US20070012590A1 - Container with cutaway corners - Google Patents
Container with cutaway corners Download PDFInfo
- Publication number
- US20070012590A1 US20070012590A1 US11/183,349 US18334905A US2007012590A1 US 20070012590 A1 US20070012590 A1 US 20070012590A1 US 18334905 A US18334905 A US 18334905A US 2007012590 A1 US2007012590 A1 US 2007012590A1
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- US
- United States
- Prior art keywords
- container
- base
- side walls
- containers
- stackable container
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
- 238000000034 method Methods 0.000 claims description 12
- 239000012815 thermoplastic material Substances 0.000 claims description 10
- 239000000463 material Substances 0.000 claims description 8
- -1 polypropylene Polymers 0.000 claims description 6
- 238000010438 heat treatment Methods 0.000 claims description 5
- 239000004743 Polypropylene Substances 0.000 claims description 4
- 239000006260 foam Substances 0.000 claims description 4
- 229920001155 polypropylene Polymers 0.000 claims description 4
- 238000005452 bending Methods 0.000 claims description 2
- 238000003860 storage Methods 0.000 abstract description 12
- 238000005520 cutting process Methods 0.000 description 5
- 239000004698 Polyethylene Substances 0.000 description 2
- 229920000573 polyethylene Polymers 0.000 description 2
- 239000000969 carrier Substances 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 239000004033 plastic Substances 0.000 description 1
- 229920003023 plastic Polymers 0.000 description 1
- 229920001169 thermoplastic Polymers 0.000 description 1
- 239000004416 thermosoftening plastic Substances 0.000 description 1
Images
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
- B65D1/00—Containers having bodies formed in one piece, e.g. by casting metallic material, by moulding plastics, by blowing vitreous material, by throwing ceramic material, by moulding pulped fibrous material, by deep-drawing operations performed on sheet material
- B65D1/34—Trays or like shallow containers
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
- B65D21/00—Nestable, stackable or joinable containers; Containers of variable capacity
- B65D21/02—Containers specially shaped, or provided with fittings or attachments, to facilitate nesting, stacking, or joining together
- B65D21/0233—Nestable containers
Definitions
- the present invention relates to containers for use in shipping, storing, and/or displaying product, and more particularly, to containers or trays that can be nestably stacked together.
- a large number of different container structures are utilized by manufacturers to ship a variety of different products to end users, which may be wholesale or retail customers. These containers may also be used to store and/or display products. Many of these boxes, trays, or like container carriers have perpendicular side walls in order to efficiently and effectively utilize the internal volume of the container for storing or displaying a product while at the same time minimizing the space needed to store or transport the containers. Additionally, many of these containers are made out of a rigid or semi-rigid material such as plastic to further the transport, support, or display of a product. However, these containers, even those with an open top, e.g., tray-like containers, have the disadvantage of not being able to be compactly stored when not in use. Empty containers that cannot be compactly stored for reuse take up valuable warehouse or storage space and also increase shipping costs as they require more space in a vehicle while being returned for reuse.
- One style of container that does allow for compact storage when not in use is one that has its side walls obtusely angled out from its bottom or base wall.
- This style of a container allows empty containers to be nested or stacked together in a relatively compact fashion.
- these style of containers have the disadvantage of wasting internal space within the container and not allowing for the effective display or storage of products. For example, for some products, space within the container, particularly near the top of the container, is wasted due to the angling out of the side walls. Additionally, when these style containers are placed next to one another for shipping or storage, space between the containers, particularly at the bottom of the container is wasted due again to the angling out of the side walls. Hence, shipping and storage costs are increased.
- Another style of containers have employed a collapsible method for achieving compact storage when not in use, but these types of boxes have the disadvantage of being required to be assembled or de-assembled before or after use, and may also lack other advantageous properties such as the rigidity of a plastic-like material which may be lacking in a cardboard-style container.
- the present invention provides a container or tray for holding product therein during shipment, storage, and/or display and being returned for reuse.
- the container has a generally rectangular base and side walls which are normally perpendicular to the base. The side walls are not attached to each other so that the corners formed between the side walls are cutaway or open.
- a portion of the base is adapted to flex or pivot so that a second container can be stackably nested within a first container, thereby saving space for shipping or storage purposes.
- a central portion of the base and the side walls of the first container form an obtuse angle which allows the second container to be nested within the first.
- the base and the side walls are biased, independently or in combination, to form a right angle between the base and the side walls both before the second container is nested within the first and after the second container is unstacked from the first container.
- the container is made out of a thermoplastic material which may be a polypropylene foam or any other suitable material.
- the material from which the container is made may vary. It is the inherent properties of the material from which the container is made which enable the side walls to spring back or return to their original positions after one or more inner trays or containers is/are removed from the interior of the outside container.
- the base of the container or tray has a plurality of aligned openings therethrough positioned near the intersection of the side walls and the base, i.e., near the right angle formed between an outer portion of the base and the side walls.
