AU2004208723A1 - Containers - Google Patents

Description

AUSTRALIA

Patents Act 1990 Enviro Pax Pty Ltd COMPLETE SPECIFICATION Invention Title.- Containers The invention is described in the following statement: m:\specifications\500000\502000\5O2467capflnaldcc.doc Title: Containers Introduction to the Invention This invention relates to containers for use as tote boxes or packaging containers and in particular relates to containers adapted for use as tote boxes in industrial and agricultural situations and environments including the automotive, plant nursery and other environments. The invention is particularly adapted to a durable tote box manufactured from a small number of components in a robust construction particularly suitable for use and reuse for component rehandling in a production line environment or for use in a plant nursery for storage and handling of plants, seedlings and the like.

Background to the Invention The invention will be particularly described with reference to its application to tote boxes for use in component part handling in a production line environment. It is to be understood, however, that the invention has wider application to tote boxes for use in other industries, such as the agriculture and plant nursery industries.

The movement of component parts along production lines in the automotive and related industries often requires the handling of a large number of components of vastly varying sizes. Such componentary must be moved from a warehousing environment, sorted and moved to a production line for transportation along the production line to provide access by assembly workers. To date such handling has been addressed by the use of wooden or cardboard crating which is only suitable for one-off application, is not of any uniformity, size, configuration or representation. Such component handling results in potential confusion for workers and in substantial waste after use, as such containers are generally unsuitable for recycling. It would be highly desirable if a uniform container system or tote box design could be adopted by various industries with such tote boxes being efficiently manufactured of recycled and recyclable materials, of a limited number of components, in a robust construction and adapted for re-use and ultimately recycling. To date such issues have been addressed with the use of polypropylene fluteboard which has many advantages over wood or cardboard including lightweight, high strength, crush resistance, water resistance and recyclability. Such products have been used for the production of tote boxes and other containers. However, such containers to date have been manufactured from plastic twin-wall hollow profile sheet using previous methodologies used in the manufacture of corrugated cardboard boxes. That is, single templates have been cut from a single sheet of twin-wall sheet folded up in an analogous manner to that of cardboard boxes.

The disadvantage of this adaptation of technology is the inability to utilise the directional strengths of fluteboard which provide substantially higher strength along the longitudinal direction of the flutes. It is desirable to manufacture containers having the four sides of the container enjoying the maximum strength of fluteboard by being positioned in the vertical orientation. However, this is not possible if boxes are manufactured from a single sheet of board.

Accordingly, it is desirable to provide an improved tote box particularly adapted for use in assembly line industrial situations.

It is also desirable to provide a tote box or container that is flexible in its use and in the applications therefore.

It is also desirable to provide a container adapted for use in agricultural and plant nursery situations.

It is also desirable to provide a container that is simple in construction, easy to assemble, is strong, re-usable and is economic to manufacture and use.

Summary of the Invention In a first aspect the invention provides an open tote box comprising a main framework built up of an assembly of extrusion lengths in-filled with sheets of fluteboard on the bottom and at least three sides of said box wherein said extrusion is of generally angular shape including two orthogonally positioned open channels joined by a closed corner wherein said open channels are sized to snugly receive said fluteboard.

Preferably, the extrusion lengths are of a synthetic plastic material such as polyethylene, polypropylene, polycarbonate or the like. The closed corner preferably has a quadrant shape in cross-section.

The fluteboard may be fixed to said frame by fasteners passing through at least one of the arms of said channel and penetrating into said fluteboard. Preferably said fasteners are passed through the internal arm of said channel. Each frame component most preferably has two fastening points to the fluteboard infill. The fastening is most preferably made toward the end of each frame component.

The corners of said box may be formed by a suitable joint in the abutting frame components. The joint can include one or a plurality of steps cut into the open channels of said extrusion. The joint may be built up of a butt joint, a single step cut and a double step cut allowing these abutting frame components to form a complete joint.

The gap left at the open channel may be sealed by a plug. The plug is preferably an eighth sphere in shape to follow the quadrant shaped line of the closed comer of the frame extrusion.

The frame joint may alternatively be formed as a mitre joint with abutting frame components cut as a double mitre joint.

The arms of the open channels preferably taper at the far edges to provide a minimal step between said channel arms and the fitted fluteboard.

The top of said open box .may include top rails fitted along the exposed fluteboard sides. The top rail may be a length of plastic extrusion formed as a single open channel of similar configuration and specification to said main framework.

