Note: Descriptions are shown in the official language in which they were submitted.
2185290
REUSABLE CONTAINER
DISCLOSURE
Background of the Invention
The present invention relates to plastic containers
and, more particularly, to a construction of a plastic
container that makes the same reusable. While the
container is designed for use with produce and other grown
food products, by reason of its features it may also
desirably be used to contain other commodities.
Many items of produce and other fresh food products
are packed in the field in wooden crates and transported
to retail outlets in the same. Typically crates of this
nature are simply placed in the trash after this single
use. This, of course, results in significant
environmental problems. Such use not only represents a
one-time use of a resource (the wood), it also results in
a major waste disposal/land fill problem. Because of
these and other problems many in the art have designed
plastic containers and container systems. Some of these
are made for recycling. Reference is made, for example,
to applicant's U.S. Patent Nos. 3,987,924 and 5,123,533.
Patents and patent applications of the same or similar
subject matter have also been filed and/or obtained in
other countries.
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Summary of the Invention
The present invention relates to a plastic container
construction facilitating reuse, and a method of using the
plastic container. The plastic container is conventional
in that it has a bottom wall with opposed edges from which
four side wall structures, a pair of end walls, and a pair
of side walls, extend. In keeping with the broad aspects
of the invention, means are provided on the wall
structures defining a path for a band of material to
secure such wall structures together to form a container
cavity with the bottom wall. Most desirably, connecting
structures in the form of complementary interlocking
constructions on adjacent side edges of the walls also
cooperate with such band path defining means for securing
the wall structures together.
When the band of material is removed from the
remainder of the structure, the walls can be placed in the
same plane as the bottom wall - in other words, the
container can go from an erect position to a fully
collapsed (flat) position so that it easily can be
returned. In this connection, each of the wall structures
is preferably connected to the bottom wall by a hinge made
of plastic - most simply just a thin area of plastic.
It will be appreciated that after a container with
this construction is used, for example, to transport a
fresh food product, it can be collapsed so that the amount
of storage it requires is minimized. It then can be
washed and sterilized for reuse while in a flattened
condition. The ability to flatten the containers not only
minimizes the amount of storage required to transport the
same, but also facilitates washing and sterilizing for
reuse. Most desirably, the container is made of a plastic
material which is not absorbent and therefore does not
provide a good host for bacteria growth nor trap residual
fumigant gases. All parts of the container are made from
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the same plastic material so that the container easily can
be recycled when it is damaged or after its reuse
lifetime.
It has been found that a container incorporating the
invention can be reused many times before it must be
disposed of. For example, in one implementation of the
invention the container is devised to last through 60
reuses over a time span of ten years.
In one realization of the invention, the plastic
container of the invention weighed between 2-3 pounds and
was intended to compete with wooden and corrugated
fiberboard containers manufactured for similar uses. In
addition, it was meant to compete with any similar
container made from plastic. Prior art plastic containers
typically cannot compete against either wood or corrugated
fiberboard products from the standpoint of price, because
of limitations in the manufacturing methods used to
produce them. Virtually all plastic containers are
manufactured using the injection molding process to make a
single part product. Due to limitations in mold design
and raw material flow into the mold, all such products use
much more plastic raw material, are much heavier than
their intended use requires, have very long cycle times to
produce each unit, and are consequently more expensive.
While such heavy and expensive plastic containers have
certain uses, they can never be cost competitive with wood
and corrugated products which have been in use for many
decades. Furthermore, a single-part injection molded
container weighing only 2 to 3 pounds would not have the
strength of the subject plastic container and, when filled
with commodity, could not be stacked as high (in cold
storage warehouses, for example) as the subject container.
The subject container is a fabricated product made
from two parts which are manufactured using different
manufacturing processes and joined together using the.
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latest state of the art assembly welding technology. The
first part is a polypropylene shell which forms the bottom
of the container and its side walls and end walls. The
second part are two polypropylene structural foam end
frames which are permanently affixed to the shell by means
of vibration welding. The shell has four hinge details
which allow it to be erected into its assembled stage or
collapsed into its flat configuration in 2-3 seconds.