- These openings which may be any desired shape or configuration, facilitate the flexing or pivoting of the container side walls to allow multiple containers to be nested and stacked together.
- the base of the container or tray has a plurality of aligned tabs formed by C-shaped cuts therethrough positioned near the intersection of the side walls and the base, i.e., near the right angle formed between an outer portion of the base and the side walls.
- These tabs which may be any desired shape or configuration, facilitate the flexing or pivoting of the container sidewalls relative to a central portion of the base to allow multiple containers to be nested and stacked together.
- the present invention also provides for a stack of containers nestably stacked inside each other, each having a base and a plurality of side walls, which are not attached to each other, but which are integral with the base.
- the base and the side walls of at least one outer container form an obtuse angle allowing additional containers to be nested inside the outer container or containers.
- the base and the side walls individually or in combination, are biased so that the container side walls form right angles with a central portion of the base before another container is nested inside the container and also after the containers are separated.
- the nestably stackable containers of the present invention can be formed by providing a blank and a heat source, heating the blank with the heat source along fold lines, bending the blank along the fold lines whereby side walls are formed perpendicular to the base and extending upwardly from the base. The base and side walls are then allowed to cool in their preferred orientation or position.
- a thermoplastic material is used to form the container which enables the container to return to its original position after being emptied of other containers.
- a plurality of openings may be created in the base by removing material from select locations of the blank.
- a plurality of tabs may be created in the base by cutting the blank at select locations in predetermined shapes or configurations. The openings or tabs create hinges or pivot points about which the side walls hinge or pivot when another like container is nestably stacked therein.
- the present invention provides a box, container or tray which has side walls which are sturdy or strong enough to keep objects therein and which is also nestably stackable.
- FIG. 1 is a perspective view of a preferred embodiment of the container of the present invention
- FIG. 1A is a cross-sectional view taken of line 1 A- 1 A of FIG. 1 ;
- FIG. 1B is a cross-sectional view of a portion of a stack of containers shown in FIGS. 1 and 1 A;
- FIG. 2 is a perspective view of another embodiment of container in accordance with the present invention.
- FIG. 2A is a cross-sectional view taken of line 2 A- 2 A of FIG. 2 .;
- FIG. 2B is a cross-sectional view of a portion of the container shown in FIGS. 2 and 2 A being flexed when additional like containers are nested within it;
- FIG. 3 is a perspective view of another embodiment of container in accordance with the present invention.
- FIG. 3A is a cross-sectional view taken of line 3 A- 3 A of FIG. 3 ;
- FIG. 3B is a cross-sectional view of a portion of the container shown in FIGS. 3 and 3 A being flexed when additional like containers are nested within it;
- FIG. 4 is a perspective view of a flat blank used to form the container shown in FIGS. 2 and 2 A before the side walls are bent into position;
- FIG. 4A is a perspective view of another blank used to form the container shown in FIGS. 2 and 2 A before its side walls are bent into position;
- FIG. 4B is a perspective view of another blank used to form the container shown in FIGS. 3 and 3 A before its side walls are bent into position;
- FIG. 5 is a perspective view showing the blank shown in FIG. 4 positioned over a heat source.
- FIG. 6 is a perspective view of the tray shown in FIGS. 1 and 1 A, showing a first side wall being bent into position.
- the container 10 comprises a base 12 and a plurality of side walls 14 , 16 , 18 and 20 , all extending upwardly from the perimeter of the base 12 and being perpendicular to the base 12 .
- the base 12 and side walls 14 , 16 , 18 and 20 define an interior 21 of the container 10 for storing or displaying products or items (not shown).
- the side walls 14 , 16 , 18 , 20 each are illustrated with at least one aperture or hole 22 which may be used as handles for transporting the container 10 . If desired, the handles may be omitted on one or more side walls. Alternatively, any number of handles of any shape or configuration may be incorporated into the container 10 .
- the side walls, 14 , 16 , 18 and 20 are not attached to each other.
- the container 10 has open or cutaway corners 24 .
- the side walls 14 , 16 , 18 and 20 are connected to the base 12 at a fold line 27 and form a right angle 28 with the base member 12 . See FIGS. 1 and 1 A.
- the side walls 14 , 16 , 18 and 20 have upper edges 30 , 32 , 34 and 36 , respectively.
- the side walls may be different heights if desired, in which case the upper edges of the side walls would not be co-planar. This may be the case in any of the embodiments described herein.
- FIG. 1B when a second container 11 like the container 10 , having a base 13 and sidewalls 15 is nested inside the interior 21 of the outer container 10 , the side walls 14 , 16 , 18 and 20 of the outer container 10 flex outward about a flex or pivot point 26 located along base 12 . See FIG. 1B .
- FIG. 1B also shows a third tray or container 17 having a base 19 and sidewalls 23 nested or nestably stacked within the second container 11 .
- the second and third containers 11 and 17 are shown in FIG. 1B in dashed lines.