According to another aspect of the invention there is provided an open tote box comprising a main framework built up of an assembly of extruded members in-filled with sheets of fluteboard on the bottom and three sides of said box, wherein said extruded members are of generally angular shape including two orthogonally positioned open channels joined by a closed corner wherein said open channels are sized to snugly receive said fluteboard in-fill, and a plurality of substantially parallel, suspension rails extend across the top opening of the box, each rail being engaged and supported by upper extruded framework members.

In one application, the suspension rails are adapted to support flexible pockets extending from the rails into the box. Preferably, each rail is of hollow, semi-circular cross-section adapted to receive a support rod within the hollow rail and around which flexible pocket material is engaged for support.

Description of the Drawings The invention will now be described in more detail with reference to the following figures and legend.

Figures 1 and 2 are exploded views of a tote box in accordance with one embodiment of the invention, Figure 3 is a cross-section end view of the frame and fluteboard panels of the box, Figure 4 is a fastener used with the tote box of Figure 1, Figure 5 is a comer joint forming the frame of the box of Figure 1, Figure 6 is a perspective view of an assembled tote box, Figure 7 is a schematic perspective view of a second embodiment of the invention, Figure 8 is a cross-sectional view of a suspension rail for use with the embodiment of Figure 7, and Figure 9 is a cross-sectional, detail view of an upper side member with engaged suspension rail.

Legend 1. Tote box 22 Tapered Point 2. Framework 26 Suspension rail 3. Plastic Extrusion 27 Flexible pockets 4. Fluteboard panel 28 Pocket material Open channel 29 Support rod 6. Closed comer 31 Opening 7. Internal arm 32 Upper frame member 8. External arm 9. Taper Top rail 11. Stacking corer 12. Handle 13. Gap 14. Fastener Plug 16. Bolt joint 17. Single step cut 18. Double step cut 19. Domed head Barbs 21. Shank Description of the Illustrated Embodiments Referring firstly to Figures 1 and 2, an exploded view of the tote box of this embodiment of the invention is shown where most of the major components of the box can be seen in their separated perspective. The tote box of this embodiment is particularly designed as an open box having a main framework built up of a number of sections of a common extrusion to make up the framework 2 of the tote box 1. The framework 7 is made up of multiple lengths of the plastic extrusion 3, which are infilled with the panels of fluteboard 4 so as to make up the sides and base configuration of the tote box. The plastic extrusion 3 is formed in a generally angular configuration with two open channels 5, positioned orthogonally and joined by a closed comer 6.

The open channels are formed with an internal arm 7 and an external arm 8 and the far edges of both the internal and external arm are provided with a taper 9.

The dimension of the open channel 5 is configured to receive the thickness of the fluteboard panel 4, snugly, such that once the bottom and four sides of the box are assembled into the eight plastic extrusion lengths, the tote box is substantially constructed.

Referring now to Figure 3, a cross-section of the end elevation of the tote box is shown, where the plastic extrusion 3 is shown to receive the fluteboard sections 4 in snug configuration. The fluteboard is held in place into the open channel 5, by way of a fastener 14, which penetrates the internal arm 7 of the open channel and into the body of the fluteboard 4. In this manner, the fluteboard panels are securely held into the respective plastic extrusions forming the framework 2 and once all the panels of fluteboard 4 are inserted and fastened, the tote box adopts a rigid and durable construction forming the basis of the box.

The particular configuration of the plastic extrusions 3, which are formed from a common extrusion, are precisely formed with the lengths of the internal and external arms being precisely formed and the closed corner 6 also having a precise shape. The closed corner particularly adopts a quadrant shaping cross section so as to provide the finished frame of the tote box with a durable robust framework that is difficult to damage by way of the physical abuse and rough handling that tends to happen in the environment of intended use.

The tapered arms of the open channel assist in minimising any sources of exposure for the box to be caught during handling and thereby minimises the damage, or potential damage to which the box is exposed.

Referring now to Figures 4 and 5, the method of assembly is detailed where the fasteners are shown as comprising a domed head 19 of shallow configuration, again minimising any projections or sources of damage for the finished box. The fastener is provided with a plurality of barbs, projecting outward from a shank 21 and terminating in a tapered point 22. The fasteners are configured for fitting by way of force entry through a suitably configured hole, formed in the open channel, most preferably at the internal arm thereof. In this manner, the plastic extrusion components can be cut to the desired length, suitable holes formed in the internal arm toward either end thereof and once the fluteboard panel is inserted therein, the fasteners can be punched through the formed hole for insertion by way of the barbs into the body of the fluteboard, so as to securely fix the fluteboard to the plastic extrusion forming that part of the framework.