This design takes advantage of the best
characteristics of each plastic manufacturing process:
the speed of the sheet line extrusion process and the
strength of the injection molding process. Since the
weight of the contents to be packed into each container is
relatively light, a high speed sheet line manufacturing
process preferably is used. The weight within each
container is borne by the thinwall shell which is
manufactured using such sheet line extrusion process. The
shell also has ribs which provide reinforcement of the
shell and reduce flexing of the container. The ribs are
formed into the shell on the sheet line. Normally, a
sheet line process can only produce a flat surface sheet
and cannot incorporate a profile member or detail.
Profile parts are manufactured using profile extrusion
dies which require special cooling fixtures and other
tools to produce. Since strength is required to stack the
loaded containers, sometimes as much as three pallet
stacks high, the weight bearing load of the pallet stack
is distributed through the container's end frames which
are made using a very fast special injection molding
process system. The rigid structure of the injection
molded end frames and the addition of the structural foam
into the polypropylene will ensure that the container,
when loaded, can be stacked as high as any warehouse can
accommodate.
The container of the invention has a feature which
makes the same particularly attractive for containing and
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the dispensing commodities. One of the wall structures of the
container is movable between the container position for the
S same to a position away from the other of the wall structures
so as to provide access to the interior of the container.
This access is provided even when the container is in a stack
of vertically adjacent containers, i.e., when the traditional
access through the container lid is blocked. Means are
provided for securing such one wall structure in the extended
position. In this way, after use of the container of the
invention to transport and otherwise handle a supply of
commodes, the container can be used to facilitate display
and/or selection from the supply.
The invention includes a method of reuse in which the
container is washed and sterilized between uses while it is in
its flattened condition. It is a simple matter to use brushes
and the like on the reusable container since when it is
flattened all parts of the same generally are in the same
plane.
In one broad aspect, then, the present invention relates
to a reusable plastic container comprising:(a) a bottom wall
having at least two pair of opposed edges; (b) a pair of end
wall structures, each of which projects from an associated
edge of one of said pair of opposed edges of said bottom wall;
(c) a pair of side wall structures, each of which projects
from an associated edge of the other of said pair of opposed
edges of said bottom wall; (d) hinge means made of plastic
connecting each of said wall structures to its associated
bottom edge permitting said wall structure to be moved between
a position defining a container cavity with the remainder of
said wall structures and said bottom wall, and a position in
which said wall structure is essentially in the same plane as
said bottom wall whereby said container is flat; and (e) means
on each of said end wall structures which, when all of said
wall structures are in said position essentially in the same
plane as said bottom wall, cooperate with another reusable
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plastic container essentially vertically adjacent the same
5 having side wall structures also essentially in the same plane
as its bottom wall, to lock said containers against meaningful
movement parallel to said plane relative to one another.
In another broad aspect, the present invention relates to
a reusable plastic container comprising:(a) a bottom wall
having at least two pair of opposed edges; (b) a pair of end
wall structures, each of which projects from an associated
edge of one of said pair of opposed edges of said bottom wall
in essentially the same direction relative to said bottom wall
as the other of said end wall structures; (c) a pair of side
wall structures, each of which projects from an associated
edge of the other of said pair of opposed edges of said bottom
wall in essentially the same direction relative to said bottom
wall as said end wall structures; (d) means on said side and
end wall structures defining a path for a band of material to
aid in securing said wall structures together to form a
container cavity with said bottom wall; (e) connecting
structures in addition to said path defining means for
securing said end and side wall structures together; (f) side
edges of adjacent ones of said wall structures being also
adjacent to one another when said end and side wall structures
extend together in said direction, and said connecting
structure includes complementary interlocking constructions on
adjacent side edges; and (g) at least one pin on said path to
register with a cooperable hole in the band of material to
position said band properly on said path.