- the side walls 14 , 16 , 18 , 20 of the container 10 return to their position shown in FIG. 1A after the containers 11 and 17 are taken out or removed from the interior 21 of the container 10 .
- two containers 11 and 17 are shown nestably stacked inside container 10 , any number of containers may be nestably stacked together to save space during shipping and/or storage.
- FIG. 2 shows an alternative embodiment of the present invention.
- container 10 a comprises a base 12 a and a plurality of side walls 14 a , 16 a , 18 a and 20 a , all extending upwardly from the perimeter of the base 12 a and being perpendicular to the base 12 a .
- the base 12 a and side walls 14 a , 16 a , 18 a and 20 a define an interior 21 a of the container 10 a for storing or displaying products or items (not shown).
- the side walls 14 a , 16 a , 18 a , 20 a each are illustrated with at least one aperture or hole 22 a used as handles for transporting the container 10 a .
- the handles may be omitted on one or more side walls.
- any number of handles of any shape or configuration may be incorporated into the container 10 a.
- the side walls 14 a , 16 a , 18 a and 20 a are not attached to each other.
- the container 10 a has open or cutaway corners 24 a .
- the side walls 14 a , 16 a , 18 a , and 20 a are connected to the base 12 a along a fold line 27 a and each side wall forms a right angle 28 a with the base 12 a . See FIGS. 2 and 2 A.
- the side walls 14 a , 16 a , 18 a and 20 a have upper edges 30 a , 32 a , 34 a and 36 a , respectively.
- the base 12 a of the container 10 a shown in FIGS. 2, 2A and 2 B has a plurality of aligned tabs 40 formed by C-shaped cuts 42 through the base 12 a .
- the tabs 40 are located generally near the intersection between the base 12 a and the side walls 14 a , 16 a , 18 a and 20 a .
- the tabs 40 are illustrated as being in a generally C-shape and a particular size, the shape and size of the tabs 40 may be different than as is shown.
- These tabs 40 as shown in FIG. 2B , provide a pivot point, further facilitate the flexing of the side walls of the container 10 a to allow multiple containers to be nested and stacked together.
- FIG. 2B when a second container 11 a like the container 10 a , having a base 13 a and sidewalls 15 a is nested inside the interior 21 a of the outer container 10 a , the side walls 14 a , 16 a , 18 a and 20 a of the outer container 10 a flex outward about a flex or pivot point 26 a along the base 12 a . See FIG. 2B . Due, at least in part due to the position of the tabs 40 , an outer portion 44 of the base 12 a , along with the side walls flexes or pivots about a pivot point 19 a . FIG.
- FIG. 2B also shows a third tray or container 17 a having a base 19 a and sidewalls 23 a nested or nestably stacked within the second container 11 a .
- the second and third containers 11 a and 17 a are shown in FIG. 2B in dashed lines. Due, at least in part to the inherent nature of the thermoplastic material from which the container 10 is made, the side walls 14 a , 16 a , 18 a and 20 a of the container 10 a return to their position shown in FIG. 2A after the containers 11 a and 17 a are taken out or removed from the interior 21 a of the container 10 a .
- two containers 11 a and 17 a are shown nestably stacked inside container 10 a , any number of containers may be nestably stacked together to save space during shipping and/or storage.
- FIG. 3 shows yet another embodiment of the present invention.
- container 10 b comprises a base 12 b and a plurality of side walls 14 b , 16 b , 18 b and 20 b , all extending upwardly from the perimeter of the base 12 b and being perpendicular to the base 12 b .
- the base 12 b and side walls 14 b , 16 b , 18 b and 20 b define an interior 21 b of the container 10 b for storing or displaying products or items (not shown).
- the side walls 14 b , 16 b , 18 b , 20 b each are illustrated with at least one aperture or hole 22 b used as handles for transporting the container 10 b .
- the handles may be omitted on any side wall, if desired.
- any number of handles of any shape or configuration may be incorporated into the container 10 b.
- the side walls 14 b , 16 b , 18 b and 20 b are not attached to each other.
- the container 10 b has open or cutaway corners 24 b .
- the side walls 14 b , 16 b , 18 b , and 20 b are connected to the base 12 b along a fold line 27 b and each side wall forms a right angle 28 b with the base 12 b . See FIGS. 3 and 3 A.
- the side walls 14 b , 16 b , 18 b and 20 b have upper edges 30 b , 32 b , 34 b and 36 b , respectively.
- the base 12 b of the container 10 b shown in FIGS. 3, 3A and 3 B has a plurality of aligned generally rectangular openings 46 created by removing material from the base 12 b .
- the openings 46 are located generally near the intersection between the base 12 a and the side walls 14 a , 16 a , 18 a and 20 a .
- the openings 46 are illustrated as being a particular shape and a particular size, the shape and size of the openings 46 may be different than as is shown.
