of the sleeve edge.

Looking specifically toFIGS.2and2A, the bottom pallet12can be vacuum thermoformed, preferably out of single sheet of material, to produce a central general flat deck42, tapered feet44in each of the four corners of the pallet bottom12, a tapered foot46midway in each of the four sides, and single center foot48. All of the feet are thermoformed using a die and vacuum to draw the polymeric sheet material into cavities in the die after the material has been heated to make it flow more readily. The feet are provided with vertical side grooves for additional strength and rigidity as will be apparent to persons of ordinary skill in the vacuum thermoforming art.

The peripheral rim30runs continuously around all four sides of the pallet to define the continuous peripheral groove28which is dimensioned and configured to receive therein the entire bottom edge of the sleeve14after the sleeve has been unfolded and reconfigured as a four-sided body. The depth of the groove28is such that lock tabs26enter slots24in the sleeve14when the bottom edges of the sleeve engage the bottom of the groove as shown inFIG.6. This is important in that it is desirable, especially when loaded containers are stacked, to transfer stacking loads down through the sleeve and the pallet feet to the floor on which the bottom pallet sits.

As shown inFIGS.2,6, and7, each of the locking tabs26and36is wedge-shaped and has a semi-circular outside edge. The tabs26and36also have sloped top and bottom surfaces50and52to act as cams during insertion and removal of the sleeve into the groove and, in particular, while the locking tabs encounter the bottom edge of the sleeve (during insertion) and the bottom edge of the slots24during removal.

To aid in the insertion and removal steps, a box-shaped relief or depression54is formed in the pallet surface42directly opposite each of the locking tabs24in the groove28as shown inFIGS.2and2A. The floor of each relief54coincides with the bottom of the groove28inFIG.4Ato provide space into which the wall of the sleeve14can flex during insertion and removal steps. The groove28is otherwise narrow enough to prevent excessive play between the sleeve and the pallet.

The Cover

The embodiment here described further comprises a molded plastic cover16which, to a great extent, mirrors the bottom pallet12with the exception that the cover in this example is less deep and has no feet. As shown inFIGS.9-11A, the cover16is formed with a continuous groove56inside of a peripheral rim40to receive the top edge of the sleeve14for assembly purposes.

As shown inFIGS.1and5, the cover16fits onto the top edge of the sleeve14and is pushed down until all of the locking tabs36enter into the slots22to lock the cover in place.

As shown inFIGS.9,10,11, and11A, reliefs39are formed in the cover directly opposite the locations of the tabs36to provide space into which the sleeve material can flex during the insertion and removal steps. The floors of the reliefs are on the same level as the groove38so that the tabs36are above the relief floor when the cover is inserted as shown.

As shown inFIG.11, the cover16has an interior deck60with bosses62, a peripheral groove38bordered by a rim40that extends around the entire cover. The lock tabs36are molded into the inside surface of groove38as shown inFIG.9A. The cover tabs36may be of twin sheet construction as shown inFIG.9or single sheet perFIG.10.

Detailed Description of the Second Embodiment

The second embodiment is generally similar to the first embodiment described above and also corresponds to the overall view as shownFIG.1. The major difference is that the locations of the locking tabs and receiver slots are reversed; i.e., the locking tabs are located on the sleeve and the “pockets” that receive the tabs are in the pallet and cover. The overall function is the same as in the first embodiment; i.e., the container is assembled by pushing the sleeve bottom edge into the pallet groove and pushing the cover down on the sleeve top edge after filling the container. Disassembly is done in reverse order. The tabs are created using molded plastic, foldable clips60that are installed on the sleeve14whereas the receiver slots are formed as pockets62in the structures of the pallet and cover to receive clip tabs64and provide the locking operation. In other respects, the two embodiments are essentially the same.

Referring toFIGS.12-14, there is shown a foldable clip structure60of molded plastic which is used to create double-ply locking tabs64along the top and bottom edges of a sleeve14′. These locking tabs, once the clips60are installed in the proper locations, fit into pockets62that are molded into the groove of the pallet and the cover, a pocket62in the pallet being shown inFIG.20. Holes are die cut into the sleeve14′ at the proper locations to coincide with the location of the clip features that extend through the sleeve material. The clips have double fold lines66that are spaced apart by approximately the thickness of the sleeve so the clips can be folded to bring male tab65into the female tab64on the opposite side of the clip60and the clip60is thereby attached to the sleeve as shown in representative drawingFIG.18.

FIGS.15,16, and17illustrate the clip60and show male and female locking buttons68and70respectively that snap together to hold the clips together when assembled to a sleeve edge. An adhesive may be used to cement the clips in the folded/applied condition.

It will be understood that the terms “lock” and “locking” as used herein to define the relationship between the sleeve, pallet, and cover when joined by the tabs and slots/pockets, refers to a fastening protocol that, while secure, is achieved and removed without the need to manually move a bolt or slide latch into a keeper or to use tools for operation.