In still another broad aspect, the present invention
relates to a reusable plastic container comprising:(a) a
bottom wall having at least two pair of opposed edges; (b) a
pair of end wall structures, each of which projects from an
associated edge of one of said pair of opposed edges of said
bottom wall in essentially the same direction relative to said
bottom wall as the other of said end wall structures; (c) a
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pair of side wall structures, each of which projects from an
associated edge of the other of said pair of opposed edges of
said bottom wall in essentially the same direction relative to
said bottom wall as said end wall structure; (d) each of said
end wall structures including a relatively rigid end frame
rigidly adhered to an end surface that is integral with and
lies within the plane of said bottom wall, each of said end
frames being defined by a piece of material which is separate
and apart from the material defining the end wall structure to
which it is adhered, and being positioned and configured to
engage a corresponding end frame of a vertically adjacent
similar container and distribute weight loading when two or
more of such containers are stacked when erected; and (e)
hinge means made of plastic connecting each of said wall
structures to its associated bottom edge permitting said wall
structure to be moved between a position defining a container
cavity with the remainder of said wall structures and said
bottom wall, and a position in which said wall structure is
essentially in the same plane as said bottom wall whereby said
container is flat, and wherein each of said end frames
cooperate, where all of said wall structures are in said
position essentially the same plane as said bottom wall, with
an end frame of another reusable plastic container essentially
vertically adjacent the same having said wall structure also
essentially in the same plane as its bottom wall, to lock said
containers against meaningful movement parallel to said plane
relative to one another.
The method of the invention and the reusable container
have many other features. For example, the container includes
connector structure which facilitates connection of vertically
adjacent containers in a stack. Other features and advantages
of the invention either will become apparent or will be
described in connection with the following, more detailed
description of a preferred embodiment of the invention.
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V~ith reference to the accompanying five sheets of
drawings:
FIG. 1 is an isometric view of a preferred embodiment of
the container of the invention in erect condition, showing a
lid to be described exploded therefrom;
15
25
35
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FIG. 2 is an isometric view illustrating a multiple
number of the containers of the invention in a flattened
condition;
FIG. 3 is an enlarged partial sectional view taken on
a plane indicated by the lines 3-3 in FIG. 2;
FIG. 4 is a plan view showing the preferred
embodiment in a flattened condition, the side shown being
the opposite of the side shown in FIG. 2;
FIG. 5 is a side elevation view of the preferred
embodiment of the container showing one side wall in a
position permitting access to the interior of the
container;
FIGS. 6A and 6B are enlarged sectional views showing
interlocking constructions at the side edges of the walls
of the container;
FIG. 7 is an isometric view illustrating a corner
edge of the preferred embodiment of the invention;
FIG. 8 is a view similar to FIG. 7 but showing the
corner edge without the band of material;
FIG. 9 is a partial isometric view illustrating how
two containers which are vertically adjacent one another
may be secured together in accordance with the invention;
FIGS. 10A and lOB are enlarged partial views
providing a more detailed illustration of the manner in
which two vertically adjacent containers may be secured
together in accordance with the invention; and
FIGS. 11A and 11B are isometric views of alternate
lid structures which may be used with the container of the
invention.
2185290
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Detailed Description of the Preferred Embodiments)
The following relatively detailed description is
provided to satisfy the patent statutes. However, it will
be appreciated by those skilled in the art that various
changes and modifications can be made without departing
from the invention.
With reference to the drawings, a preferred
embodiment of the container of the invention is generally
referred to by the reference numeral 11. It includes a
bottom wall 12, a pair of end wall structures 13 and 14
and a pair of side wall structures 16 and 17. (It is to
be noted the bottom wall and the side wall structures have
extruded ribs formed when the shell providing the bottom
and side walls is extruded. The shell is embossed to
provide additional strength without adding weight or
additional shell thickness.)
Each of the wall structures is connected to its
associated bottom edge by a hinge which is made of
plastic. In this connection, the whole structure (except
for the structural end frames to be discussed) is made as
a one-piece plastic part, preferably from polypropylene
(PP), with appropriate hinges. That is, the plastic at
the junctions between the walls and the bottom edges is
made thinner so as to permit the walls to be moved between
the two positions represented in FIGS. 1 and 2. It should
be realized that the technique of making such hinges from
plastic is quite advanced and hinges can be provided which
can be cycled many times without adverse consequences.