- These openings 46 as shown in FIG. 3B , provide a pivot point, further facilitate the flexing of the side walls of the container 10 a to allow multiple containers to be nested and stacked together.
- FIG. 3B when a second container 11 b like the container 10 b , having a base 13 b and sidewalls 15 b is nested inside the interior 21 b of the outer container 10 b , the side walls 14 b , 16 b , 18 b and 20 b of the outer container 10 b flex outward about a flex or pivot point 19 b along the base 12 b . See FIG. 3B . Due, at least in part due to the position of the openings 46 , an outer portion 48 of the base 12 b , along with the side walls flexes or pivots about a pivot point 26 b . FIG.
- FIG. 3B also shows a third tray or container 17 b having a base 19 b and sidewalls 23 b nested or nestably stacked within the second container 11 b .
- the second and third containers 11 b and 17 b are shown in FIG. 3B in dashed lines. Due, at least in part to the inherent nature of the thermoplastic material from which the container 10 b is made, the side walls 14 b , 16 b , 18 b and 20 b of the container 10 b return to their position shown in FIG. 3A after the containers 11 b and 17 b are taken out or removed from the interior 21 b of the container 10 b .
- two containers 11 b and 17 b are shown nestably stacked inside container 10 b , any number of containers may be nestably stacked together to save space during shipping and/or storage.
- FIGS. 4-6 illustrate the method of making container 10 .
- the first step in the method is providing a blank 50 die cut or otherwise formed from a flat piece of stock. Handles 22 may be cut from the blank 50 , if desired.
- the blank 50 is made of polypropylene foam.
- any like thermoplastic material could be used with the claimed process.
- Polyethylene is advantageous because it is a thermoplastic material which allows it to be heated, bent, and then retains its new shape when cooled.
- Polyethylene is a non-brittle thermoplastic which allows the container to have greater flexibility when multiple containers are nested together and it also has a surface temperature which is appropriate for many container applications.
- the blank 50 is positioned over a heat source 52 which may be a wire, light source, or other like heating mechanism.
- FIG. 5 illustrates a pair of heated wires 54 as the heat source 52 .
- the blank 50 and the heat source 52 are positioned so that the heat source 52 will heat the blank 50 along desired fold lines.
- the side wall 14 is bent upward along the fold line 27 thereby creating a side wall 14 perpendicular to the base 12 .
- the blank 50 is bent into shape, it is allowed to cool. Once it cools, it will retain its new shape. The process can then be repeated for each of the other side walls 16 , 18 and 20 until a container or tray is completely formed.
- the method may include a step of creating a plurality of tabs 42 in the blank 50 and more particularly in the central portion of the blank 50 which becomes the base 12 when the container 10 a is formed.
- a cutting tool 56 may be moved relative to a stationary blank 50 or alternatively, the blank 50 may be moved relative to a stationary cutting tool 54 to cut the blank 50 at the desired locations to form the tabs 40 .
- the method may include a step of creating a plurality of openings 42 in the blank 50 and more particularly in the central portion of the blank 50 which becomes the base 12 when the container 10 b is formed.
- a cutting tool 58 may be moved relative to a stationary blank 50 or alternatively, the blank 50 may be moved relative to a stationary cutting tool 58 to cut the blank 50 at the desired locations to form the openings 46 .
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Abstract
The present invention provides a container for holding product therein during shipment, storage, or display and being returned for reuse. The container has a base and perpendicular side walls. The side walls are not attached to each other. The base and side walls are adapted, individually or in combination, to flex so that a second container can be nested within a first container. When the second container is placed within the first container, a portion of the base and the side walls of the first container form an obtuse angle. The base and the side walls are biased to form a right angle before the second container is nested within the first and after the second container is unstacked from the first container.
Description
- The present invention relates to containers for use in shipping, storing, and/or displaying product, and more particularly, to containers or trays that can be nestably stacked together.
- A large number of different container structures are utilized by manufacturers to ship a variety of different products to end users, which may be wholesale or retail customers. These containers may also be used to store and/or display products. Many of these boxes, trays, or like container carriers have perpendicular side walls in order to efficiently and effectively utilize the internal volume of the container for storing or displaying a product while at the same time minimizing the space needed to store or transport the containers. Additionally, many of these containers are made out of a rigid or semi-rigid material such as plastic to further the transport, support, or display of a product. However, these containers, even those with an open top, e.g., tray-like containers, have the disadvantage of not being able to be compactly stored when not in use. Empty containers that cannot be compactly stored for reuse take up valuable warehouse or storage space and also increase shipping costs as they require more space in a vehicle while being returned for reuse.
- One style of container that does allow for compact storage when not in use is one that has its side walls obtusely angled out from its bottom or base wall. This style of a container allows empty containers to be nested or stacked together in a relatively compact fashion. However, for some products, these style of containers have the disadvantage of wasting internal space within the container and not allowing for the effective display or storage of products. For example, for some products, space within the container, particularly near the top of the container, is wasted due to the angling out of the side walls. Additionally, when these style containers are placed next to one another for shipping or storage, space between the containers, particularly at the bottom of the container is wasted due again to the angling out of the side walls. Hence, shipping and storage costs are increased.