Referring now toFIGS.19-26, an additional configuration of the foldable plastic clip80is shown. In these figures, the clip80is formed of a plastic material such as polyethylene to have two panels82and84joined by an integral double hinge85which permits the two panels to be folded essentially as shown inFIG.20into a parallel configuration to sandwich the sleeve material102between them as shown inFIG.21. The double hinge85is configurated with two hinge lines far enough apart to accommodate the thickness of the sleeve between them, e.g., 9 mm to 11 mm. In addition, the sleeve is configured to fold flat accordion-style by means of center fold lines83in two of the four panels.

Clip panel84has formed in the inside surface thereof an oblong protrusion86which fits into a hole88in the panel82to firmly locate the two panels82and84relative to one another when the panels are folded into a parallel configuration and locked together as hereinafter described. As shown inFIG.21a hole104is formed in the sleeve to accommodate the protrusion86as it makes its way into the elongate aperture88in panel82.

In addition, panel84has formed on the inside surface thereof a male locking mechanism90on one side of the protrusion86and a female locking receptacle94on the other side of the protrusion86. Opposite gender elements92and96are formed integrally on the inside surface of the panel82; i.e. a female locking mechanism92is configured to receive a male locking element or barb90on the opposite panel in a locking relationship therein. It will be noted that the male element has staggered insertion surfaces; i.e. one element being extended in one direction and the other element in the other direction and the female locking receptacle92is similarly configured to have undercut recesses of opposite configuration that are staggered so that when the male elements90fit therein they lock together. Again, a hole108is formed in the sleeve to allow passage of the locking elements therethrough.

In a similar fashion locking element96on the panel82is staggered from side to side and the undercut receptacle94on the opposite panel is similarly configured to receive the staggered male element therein in a locking relationship. Conventional undercuts are used to insure a snap fit in both locking mechanisms and holes106and108are formed in the panel to receive all of the elements of the locking tabs.

As shown inFIGS.24-26, it is desirable to be able to fold the sleeve14flat for storage or return shipment. To accomplish this, inwardly folding hinge lines83are formed in two opposite sleeve panels and the sleeve can thus fold “accordion-style” as shown inFIG.26.

To ensure that the outwardly-protruding tabs of the clips80on these inwardly-foldable panels do not collide and prevent full-folding, the clips80on the accordion-fold panels are offset from center and slots81are provided to receive the tab of the clip80on the adjacent panel when fully folded. A similar arrangement is made for the cover16.

Although the most common arrangement is to have eight locks on each of the pallet-sleeve combination and the cover-sleeve combination, with two clips on each of the top and bottom sleeve panel edges, various alternative arrangements are possible. For example, the cover may have locks only on two panels as shown inFIG.24.

Assembly of the clips to the sleeve102is reasonably simple; i.e. the three necessary slots are formed in the sleeve102at every location where a lock is to be provided; e.g., there will be two sets of such slots on each of the faces or sides of the sleeve. The clips are folded and locked together with the sleeve material102sandwiched between them and with the locking tab96formed on the outside surface of panel84pointing in the direction of an aperture62in, for example, the pallet side wall is shown inFIG.22. After all of the clips have been installed, the sleeve can be inserted into the peripheral groove of the pallet with the tabs96fitting into the apertures62in the outer peripheral rim or wall of the pallet to lock them elements together. Again, there can be a relief or a slight widening of the groove opposite the aperture62formed in the interior deck of the pallet.

A similar arrangement is provided for the cover, i.e., the cover receives the top edge of the sleeve inside of the rim with the clips providing tabs that snap into apertures in the outside rim. It is important that the sleeve edge fully contact the cover inside surface as shown inFIG.9so stacking of containers does not impose a vertical load on the tab lock.

By way of summary, a passive locking mechanism between a container sleeve and both the pallet and cover of a three-part container is provided. In all cases the locking mechanism is provided by means of sets of protruding tabs and either pocket or apertures in the opposite member which receive those tabs. In one embodiment the tabs are formed in the pallet and cover and slots to receive the tabs are formed in a simple fashion along the top and bottom edges of the sleeve.

In the second and preferred embodiments the tabs are provided by means of foldable plastic clips that lock on to the interior and outside surfaces of the sleeve walls at various locations, preferable two spaced apart locations on the top and bottom edges of the sleeve panels. In these embodiments, simple apertures are provided in the outside rim or wall of the pallet and the outside wall of the cover to receive the tabs therein. The tabs or clips containing the tabs snap lockingly on to the sleeve sidewalls and essentially reinforce the slots in the sleeve to prevent tearing. In all embodiments, the tab locks do not engage until the sleeve edges are fully inserted; i.e., the sleeve edge “bottoms out” on the floor of the pallet groove and the top of the cover deck.

It is to be understood that the invention has been described with respect to illustrative embodiments and that various modifications thereto may be made to accommodate size and material requirements and the like without departing from the sprit and scope of the invention as defined in the appended claims.