A band of material 18 circumscribes the walls holding
all of the same together to form a container cavity with
the bottom wall. Printing or the like showing a grower's
logo, the contents of a container, etc., can be included
on the band of material at appropriate locations. The
location for the band itself is set. The side and end
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wall structures define a path for the same. This band
also is most desirably made of a recyclable material. In
this connection, it will be recognized that with reuse of
the container (but not the band for each container) there
will be many bands which can be shredded and recycled.
The band also most desirably is of the same material as
the remainder of the container, e.g., polypropylene.
Each of the end walls includes a relatively rigid
frame 19. It is the frames 19 of each container which are
the main structural members which take the load when the
containers are stacked. While each of the end walls is
most desirably made from the same plastic material as the
bottom and side wall structures of the container, each end
frame is an injected molded, structural foam part. In
this connection, appropriate energy directors are provided
in its design to facilitate welding.
Each end frame is positioned against a surface of the
end wall of which it is a part as shown in FIG. 3 for
connection thereto. In one implementation of the
invention this was via vibration welding.
The side edges of each frame include posts 20-23 that
are relieved for the band and thus define the basic
vertical positioning of such band relative to the wall
structures. Each end frame also has a pair of pins 24 and
26 which register with apertures in the band to hold the
same generally in position.
It will be appreciated that although it is the side
and end wall structures which actually engage the contents
of the container, the band 18 adds structural integrity to
hold the wall structures together with the bottom wall to
form a container cavity. It should be noted that from the
broad standpoint one need not provide a band - an exterior
wrapping of strong tape will provide the same structural
integrity. Moreover, the band and the remainder of the
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container can be manufactured at separate locations, even
by different parties.
The invention includes in addition to the band 18,
connecting structure for securing the end and side walls
together. The side walls have flaps 29-33 which when the
container is assembled with the walls adjacent one
another, extend between the frame 19 of each end wall and
a plastic filler panel 34 of the end wall (see FIGS. 5 and
6A). In this connection, each frame 19 includes not only
the end posts and horizontally connecting members as
illustrated, but also a pair of plates 36 and 37. Each
end flap 29-33 includes a slot 38 which when the side and
end walls are assembled as discussed is engaged by a
projecting tab/hooking device 39 on the interior side of
each of the respective plates 36 and 37. Each of the
plastic filler panels 34 is slotted adjacent the
projection as illustrated at 40. The slots 40 enable that
portion of the plastic filler panel between the same to
bow under pressure, as is illustrated in FIG. 6B. This
bowing facilitates removal of the projection 39 from its
associated slot when the side walls are to be disengaged
from the end walls.
It will be seen from the above that complementary
interlocking constructions are provided on the adjacent
edges of the wall structures. In the preferred embodiment
being described, the purpose of the interlocking
constructions simply is to enable erection of the
container and securance of the side walls together before
the band 18 is installed. It is the band which provides
the structural integrity that is necessary for the
container to contain commodities. It will be recognized,
though, that depending upon the commodity such a band or
an alternative for it may not be necessary in this
embodiment of the invention. Moreover, in other
realizations of the instant invention the complementary
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interlocking constructions may be made sufficiently strong
to provide the desired structural integrity by themselves.
The above construction facilitates the opening of a
side to enable the contents of the container to be seen or
to facilitate physical access to such contents. In this
connection, means are provided for securing a side wall in
a position away from the other of the wall structures and
bottom wall making up the container. This is illustrated
in FIG. 5. After the band 18 is removed, one of the side
walls can be tipped out simply by releasing the detent 39
from the slot 38 in each of the side walls. Means
including hole 41 is also provided in each of the flaps 32
to hold the flaps in an extended, but limited, position.
The hole 41 in a flap is brought into registration with a
hole 42 in its associated end frame plate so that a dowel
or pin can be used for securing a side wall in its desired
position.