- Another style of containers have employed a collapsible method for achieving compact storage when not in use, but these types of boxes have the disadvantage of being required to be assembled or de-assembled before or after use, and may also lack other advantageous properties such as the rigidity of a plastic-like material which may be lacking in a cardboard-style container.
- Accordingly, there is a need for a container with generally perpendicular side walls for shipping, storing, and/or displaying a product that also allows for the compact storing or nesting of the containers or trays when not in use. There is further a need for a method to produce such a stackable container.
- The present invention provides a container or tray for holding product therein during shipment, storage, and/or display and being returned for reuse. Specifically, the container has a generally rectangular base and side walls which are normally perpendicular to the base. The side walls are not attached to each other so that the corners formed between the side walls are cutaway or open. A portion of the base is adapted to flex or pivot so that a second container can be stackably nested within a first container, thereby saving space for shipping or storage purposes. When the second container is placed within the first container, a central portion of the base and the side walls of the first container form an obtuse angle which allows the second container to be nested within the first. Moreover, the base and the side walls are biased, independently or in combination, to form a right angle between the base and the side walls both before the second container is nested within the first and after the second container is unstacked from the first container. In a preferred embodiment, the container is made out of a thermoplastic material which may be a polypropylene foam or any other suitable material. However, the material from which the container is made may vary. It is the inherent properties of the material from which the container is made which enable the side walls to spring back or return to their original positions after one or more inner trays or containers is/are removed from the interior of the outside container.
- In one embodiment, the base of the container or tray has a plurality of aligned openings therethrough positioned near the intersection of the side walls and the base, i.e., near the right angle formed between an outer portion of the base and the side walls. These openings, which may be any desired shape or configuration, facilitate the flexing or pivoting of the container side walls to allow multiple containers to be nested and stacked together.
- In another embodiment, the base of the container or tray has a plurality of aligned tabs formed by C-shaped cuts therethrough positioned near the intersection of the side walls and the base, i.e., near the right angle formed between an outer portion of the base and the side walls. These tabs, which may be any desired shape or configuration, facilitate the flexing or pivoting of the container sidewalls relative to a central portion of the base to allow multiple containers to be nested and stacked together.
- The present invention also provides for a stack of containers nestably stacked inside each other, each having a base and a plurality of side walls, which are not attached to each other, but which are integral with the base. The base and the side walls of at least one outer container form an obtuse angle allowing additional containers to be nested inside the outer container or containers. The base and the side walls, individually or in combination, are biased so that the container side walls form right angles with a central portion of the base before another container is nested inside the container and also after the containers are separated.
- The nestably stackable containers of the present invention can be formed by providing a blank and a heat source, heating the blank with the heat source along fold lines, bending the blank along the fold lines whereby side walls are formed perpendicular to the base and extending upwardly from the base. The base and side walls are then allowed to cool in their preferred orientation or position. In a preferred embodiment, a thermoplastic material is used to form the container which enables the container to return to its original position after being emptied of other containers. Additionally, a plurality of openings may be created in the base by removing material from select locations of the blank. Alternatively, a plurality of tabs may be created in the base by cutting the blank at select locations in predetermined shapes or configurations. The openings or tabs create hinges or pivot points about which the side walls hinge or pivot when another like container is nestably stacked therein.
- The present invention provides a box, container or tray which has side walls which are sturdy or strong enough to keep objects therein and which is also nestably stackable. The above and other objects and advantages of the present invention shall be made apparent from the accompanying drawings and the description thereof.
- The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with a general description of the invention given above and the detailed description of the embodiments given below, serve to explain the principles of the invention.