Referring now to Figure 5, a typical corner joint is shown where the three components of plastic extrusion are formed firstly as a butt joint 16, which is then mated to an adjacent plastic extrusion having a single step cut 17 and finally, the third plastic extrusion has a double cut 18, allowing the joint to be formed, then a small corned gap 13 being exposed. The gap 13 can be sealed by a suitably configured plug where the plug most preferably has a head in the form of a 1 8 th sphere. In this manner, the plug can be fitted into any one of the three available ends of the closed corner so as to seal off the joint and form an effectively seamless corner for the tote box.

Referring now to Figure 6, once the box is assembled, top rails 10 can be provided along the top of the fluteboard panels 4 and finally, stacking corners 11 can be positioned and fitted to the top rails. In this manner, the box is now complete and of robust and durable construction, able to withstand repeated use in assembly line situations. The box panels may be provided with handles 12 as appropriate for ease of handling.

Referring to Figures 7 to 9, the tote box 1 of this embodiment is similar to that illustrated in Figures 1 to 6 except that one side panel 4 is omitted.

A plurality of suspension rails 26 extend between the upper framework 2 defining the open top of the tote box 1. The suspension rails 26, as particularly shown in Figure 8, are of a hollow, semi-circular cross section and are preferably of an extruded plastics material, similar to that forming the plastic extrusion 3 of the framework 2.

The suspension rails 26 support flexible pockets 27 that are adapted to hold components or the like, such as automotive components, so as to provide transport, storage and dispensing facilities for such components in an assembly line environment or other similar environments. The flexible pockets 27 may be formed of a flexible fabric material, a synthetic plastics sheet material or any other suitable material to support whatever is to be loaded into the pockets 27.

As shown in Figure 8, in the preferred embodiment illustrated, the flexible pocket material 28 is engaged about a support rod 29 engaged within the hollow suspension rail 26. When tension is applied to the pocket material 28, the support rod 29 is caused to move towards the opening 31 through which the material 28 passes to the interior of the rail 26. The support rail 29 engaged within the opening 31 locks the material 28 to the edges of the opening 31 thus securely holding the pockets 27 in position.

The suspension rails 26 are supported by the upper framework member 32 on each side of the tote box 1. The upper framework member 32 has an internal arm 7 formed with openings to receive each rail 26. The rails 26 pass into but preferably not completely through the flip board panel which forms the closed side of the tote box 1 opposite the open side, as shown in Figure 9.

In use, the tote box of the invention provides a highly durable, economical and recyclable tote box, comprising a limited number of components that can be mass produced, shipped in a flat park and assembled on site. The in-fill panels of fluteboard can be cut and configured to maximise the directional strength of the material and dedicated endorsements or embellishments can be provided with the fluteboard so as to dedicate the tote box for its particular use on the assembly line or elsewhere. This allows assembly of the box in a rapid and tailor-made fashion. In this manner, tote boxes can be mass produced whilst having a variety of endorsements on the respective panels thereof, which can be mixed and matched as required without the limitations of the box being cut from a single piece of fluteboard. The particular method of manufacture, and in particular the use of framework as a structural component of the tote box provides a box that is waterproof, is lightweight and lighter than an equivalent cardboard structure and compares favourably to the strength of wood. The base of the box will not droop or sag. The tote box of the invention is versatile and finds applications in a wide range of industries, including the automotive or white goods packaging industries, with a tote box functioning as a returnable packaging tool between parts manufacture and the line side of motor vehicle, white goods or any other manufacture. The invention is also particularly usable and suitable for agriculture industries including nurseries and the like, which will find particular use of the tote box for its strength and waterproof properties. Further, hot houses and cool houses may eventually be growing plants in extreme climate conditions and will find use for the tote boxes of the invention which are able to withstand the extreme conditions In addition, the ability to mass produce the box means the box can be manufactured in a wide range of sizes and can be manufactured on a production line and can be tailored to a customers brief for the use of dedicated insert panels bearing a customers logo, device or other indicia.