As a major feature of the invention, the container is
changeable from a position in which the wall structures
define a container as described above to a flat condition
in which such wall structures are in generally the same
plane as the bottom (see FIG. 2). This aids significantly
to the reusability of the container. That is, after use
it is only necessary to remove the band by cutting or the
like, and then place the container in a flat condition. A
plurality of the flattened containers then can be
palletized and shipped. In this connection, as
illustrated in FIG. 3 protruding lips 42 and tits 43 of
one flattened container protrude into its neighbor to aid
in positioning containers relative to one another. These
tits and lips define a pathway for a lid as will be
described when the containers are erected and, thus, have
a dual function.
The invention also includes the method of washing and
sterilizing the containers for reuse while they are still
v 2185290
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in their flattened condition. As mentioned previously,
the plastic material selected for the containers (and for
the band) is nonabsorbent. This simplifies the nature of
the washing and sterilizing equipment that is necessary.
In this connection, it enables easy access to all parts of
the container with a brush. Vertically adjacent
containers in a stack can be separated to enable a brush
to pass therebetween and then the containers passed by
appropriate brushes on a continuous conveyor or the like.
Once the containers are washed and sterilized,
flattened pallet containers then can be palletized and
shipped to a packer, grower or other user for reuse. The
ratio of volume used by a flattened palleted container
relative to an erected container is approximately 1:8.
When the containers are at a packer/grower site, they can
be erected. In one implementation of the invention, it
takes approximately 3-5 seconds to erect the containers by
hand. Machinery can be provided to do so, though, in
between 1 and 2 seconds. The band also is applied before
a container is reused. In a specific implementation
matching the embodiment being described, application of
the band by hand is accomplished within about 3-5 seconds.
It can be installed by relatively simple and inexpensive
machinery in between 1 and 2 seconds.
As another feature of the instant invention, each
container includes connector structure for securing the
container to a generally vertically adjacent container.
The connector structure in the particular implementation
to be described is designed to provide connection to
facilitate handling when the containers are empty or quite
light. It is recognized, though, that more structurally
strong connector arrangements can be used if desired to
enable the containers to be secured together even when
relatively heavy. Each of the posts of the end frames
includes a dovetail slot at its top surface to capture a
clip for such securance. FIG. 9 illustrates the manner in
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which adjacent containers are stacked on one another,
whereas FIGS. l0A and lOB provide details of the
construction. Each post, represented by the post 20 in
the figures, includes a dovetail slot 46. (It should be
mentioned that the views in FIGS. l0A and 10B are the back
side of the end frame posts and molding details forming no
part of the invention as described are shown.) A clip 47
is provided configured to be captured by the dovetail slot
as illustrated. As shown in the drawings, such dovetail
slot has opposing walls which define an opening for the
clip, which walls are configured relative to the clip to
obstruct removal of the clip through such opening. The
clip, however, can be slid into the dovetail slot from the
end of the same. The upper portion of the clip is defined
by a pair of prongs 48 which resiliently can enter and be
captured within a complementary dovetail slot 49 on the
adjacent upper container. These clips are also most
desirably of the same material as the remainder of the
container.
FIGS. 11A and 11B illustrate alternate lids for the
container. The lid 51 of FIG. 11A includes a pair of
edges 52 and 53 which are shaped to capture the upper edge
of the container side walls when installed so as to
provide additional structural support to the side walls.
The lid 54 of FIG. 11B is designed not to extend all the
way to the side walls but rather leave a meaningful gap to
permit significant air access to a product within the
container, as well as "visual access" as is appropriate.
This lid is the one shown in the other figures and
includes, as is indicated on two opposed end edges, a pair
of tabs 56 which register with and fit within
corresponding slots 57 defined by the end frame members
19. The lip 42 and the tits 43 on each end define a guide
path for the end edges of the lids.
As mentioned at the beginning of the detailed
description, protection is not necessarily limited to the
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specific embodiment described above. Various changes and
modifications can be made. The claims, their equivalents
and their equivalent language define the scope of
protection.