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FIG. 1 is a perspective view of a preferred embodiment of the container of the present invention; -
FIG. 1A is a cross-sectional view taken ofline 1A-1A ofFIG. 1 ; -
FIG. 1B is a cross-sectional view of a portion of a stack of containers shown inFIGS. 1 and 1 A; -
FIG. 2 is a perspective view of another embodiment of container in accordance with the present invention; -
FIG. 2A is a cross-sectional view taken ofline 2A-2A ofFIG. 2 .; -
FIG. 2B is a cross-sectional view of a portion of the container shown inFIGS. 2 and 2 A being flexed when additional like containers are nested within it; -
FIG. 3 is a perspective view of another embodiment of container in accordance with the present invention; -
FIG. 3A is a cross-sectional view taken ofline 3A-3A ofFIG. 3 ; -
FIG. 3B is a cross-sectional view of a portion of the container shown inFIGS. 3 and 3 A being flexed when additional like containers are nested within it; -
FIG. 4 is a perspective view of a flat blank used to form the container shown inFIGS. 2 and 2 A before the side walls are bent into position; -
FIG. 4A is a perspective view of another blank used to form the container shown inFIGS. 2 and 2 A before its side walls are bent into position; -
FIG. 4B is a perspective view of another blank used to form the container shown inFIGS. 3 and 3 A before its side walls are bent into position; -
FIG. 5 is a perspective view showing the blank shown inFIG. 4 positioned over a heat source; and -
FIG. 6 is a perspective view of the tray shown inFIGS. 1 and 1 A, showing a first side wall being bent into position. - Referring to
FIG. 1 , there is illustrated a container ortray 10 according to one embodiment of the present invention. Thecontainer 10 comprises abase 12 and a plurality ofside walls base 12 and being perpendicular to thebase 12. Thebase 12 andside walls container 10 for storing or displaying products or items (not shown). Theside walls hole 22 which may be used as handles for transporting thecontainer 10. If desired, the handles may be omitted on one or more side walls. Alternatively, any number of handles of any shape or configuration may be incorporated into thecontainer 10. - As shown in
FIG. 1A , the side walls, 14, 16, 18 and 20 are not attached to each other. Hence, thecontainer 10 has open orcutaway corners 24. Although one configuration or shape of openings at thecorners 24 is illustrated, theopen corners 24 may be other sizes or shapes. Theside walls fold line 27 and form aright angle 28 with thebase member 12. SeeFIGS. 1 and 1 A. Theside walls upper edges - As shown in
FIG. 1B , when asecond container 11 like thecontainer 10, having a base 13 and sidewalls 15 is nested inside the interior 21 of theouter container 10, theside walls outer container 10 flex outward about a flex orpivot point 26 located alongbase 12. SeeFIG. 1B .FIG. 1B also shows a third tray orcontainer 17 having a base 19 andsidewalls 23 nested or nestably stacked within thesecond container 11. The second andthird containers FIG. 1B in dashed lines. Due, at least in part to the inherent nature of the thermoplastic material from which thecontainer 10 is made, theside walls container 10 return to their position shown inFIG. 1A after thecontainers interior 21 of thecontainer 10. Although twocontainers container 10, any number of containers may be nestably stacked together to save space during shipping and/or storage. -
FIG. 2 shows an alternative embodiment of the present invention. In this embodiment, like parts will be described with like numbers to those described above but with an “a” designation after the number. In this embodiment, container 10 a comprises a base 12 a and a plurality ofside walls side walls side walls hole 22 a used as handles for transporting the container 10 a. If desired, the handles may be omitted on one or more side walls. Alternatively, any number of handles of any shape or configuration may be incorporated into the container 10 a. - As shown in
FIG. 2 , theside walls cutaway corners 24 a. Although one configuration or shape of openings at thecorners 24 a is illustrated, theopen corners 24 a may be other sizes or shapes. Theside walls right angle 28 a with the base 12 a. SeeFIGS. 2 and 2 A. Theside walls upper edges - The base 12 a of the container 10 a shown in
FIGS. 2, 2A and 2B has a plurality of alignedtabs 40 formed by C-shaped cuts 42 through the base 12 a. Thetabs 40 are located generally near the intersection between the base 12 a and theside walls tabs 40 are illustrated as being in a generally C-shape and a particular size, the shape and size of thetabs 40 may be different than as is shown. Thesetabs 40, as shown inFIG. 2B , provide a pivot point, further facilitate the flexing of the side walls of the container 10 a to allow multiple containers to be nested and stacked together. - As shown in
FIG. 2B , when asecond container 11 a like the container 10 a, having a base 13 a and sidewalls 15 a is nested inside the interior 21 a of the outer container 10 a, theside walls FIG. 2B . Due, at least in part due to the position of thetabs 40, anouter portion 44 of the base 12 a, along with the side walls flexes or pivots about a pivot point 19 a.FIG. 2B also shows a third tray or container 17 a having a base 19 a and sidewalls 23 a nested or nestably stacked within thesecond container 11 a. The second andthird containers 11 a and 17 a are shown inFIG. 2B in dashed lines. Due, at least in part to the inherent nature of the thermoplastic material from which thecontainer 10 is made, theside walls FIG. 2A after thecontainers 11 a and 17 a are taken out or removed from the interior 21 a of the container 10 a. Although twocontainers 11 a and 17 a are shown nestably stacked inside container 10 a, any number of containers may be nestably stacked together to save space during shipping and/or storage. -
