Note: Descriptions are shown in the official language in which they were submitted.
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Folding Container with Elastically Suspended Floor
FIELD AND BACKGROUND OF THE INVENTION
The present invention relates to containers used for shipping and
displaying produce and, in particular, it concerns a folding container with an
elastically suspended floor useful in shipping and displaying produce.
A growing trend in retail industries is the shipping of produce in
containers which are also suitable for displaying and selling the produce at a
retail outlet. This greatly reduces the labor involved in transferring produce
from
shipping containers to display units and arranging product displays. The
present
invention is particularly, although not exclusively, related to shipping
containers
(alternatively referred to as "crates", "boxes" or "bins"), typically made
from
molded plastic materials, which are at least partially foldable so as to
reduce the
volume of the containers for return (empty) transport. One typical set of
examples to which the present invention is applicable are containers referred
to
as "bulk-boxes" of horizontal dimensions 60x80 cm or 60x40 cm, and of height
75-110cm.
When containers such as these are used for dispensing retail produce, the
"top of the pile" moves downwards as the upper items are removed. This may
make it more awkward for a customer to access the goods, requiring him or her
to bend over and reach downwards to take the remaining goods. Additionally,
there is a negative psychological effect according to which the produce left
at the
lower height is perceived by customers as "left over" or old, and hence is
considered less desirable.
For these and other reasons, it would be advantageous to provide a
shipping and display container which would provide a self-raising floor which
would tend to raise the perceived height of the pile of produce as produce is
removed. At the same time, it would be advantageous if the self-raising floor
did
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not interfere with folding of a folding container to facilitate reduced volume
return transportation in a conventional manner.
SUIVIMARY OF THE INVENTION
The present invention is a shipping and display container with elastically
suspended floor.
According to the teachings of the present invention there is provided, a
container comprising: (a) a set of four walls, each of the walls being
implemented
as a folding wall having at least one folding portion deployable between an
upright container-forming position and a folded position; (b) a floor deployed
within and vertically displaceable relative to the set of walls; and (c) a
suspension
arrangement including at least four elastic suspension elements, the
suspension
arrangement being deployed to suspend the floor relative to the set of walls
such
that, when the floor is loaded with a first load, the floor assumes a lowered
position and, when a part of the load is removed, the suspension arrangement
raises the floor towards a raised position.
According to a further feature of the present invention, each of the elastic
suspension elements includes a length of an elastomeric material.
According to a further feature of the present invention, each of the elastic
suspension elements includes a helical spring.
According to a further feature of the present invention, the set of walls
feature an arrangement of stopper features deployed to engage the floor so as
to
define a fully raised position.
According to a further feature of the present invention, the stopper
features are deployed below the folding portions.
According to a further feature of the present invention, each of the
suspension elements is attached to the folding portion of one of the walls.
According to a further feature of the present invention, there is also
provided a base fixedly attached to the set of walls below the floor.
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According to a further feature of the present invention, the base is
configured to provide at least one channel for insertion of a pallet jack for
lifting
the container.
There is also provided, according to a further feature of the present
invention, a container comprising: (a) a set of four walls; (b) a floor
deployed
within and vertically displaceable relative to the set of walls; and (c) a
suspension
arrangement including at least four elastic suspension elements, the
suspension
arrangement being deployed to suspend the floor relative to the set of walls
such
that, when the floor is loaded with a first load, the floor assumes a lowered
position and, when a part of the load is removed, the suspension arrangement
raises the floor towards a raised position, the suspension arrangement further
including an adjustment mechanism configured for adjusting an effective length
of the elastic suspension elements.
According to a further feature of the present invention, the adjustment
mechanism is configured to adjust an effective length of the elastic
suspension
elements between an operative length wherein the floor is elastically biased
towards a raised position and an inoperative length wherein the floor assumes
the
lowered position even in the absence of an applied load.
According to a further feature of the present invention, the adjustment
mechanism is configured to simultaneously adjust an effective length of all of
the
elastic suspension elements substantially equally.
According to a further feature of the present invention, the adjustment
mechanism includes a rotatable drum associated with the floor, each of the
elastic
suspension elements being linked to the drum so that rotation of the drum
effects
simultaneous adjustment of an effective length of all of the elastic
suspension
elements.