Claims (27)

1. An open tote box comprising a main framework built up of an assembly of plastic extrusion lengths of common cross-section in-filled with panels of fluteboard on the bottom and at least three sides of said box wherein said extrusion is of equally angular shape including two orthogonally positioned open channels found by a closed corner wherein said open channels are sized to snugly receive said fluteboard panels.

2. An open tote box according to claim 1, wherein the closed corner of said plastic extrusion has a quadrant shape in cross-section.

3. An open tote box according to claim 1 or 2 wherein said fluteboard panels are fixed to said frame by fasteners passing through at least one of the arms of said channel and penetrating into said panel.

4. An open tote box according to claim 3, wherein each panel is fastened at at least two locations adjacent the ends of said frame component.

5. An open tote box according to any one of claims 1 to 4 wherein the bottom corners of said box are formed by a suitable joint in the mating formwork components.

6. An open tote box according to claim 5, wherein said joint is built up of a butt joint, single step and double step cut allowing the assembled union of these framework components to form a complete joint with a gap at the closed corner of each frame component.

7. An open tote box according to claim 6 wherein said gap is sealed by a plug having a head of one eighth sphere shape to follow the contour of the closed corner and form an apex to said corner.

8. A tote box according to claim 5, wherein said joint is a compound mitre joint.

9. A tote box according to any one of claims 1 to 8 wherein the arms of the open channel of said extrusion taper at the front edges thereof to provide a minimal step between said channel arms and the fitted fluteboard panel.

A tote box according to claim 3 wherein said fasteners are forced entry barbed fasteners comprising: a shallow domed head, a shank extending from the head and having a plurality of barbs and terminating in a tapered point.

11. An open tote box according to any one of claims 1 to 10 wherein the top of said box includes a top rail fixed along the exposed fluteboard panel forming the sides of said box.

12. An open tote box according to claim 11, wherein said top rail is a length of plastic extrusion formed in a single open channel of similar configuration to said main framework components.

13. A tote box according to any one of claims 1 to 12 wherein the in-fill panels are provided on only three sides of the box.

14. An open tote box comprising a main framework built up of an assembly of extruded members in-filled with sheets of fluteboard on the bottom and three sides of said box, wherein said extruded members are of generally angular shape including two orthogonally positioned open channels joined by a closed corner wherein said open channels are sized to snugly receive said fluteboard in-fill, and a plurality of substantially parallel, suspension rails extend across a top opening of the box, each rail being engaged and supported by upper extruded framework members.

A tote box according to claim 14 wherein the suspension rails are adapted to support flexible pockets extending from the rails into the box.

16. A tote box according to claim 14 or claim 15 wherein each rail is of hollow, semi-circular cross-section adapted to receive a support rod within the hollow rail and around which flexible pocket material is engaged for support.

17. A tote box according to any one of claims 14 to 16 wherein each rail is supported by opposed upper side framework members by passing the rails through holes in internal arm sections of the members and, in the case of the side opposed the open side, also part way through the respective fluteboard panel.

18. A tote box according to any one of claims 14 to 17 wherein the closed corner of said plastic extrusion has a quadrant shape in cross-section.

19. A tote box according to any one of claims 14 or 18 wherein said fluteboard panels are fixed to said frame members by fasteners passing through at least one of the arms of said channel and penetrating into the respective panel.

A tote box according to claim 19, wherein each panel is fastened at at least two locations adjacent the ends of the respective frame members.

21. A tote box according to any one of claims 14 to 20 wherein the bottom corners of said box are formed by a suitable joint in the mating formwork components.

22. A tote box according to claim 21, wherein said joint is a built up of a butt joint, single step and double step cut allowing the assembled union of the framework components to form a complete joint with a gap the closed corner of each frame member.

23. A tote box according to claim 22 wherein said gap is sealed by a plug having a head of one eighth sphere shape to follow the contour of the closed corner and form an apex to said comer.

24. A tote box according to claim 21, wherein said joint is a compound mitre joint.

25. A tote box according to any one of claims 14 to 24 wherein the arms of the open channel of said extrusion taper at the front edges thereof to provide a minimal step between said channel arms and the fitted fluteboard panel.

26. A tote box according to claim 19 wherein said fasteners are forced entry barbed fasteners comprising a shallow domed head, shank having a plurality of barbs and terminating in a tapered point.

27. A tote box substantially as hereinbefore described with reference to the accompanying drawings Dated this sixth day of September 2004 Enviro Pax Pty Ltd Patent Attorneys for the Applicant: F B RICE CO