FIG. 3 shows yet another embodiment of the present invention. In this embodiment, like parts will be described with like numbers to those described above but with an “b” designation after the number. In this embodiment,container 10 b comprises a base 12 b and a plurality ofside walls side walls container 10 b for storing or displaying products or items (not shown). Theside walls hole 22 b used as handles for transporting thecontainer 10 b. Of course, the handles may be omitted on any side wall, if desired. Alternatively, any number of handles of any shape or configuration may be incorporated into thecontainer 10 b. - As shown in
FIG. 3 , theside walls container 10 b has open orcutaway corners 24 b. Although one configuration or shape of openings at thecorners 24 b is illustrated, theopen corners 24 b may be other sizes or shapes. Theside walls fold line 27 b and each side wall forms aright angle 28 b with the base 12 b. SeeFIGS. 3 and 3 A. Theside walls upper edges - The base 12 b of the
container 10 b shown inFIGS. 3, 3A and 3B has a plurality of aligned generallyrectangular openings 46 created by removing material from the base 12 b. Theopenings 46 are located generally near the intersection between the base 12 a and theside walls openings 46 are illustrated as being a particular shape and a particular size, the shape and size of theopenings 46 may be different than as is shown. Theseopenings 46, as shown inFIG. 3B , provide a pivot point, further facilitate the flexing of the side walls of the container 10 a to allow multiple containers to be nested and stacked together. - As shown in
FIG. 3B , when asecond container 11 b like thecontainer 10 b, having a base 13 b and sidewalls 15 b is nested inside the interior 21 b of theouter container 10 b, theside walls outer container 10 b flex outward about a flex orpivot point 19 b along the base 12 b. SeeFIG. 3B . Due, at least in part due to the position of theopenings 46, anouter portion 48 of the base 12 b, along with the side walls flexes or pivots about apivot point 26 b.FIG. 3B also shows a third tray orcontainer 17 b having a base 19 b and sidewalls 23 b nested or nestably stacked within thesecond container 11 b. The second andthird containers FIG. 3B in dashed lines. Due, at least in part to the inherent nature of the thermoplastic material from which thecontainer 10 b is made, theside walls container 10 b return to their position shown inFIG. 3A after thecontainers container 10 b. Although twocontainers container 10 b, any number of containers may be nestably stacked together to save space during shipping and/or storage. -
FIGS. 4-6 illustrate the method of makingcontainer 10. The first step in the method is providing a blank 50 die cut or otherwise formed from a flat piece of stock.Handles 22 may be cut from the blank 50, if desired. In a preferred embodiment, the blank 50 is made of polypropylene foam. However, any like thermoplastic material could be used with the claimed process. Polyethylene is advantageous because it is a thermoplastic material which allows it to be heated, bent, and then retains its new shape when cooled. Polyethylene is a non-brittle thermoplastic which allows the container to have greater flexibility when multiple containers are nested together and it also has a surface temperature which is appropriate for many container applications. - As shown in
FIG. 5 , the blank 50 is positioned over aheat source 52 which may be a wire, light source, or other like heating mechanism.FIG. 5 illustrates a pair ofheated wires 54 as theheat source 52. The blank 50 and theheat source 52 are positioned so that theheat source 52 will heat the blank 50 along desired fold lines. Once the blank 50 is sufficiently heated, as shown inFIG. 5 , theside wall 14 is bent upward along thefold line 27 thereby creating aside wall 14 perpendicular to thebase 12. After the blank 50 is bent into shape, it is allowed to cool. Once it cools, it will retain its new shape. The process can then be repeated for each of theother side walls - As shown in
FIG. 4A , the method may include a step of creating a plurality of tabs 42 in the blank 50 and more particularly in the central portion of the blank 50 which becomes the base 12 when the container 10 a is formed. As shown inFIG. 4A , acutting tool 56 may be moved relative to a stationary blank 50 or alternatively, the blank 50 may be moved relative to astationary cutting tool 54 to cut the blank 50 at the desired locations to form thetabs 40. - As shown in
FIG. 4B , the method may include a step of creating a plurality of openings 42 in the blank 50 and more particularly in the central portion of the blank 50 which becomes the base 12 when thecontainer 10 b is formed. As shown inFIG. 4B , acutting tool 58 may be moved relative to a stationary blank 50 or alternatively, the blank 50 may be moved relative to astationary cutting tool 58 to cut the blank 50 at the desired locations to form theopenings 46. - While various embodiments of the present invention have been illustrated and described in considerable detail, it is not the intention of the applicant to restrict or in any way limit the scope of the claims to such detail. Additional advantages and modifications will readily appear to those skilled in the art. The invention in its broader aspect is, therefore, not limited to the specific details, representative system, apparatus, and method, and illustrative example shown and described. Accordingly, departures may be made from such details without departing from the spirit or scope of the applicant's general inventive concept.
Claims (20)
1. A first stackable container comprising:
a base;
a plurality of side walls integral with the base and extending upwardly from the base, the side walls being unattached to one another and perpendicular to the base;
wherein the side walls are adapted to flex outwardly upon a second stackable container being nested within the first stackable container.
2. The first stackable container of claim 1 wherein a portion of the base and the side walls of the first stackable container form an obtuse angle when the second stackable container is nested within the first stackable container.
3. The first stackable container of claim 1 wherein the base and the side walls are biased to form a right angle between the base and the side walls before the second stackable container is nested within the first stackable container and after the second stackable container is removed from inside the first stackable container.