. According to a further feature of the present invention, the adjustment
mechanism further includes a handle accessible from an upper surface of the
floor for manually rotating the drum.
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According to a further feature of the present invention, the adjustment
mechanism further includes a locking arrangement for locking the drum in at
least one position relative to the floor.
According to a further feature of the present invention, the adjustment
mechanism further includes a ratchet arrangement for allowing rotation of the
drum to shorten an effective length of the elastic suspension elements and to
inhibit rotation of the drum to lengthen an effective length of the elastic
suspension elements.
According to a further feature of the present invention, the adjustment
mechanism further includes a ratchet override mechanism selectively operable
to
release the ratchet arrangement to allow rotation of the drum to lengthen an
effective length of the elastic suspension elements.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is herein described, by way of example only, with reference
to the accompanying drawings, wherein:
FIGS. lA and 1B are a side view and an isometric view, respectively, of a
first embodiment of a container, constructed and operative according to the
teachings of the present invention, with a front wall removed to show an
elastically suspended floor in an unloaded fully-raised position;
FIGS. 2A and 2B are views similar to Figures IA and 1B, respectively,
showing the elastically suspended floor in a partly-loaded intermediate
position;
FIGS. 3A and 3B are views similar to Figures IA and 1B, respectively,
showing the elastically suspended floor in a fully-loaded lowered state;
FIGS. 4A and 4B are isometric views of the container of Figure lA in a
partly folded state, Figure 4B having a front wall removed to reveal the
internal
folded configuration;
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FIGS. 5A and 5B are isometric views of the container of Figure lA in a
fully folded state, Figure 5B having a front wall removed to reveal the
internal
folded configuration;
FIGS. 6A and 6B are isometric views of a second embodiment of a
container, constructed and operative according to the teachings of the present
invention, with a front wall removed to show a floor in a lowered state and in
a
raised elastically-suspended state, respectively;
FIGS. 7A and 7B are isometric views of the floor and suspension
arrangement alone from the container of Figure 6A shown in the lowered state
and the raised elastically-suspended state, respectively;
FIGS. 8A and 8B are views similar to Figures 7A and 7B, respectively,
cut-away to show details of an adjustment mechanism for adjusting an effective
length of said elastic suspension elements;
FIGS. 9A is a view similar to Figure 7B with an upper surface of the floor
removed; and
FIGS. 9B and 9C are enlarged views of the region of Figure 9A
designated "A" showing a ratchet arrangement in an operative and an overridden
state, respectively.
DESCRIPTION OF THE PREFERRED EMBODIlVIENTS
The present invention is a shipping and display container with elastically
suspended floor.
The principles and operation of containers according to the present
invention may be better understood with reference to the drawings and the
accompanying description.
By way of introduction, the present invention is a foldable container in
which a shelf or "floor" for supporting produce within the container is
suspended
via elastic suspension elements from the walls of the container, when in its
open
state, so as to automatically adjust the height of the floor, and hence of the
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produce, as a function of the weight of the produce within the container. The
invention will be presented herein with reference to two non-limiting
examples:
first, a basic embodiment will be described with reference to Figures 1A-5B;
then, with reference to Figures 6A-9C, an alternative embodiment including an
adjustment mechanism will be described.
Referring now to the drawings, Figures lA-5B show a container, generally
designated 10, constructed and operative according to the teachings of the
present
invention, for shipping and display of produce. Generally speaking, container
10
includes a set of four walls 12, 14, 16 and 18, and a floor 20, deployed
within and
vertically displaceable relative to the set of walls. A suspension
arrangement,
including at least four elastic suspension elements 22, is deployed to suspend
floor 20 relative to the set of walls such that, when the floor is loaded with
a first
load (not shown), the floor assumes a lowered position (Figures 3A and 3B)
and,
when a part of the load is removed, the suspension arrangement raises the
floor
towards a raised position (Figures 2A-2B and Figures 1A-1B).
At this stage, it will already be appreciated that the present invention
provides a solution to the aforementioned disadvantages of user inconvenience
and the psychological "end of the pile" effect by gradually raising the level
of the
lower produce as a function of the remaining weight as the top layers are
removed.
Before addressing the features of the invention in more detail, it will be
helpful to define certain terminology as used herein in the description and
claims.
Firstly, where reference is made to elements being "elastic" or operating
"elastically", it should be noted that these terms are used herein in their
broadest
sense to refer to any element which provides a resilient restoring force
without
undergoing significant permanent deformation during each cycle of motion.
Thus, the "elastic suspension elements" of the present invention may be
implemented using a length of an elastomeric material, a helical spring or any
other stretchable element with suitable properties. Most preferably, the
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suspension elements are formed, primarily or exclusively, from an elastomer
material, such as natural or synthetic rubber. Elastomeric suspension elements
are
not generally susceptible to damage through bending during folding of the
container, which may in certain circumstances be problematic for helical
metallic
springs or the like.
The term "container" is used herein as a generic term for containers,
crates, boxes, bins and the like, independent of the construction materials
from
which they are formed and independent of whether they have solid walls or open
vented structures. Furthermore, the term "container" is used to include a
structure
in which the suspended floor of the present invention is the only base of the
structure formed by the set of four walls.
Turning now to the features of container 10 in more detail, four
suspension elements 22 are typically used, although additional suspension
elements (e.g., six total) may be optionally be provided, preferably deployed
symmetrically. Optionally, the number of suspension elements may be varied,
for
example by doubling-up each element in each corner, to accommodate produce
of different weights. Alternatively, or additionally, the suspension elements
may
be interchangeably attached, allowing replacement of the suspension elements
with suspension elements having different thicknesses, lengths or other
mechanical properties, all according to the intended use of the container.
Furthermore, combinations of suspension elements of different lengths or
otherwise differing properties may be used together to provide a desired force
vs.
displacement function, for example, rendering the force vs. displacement
function more linear than would be achieved with a single elastic suspension
element.
Container 10 is preferably of a type where opposite pairs of walls fold
inwards. Suspension elements 22 are preferably attached to the pair of walls
12
and 16 configured to fold first. In the preferred implementation illustrated
herein,
this is the pair of sides 12 and 16 extending along the shorter sides of the
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container. This has a particular advantage, as seen in Figures 4B and 5B, that
the
height of the folding portion of the walls folds into the larger ("length")
dimension, thereby reducing the amount of overlap of the folded walls. This
minimizes the interference of the first-to-fold side 16 with suspension
elements
22 of the second-to-fold side 12.
The set of walls optionally feature an arrangement of stopper features 23
(only one shown) deployed to engage the floor so as to define a fully raised
position (Figures 1A and 1B). This allows implementation of the suspension
elements with a degree of pre-tensioning in the fully raised position so that
they
reach the fully raised position while there is still some load applied to
floor 20. In
certain particularly preferred implementations, stopper features 23 are
deployed
to define a fully raised position of floor 20 which is no higher than the
level of
hinges in the first-to-fold sides of a foldable container, thereby ensuring
that the
floor does not reach a position which would interfere with folding of the
container walls.
In the particularly preferred implementation shown here, container 10
includes a base 24 fixedly attached to the set of walls below floor 20. This
helps
to ensure structural integrity and rigidity of the container as a whole, and
renders
the container usable in a conventional manner if the floor and suspension
arrangement are removed. In the preferred implementation shown here, base 24
is configured to provide at least one channel 26, 28 for insertion of a pallet
jack
(not shown) for lifting the container.
Turning now to Figures 6A-9C, there is shown a second preferred
embodiment of a container, generally designated 30, constructed and operative
according to the teachings of the present invention. Container 30 is generally
similar to container 10 described above, and equivalent elements are
designated
similarly. It is a particularly preferred feature of this embodiment of the
present
invention that container 30 includes a suspension-element length adjustment
mechanism 32 for adjusting the effective length of the suspension elements 22.
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Typically, the "effective length" of the suspension elements is the length
from a
point of attachment to the container walls to the point of entry to floor 20.
Preferably, the suspension-element length adjustment mechanism is manually
operable (directly by hand, or by use of a mechanical "key"), and preferably
simultaneously adjusts the length of all of the suspension elements in a
similar
manner.
Provision of a suspension-element length adjustment mechanism serves
one or both of two important functions. One function is to allow adjustment of
the lifting force to make the mechanism useful for produce of different
weights.
Thus, for potatoes or watermelons, the suspension elements are shortened more
to provide a greater lifting force than for less dense, or less densely
packed,
produce. As a result, the same container can be used to maintain a comfortable
top-of-the-stack level for dispensing a wide range of produce. It will be
noted
that this function may also be used to advantage in a container which is not
foldable.
The second function is release of tension in the suspension elements prior
to folding of the container for return shipping or storage, thereby ensuring
that
there are no potentially dangerous or inconvenient stresses or a tendency to
open.
Prior to loading with produce, the effective length of the suspension
elements is adjusted (shortened) so as to define a level of tension for the
fully
loaded state and/or the position of the fully raised state. Here too,
mechanical
stopper features may be provided to separately define a fully-raised position.
Turning now to the features of this embodiment in more detail, a non-
limiting example of a preferred implementation of adjustment mechanism 32 is
illustrated in Figures 7A-9C. In this case, the adjustment mechanism is based
on
a drum or wheel 34, deployed primarily below or within floor 20, to which
suspension elements 22 are anchored. Rotation of wheel 34, for example by
turning a handle 36 accessible from the upper side of floor 20, causes winding
in
of suspension elements 22 simultaneously from the state of Figure 8A to that
of
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Figure 8B, thereby shortening their effective length and/or pre-tensioning
them
against stopper elements. In the example shown here, the suspension elements
wind onto a reduced diameter spool surface which is located between upper and
lower disks, the upper disk having been removed in Figures 8A and 8B for
clarity
of presentation. The handle may be recessed into the floor, or may be a
removable "key" used by authorized personnel only. Optionally, a locking
mechanism may be operated automatically by folding down of the handle or
removal of the key.
Once a desired length or degree of tension is achieved, the wheel is locked
against rotation, for example, by insertion of one or more locking pin through
holes formed in the wheel and the floor, or more preferably by a ratchet
mechanism such as illustrated in Figures 9B and 9C below.
Referring specifically to Figure 9B, drum 34 is here formed with an outer
edge formed as a saw-toothed gear wheel against which a spring-biased ratchet
arm 38 bears. This configuration allows rotation of the drum clockwise as
shown
to shorten an effective length of elastic suspension elements 22, but inhibits
rotation of the drum in the reverse direction, preventing lengthening of the
elastic
suspension elements. This conveniently allows shortening of the suspension
elements to raise floor 20 and/or pre-tension it against stopper features,
then
maintaining the desired level of tension during loading and unloading of
produce.
When the contents of the container have been removed, lowering of floor 20 is
performed by turning a release lever 40 with an eccentric cam form which bears
on ratchet arm 38, disengaging it from the teeth of drum 34 so as to override
the
ratchet arrangement and allow rotation of the drum to lengthen an effective
length of the elastic suspension elements to an inoperative length, allowing
floor
20 to assume the position of Figure 6A ready for folding of the container and
return transportation.
It will be clear to one ordinarily skilled in the art that many other
implementations of a suspension-element length adjustment mechanisms are
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possible. By way of a further non-limiting example, a similar result may be
achieved by use of a scissors mechanism under the floor. Furthermore, it
should
be noted that the suspension-element length adjustment mechanism may
alternatively be deployed as part of the walls of the container rather than in
the
floor.
Referring now to both of the above embodiments, the particularly
preferred implementations shown here have fold-down openings 42 in an upper
part of at least one of the side walls of the container. Because of the rising
motion
of the floor, these access openings can be positioned relatively high in the
walls
and still afford sufficient access for a customer to the produce within the
container. In the preferred examples illustrated here, the fold-down openings
extend down to no more than about a third of the total fillable depth of the
container when the floor is in its lowered/loaded state.
The range of motion of floor 20 is preferably at least about 10%, more
preferably at least 20%, and most preferably at least 25% of the total
fillable
depth of the container. The maximum height reached by the floor is typically
no
more than about 70% of the total fillable depth of the container.
The container may be made from any material. Most preferably, the
invention is implemented using molded plastic containers. As mentioned above,
the container may be adapted, for example as shown, to be handled by a pallet
jack or fork lift.
It will be appreciated that the above descriptions are intended only to
serve as examples, and that many other embodiments are possible within the
scope of the present invention as defined in the appended claims.
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