4. The first stackable container of claim 1 wherein the first stackable container is made of a thermoplastic material.
5. The first stackable container of claim of claim 1 wherein the first stackable container is made of polypropylene foam.
6. The first stackable container of claim of claim 1 wherein the base has a plurality of openings therethrough.
7. The first stackable container of claim of claim 1 wherein the base has a plurality of tabs.
8. The first stackable container of claim of claim 1 wherein the base has a hinge which enables the side walls to pivot about the hinge when another container is nested inside the first stackable container.
9. The first stackable container of claim of claim 8 wherein material has been removed from the base to define the hinge.
10. The first stackable container of claim of claim 1 wherein an outside portion of the base and each sidewall remain perpendicular to each other after at least one other container is nested inside the first stackable container.
11. A stack of containers adapted for holding a product comprising:
a first and second container each having a base and a plurality of side walls, the side walls being unattached to one another;
wherein the second container is nested inside the first container such that a portion of the base and side walls of the first container form an obtuse angle.
12. The stack of containers of claim 11 wherein the base and the side walls of each of the containers are biased to form a right angle between the base and the side walls before the containers are nested together and after the containers are separated.
13. The stack of containers of claim 11 wherein the containers are made of a thermoplastic material.
14. The stack of containers of claim 11 wherein the containers are made of polypropylene foam.
15. The stack of containers of claim 11 wherein the bases of the containers have openings therethrough.
16. The stack of containers of claim 11 wherein the bases of the containers have tabs formed therein.
17. A method for making a stackable container comprising the steps of:
providing a blank and a heat source;
heating the blank with the heat source along fold lines;
bending the blank at the fold lines so as to create a container having a base and side walls perpendicular to the base, the side walls being unattached to each other; and
allowing the base and side walls to cool.
18. The method of claim 17 wherein heating the blank along fold lines comprises heating a blank of thermoplastic material along fold lines.
19. The method of claim 17 further comprising the step of creating a plurality of openings in the base.
20. The method of claim 17 further comprising the step of creating a plurality of tabs in the base.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US11/183,349 US20070012590A1 (en) | 2005-07-18 | 2005-07-18 | Container with cutaway corners |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US11/183,349 US20070012590A1 (en) | 2005-07-18 | 2005-07-18 | Container with cutaway corners |
Publications (1)
Publication Number | Publication Date |
---|---|
US20070012590A1 true US20070012590A1 (en) | 2007-01-18 |
Family
ID=37660687
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US11/183,349 Abandoned US20070012590A1 (en) | 2005-07-18 | 2005-07-18 | Container with cutaway corners |
Country Status (1)
Country | Link |
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US (1) | US20070012590A1 (en) |
Cited By (6)
Publication number | Priority date | Publication date | Assignee | Title |
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US20070151891A1 (en) * | 2005-10-11 | 2007-07-05 | Miguel Angel Rioja Calvo | Metallic Storage Box |
FR2918971A1 (en) * | 2007-07-18 | 2009-01-23 | Normandie Appats Soc Par Actio | Shipworm conditioning case for aerial transport application, has tabs with length higher than length of fold such that supports of tabs provide retention space and empty baffle space between air volume and exterior of trays |
US20120213617A1 (en) * | 2009-08-17 | 2012-08-23 | Max Winkler | Angular load support as well as storage and order-picking system having an angular load support being applicable universally |
US20160006189A1 (en) * | 2014-07-01 | 2016-01-07 | Walter J. Morehead | Organizing Device |
USD843111S1 (en) | 2018-09-04 | 2019-03-19 | Rehrig Pacific Company | Nestable beverage crate |
US11352181B2 (en) | 2013-05-10 | 2022-06-07 | Rehrig Pacific Company | Low depth crate |
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Publication number | Priority date | Publication date | Assignee | Title |
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US20070151891A1 (en) * | 2005-10-11 | 2007-07-05 | Miguel Angel Rioja Calvo | Metallic Storage Box |
FR2918971A1 (en) * | 2007-07-18 | 2009-01-23 | Normandie Appats Soc Par Actio | Shipworm conditioning case for aerial transport application, has tabs with length higher than length of fold such that supports of tabs provide retention space and empty baffle space between air volume and exterior of trays |
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US20120213617A1 (en) * | 2009-08-17 | 2012-08-23 | Max Winkler | Angular load support as well as storage and order-picking system having an angular load support being applicable universally |
US11352181B2 (en) | 2013-05-10 | 2022-06-07 | Rehrig Pacific Company | Low depth crate |
US20160006189A1 (en) * | 2014-07-01 | 2016-01-07 | Walter J. Morehead | Organizing Device |
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AS | Assignment |
Owner name: BRADFORD COMPANY, MICHIGAN Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:NYEBOER, CALVIN D.;REEL/FRAME:016789/0265 Effective date: 20050714 |
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STCB | Information on status: application discontinuation |
Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION |