WO2005100176A2

WO2005100176A2 - Knock-down crate with walls stored in base and method employing such a crate

Info

Publication number: WO2005100176A2
Application number: PCT/IL2005/000384
Authority: WO
Inventors: Nir Hadar
Original assignee: Polymer Logistics (Israel) Ltd.
Priority date: 2004-04-19
Filing date: 2005-04-10
Publication date: 2005-10-27
Also published as: WO2005100176A3; EP1737737A4; EP1737737B1; AU2005232974A1; EP1737737A2; BRPI0509009A; AU2005232974B2; JP2007532430A

Abstract

A knock-down crate having a base associated with four sides. In a first embodiment, the base and the sides are hingedly interconnected. In alternative embodiments, the sides are detachably engageable with the base for deployment parallel to the length and breadth of the base. The upper surface of the base has an elongated recess extending most of the length and sized for receiving at least some of the sides. The sides can be deployed such that the base and four sides form a four-sided crate with the recess of the base contributing to the available volume of the crate. When not in use, at least some of the sides are received within the recess in the base for compact transportation.

Description

KNOCK-DOWN CRATE WITH WALLS STORED IN BASE AND METHOD EMPLOYING SUCH A CRATE

FIELD AND BACKGROUND OF THE INVENTION

The present invention relates to crates and, in particular, it concerns a

knock-down crate in which the walls can be stored in a recess in the base, and a

corresp onding method for transporting produce.

It is known to provide containers of many types for transporting

produce, manufactured articles, raw materials etc. from one location to another.

Such containers are generally configured to be lifted by a fork-lift vehicle and

are stackable. These containers, typically referred to as "bins", "box-pallets",

"crates" or "totes", will be referred to generically herein as "crates".

In many cases, molded polymer containers are chosen for their light

weight, robustness and long usable lifetime. To realize the maximum strength

of the polymer materials, polymer crates are often molded in a single piece. As

a result, however, they occupy the same volume when transported empty on a

return journey as when full on an outbound journey. This extremely inefficient

use of space is very costly. Various disassembling or foldable crates have been d&veloped in an

attempt to reduce the transport volume requirements when the crates are empty.

All such crates which either disassemble (i.e., come apart into separate

elements) or fold (i.e., with all elements remaining interconnected) are referred

to generically herein as "knock-down crates". An example of a foldable crate

may be found in U.S. Patent No. 5,094,356 to Miller. Examples of crates which

disassemble may be found in U.S. Patent No. 5,638,973 to Dewey et al., U.S.

Patent No. 6,142,329 to Dotan, and U.S. Patent Application Publication No.

2002/0084274 to Dotan. These publications are hereby incorporated by

reference as if set forth entirely herein.

While offering more efficient use of volume, knock-down crates

generally suffer from a number of disadvantages. Specifically with respect to

crates which disassemble into separate elements, the base and ttie sides once

separated are generally much less convenient to handle. Furtheraiore, the

number of individual elements which must be handled is greatly increased, and

considerable extra labor may be required for packing individual bases and sides

compactly for volume-efficient transportation to the next point of use.

There is therefore a need for a knock-down crate in which the walls can

be stored in a recess in the base for compact and convenient handling when

unloaded. SUMMARY OF THE INVENTION

The present invention is knock-down crate and a corresponding method

for transporting produce.

According to the teachings of the present invention there is provided, a

knock-down crate comprising: (a) a base having a length, a breadth, and an

upper surface; and (b) a first pair of sides associated with the base and

configured to alternate between a first deployment parallel to the length and a

storage deployment, and a second pair of sides associated with the base

configured to alternate between a first deployment parallel to the breadth and a

storage deployment, wherein the upper surface of the base features an

elongated recess extending substantially the entirety of the length, the recess

being sized for receiving at least one of the first and second pairs of sides, such

that, when the first and second pairs of sides are deployed in the first

deployment, the base and the sides define a four-sided crate with the recess

contributing to an internal volume of the crate, and when the first and second

pairs of sides are deployed in the storage deployment, at least one of the first

and second pairs of sides is receivable so as to be substantially contained

within the recess for compact transportation.

According to a further teaching of the present invention, association of

the first and second pairs of sides with the base includes hinged interconnection

of at least one of the first and second pairs of sides with the base such that the

at least one of the first and second pairs of sides is rotatable between the first

deployment and the storage deployment.

J According to a further teaching of the present invention, both the first

and second pairs of sides are hingedly interconnected to the base.

According to a further teaching of the present invention, one of the first

and second pairs of sides is receivable so as to be substantially contained

within the recess and the other of the first and second pairs of sides covers the

recess.

According to a further teaching of the present invention, the at least one

of the first and second pairs of sides having the hinged interconnection includes

at least the first pair of sides, and the first pair of sides is hingedly interconnect

so as to allow each side of the pair to move away from an edge of the base

when deployed in the recess.

According to a further teaching of the present invention, the hinged

interconnection allows a base region of the each side to descend into a depth of

the recess, so as to allow each of the sides of the first pair to lie parallel to the

upper surface.

According to a further teaching of the present invention, at least one of

the first and second pairs of sides includes attachment features configured so as

to disengagably attach adjacent sides one to another when the first and second

pairs of sides are deployed in the first deployment. According to a further teaching of the present invention, the pair of sides

that covers the recess folds such that each side of the pair folds over no more

than half of one of the length and the breadth. According to a further teaching of the present invention, the other of the

first and second pairs of sides includes a foldable extension portion along a top

region of at least one side of the pair of sides.

According to a further teaching of the present invention, the length is

substantially equal to the breadth.

According to a further teaching of the present invention, the elongated

recess is a closed-ended recess terminating at two end walls.

According to a further teaching of the present invention, each side of

one of the first and second pair of sides has a length no greater than a length of

the closed-ended recess.

According to a further teaching of the present invention, association of

the first and second pairs of sides with the base is a detachable engagement

such that the first and second pairs of sides, when detached from the base, are

receivable so as to be substantially contained within the recess to attain the

storage deployment.

According to a further teaching of the present invention, the length is

substantially equal to the breadth.

According to a further teaching of the present invention, the first pair of

sides and the second pair of sides are interchangeable. According to a further teaching of the present invention, the elongated

recess is an open-ended recess extending the entirety of the length.

According to a further teaching of the present invention, at least the

second pair of sides each features a downwardly projecting tab configured to substantially close an end of the open-ended recess when the side is engaged

with the base.

According to a further teaching of the present invention, the first pair of

sides and the second pair of sides are interchangeable, the base including a pair

of slots extending parallel to the length and configured for receiving the

downwardly projecting tab of the first pair of sides.

According to a further teaching of the present invention, the elongated

recess is a closed-ended recess tenninating at two end walls.

According to a further teaching of the present invention, each side of the

first and second pair of sides has a length no greater than a length of the closed-

ended recess.

According to a further teaching of the present invention, each side of the

first and second pairs of sides includes attachment features for attachment to

two adjacent sides, and wherein the attachment features are further configured

such that each pair of the sides are doubly-interlockable to fonn a unit with the

pair of sides associated in close parallel relation.

According to a further teaching of the present invention, upper and

lower edges of the first and second pairs of sides and upper and lower

peripheral regions of the base are formed with complementary alignment

projections and recesses such that, when the first and second pairs of sides are

engaged with the base to fonn the four-sided crate, the alignment projections

and recesses on the upper edges of the sides and on the lower peripheral region

of the base serve to align the four-sided crate with similar crates placed above and below the four-sided crate, and when the first and second pairs of sides are

received within the recess, the alignment projections and recesses on the upper

and lower peripheral regions of the base serve to align the base with similar

bases placed above and below the base. According to a further teaching of the present invention, the base and the

first and second pairs of sides are all fonned primarily from molded plastic

material.

According to a further teaching of the present invention, the base has a

pair of elongated channels extending parallel to the length for receiving tines of

a forklift mechanism.

According to a further teaching of the present invention, a major part of

the recess lies between the elongated channels.

There is also provided according to the teachings of the present

invention, a method for using a knock-down crate to transport produce from a

loading location to an unloading location, the method comprising the steps of:

(a) providing a knock-down crate having: (i) a base with an upper surface

including an elongated recess, and (ii) four sides deployable in a crate

configuration wherein the four sides are engaged with the base and each other

to fonn a four-sided crate, the four sides being further deployable in a knock-

down configuration wherein the four sides are deployed in a storage

deployment with at least two of the four sides received substantially within the

elongated recess; (b) deploying the crate in the crate configuration; (c) loading

the crate at the loading location with produce, at least part of the produce lying within the elongated recess; (d) transporting the produce in the crate to the

unloading location; (e) unloading the produce from the crate; and (f) deploying

the crate in the knock-down configuration with at least two of the four sides

located substantially within the elongated recess for transport to a next loading

location.

According to a further teaching of the present invention, upper and

lower edges of the sides and upper and lower peripheral regions of the base are

foπned with complementary aligmnent projections and recesses, the method

further comprising: (a) stacking the crate when in the crate configuration with

other similar crates such that the aligmnent projections and recesses on the

upper edges of the sides and on the lower peripheral region of the base serve to

align the crate with the other similar crates placed above and below the crate;

and (b) stacking the crate when in the knock-down configuration with other

similar crates such that the aligmnent projections and recesses on the upper and

lower peripheral regions of the base serve to align the crate with the other

similar crates placed above and below the crate.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention is herein described, by way of example only, with

reference to the accompanying drawings, wherein: Fig. 1 is an isometric view of a first embodiment of a knock-down crate

constructed and operative according to the teachings of the present invention,

in which the four sides are hingedly interconnected to the base; FIGS. 2-10 are isometric views of the embodiment of FIG.1, illustrating,

in sequence, steps for folding the crate from the assembled deployment to the

storage deployment;

FIGS. 11A-11E are isometric cross sections of the embodiment of FIG.

1 illustrating, in sequence, step of folding one pair of sides into the recess for

deployment to the storage deployment;

FIGS. 12A and 12B are schematic isometric views of a base and a set of

four sides, respectively, for use in a second embodiment of a knock-down crate

constructed and operative according to the teachings of the present invention,

in which the four sides are detachably engaged with the base;

FIG. 13 is a schematic isometric view of a four-sided crate constructed

from the base and sides of Figures 12A and 12B;

FIG. 14 is a schematic isometric view showing the sides of Figure 12B

received within a recess in the base of Figure 12A; FIG. 15 is a schematic isometric view showing the interconnection of

two of the sides of Figure 12B;

FIGS. 16A and 16B are schematic isometric views showing two of the

sides of Figure 12B immediately prior to, and after, interconnection to fonn a

two-side unit; FIG. 17 is a schematic partially cut-away isometric view of the crate of

the present invention during assembly or disassembly;

FIG. 18 is a schematic partially cut-away isometric view of the knocked-

down crate of Figure 14; FIGS. 19A and 19B are schematic isometric views of a base and a set of

four sides, respectively, for use in a third embodiment of a knock-down crate

constructed and operative according to the teachings of the present invention;

FIG. 20 is a schematic isometric view of a four-sided crate constructed

from the base and sides of Figures 19A and 19B;

FIG. 21 is a schematic isometric view showing the sides of Figure 19B

received within a recess in the base of Figure 19A;

FIG. 22 is a schematic cross-sectional view of the crate of Figure 3 or

Figure 20 in use filled with produce; FIG. 23 is a schematic cross-sectional view similar to Figure 22 showing

the crate in its knocked-down configuration for return transport; and

FIGS. 24A-24C are schematic cross-sectional views showing stacking

features of the crates of the present invention prior to assembly, when

assembled, and when in the knocked-down state, respectively.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

The present invention is a knock-down crate in which the walls can be

stored in a recess in the base for compact and convenient handling when

unloaded, and a corresponding method for transporting produce.

The principles and operation of knock-down crates according to the

present invention may be better understood with reference to the drawings and

the accompanying description. By way of introduction, the crate of the present invention includes a

base associated wititi four sides. The principles of the present invention will be

discussed herein with regard to three basic embodiments. The first

embodiment, in which the base and the sides are hingedly interconnected, will

be discussed regarding Figures 1-1 IE. The second and third embodiments, in

which the sides are detachably engageable with the base, will be discussed with

regard to Figures 12A-18 and 19-23, respectively.

Referring now to the drawings, Figure 1 shows a first preferred

embodiment of a knock-down crate, generally designated 300, constructed and

operative according to the teachings of the present invention. Generally

speaking, crate 300 is fonned from a base 312 and two pairs of sides 314 and

3146, 316α and 3166 all four of which are hingedly interconnected to base 312.

In this embodiment, sides 314« and 3146 are interconnected to base 312 by a

non-limiting example of a double hinge 370, as will be discussed in detail

below the regard to Figures 11 A- 1 IE.

Sides 316α and 3166 are hingedly interconnected to base 312 by hinge

350 that, in this non-limiting example, extends for substantially the entire

length of each side. It should be noted that substantially any suitable hinge

arrangement is within the scope of the present invention. An upper surface 318

of base 312 features an elongated recess 320 extending substantially the

entirety of a length L of base 312 and sized for receiving sides 314α and 3146

in a storage deployment. Once sides 314α and 3146 are stored in recess 320,

sides 316« and 3166 are folded inwardly to cover sides 314a and 3146, recess 320 and the exposed portions of upper surface 318 of base 312. It should be

noted that the word "inwardly" is used herein to refer to movement toward the

center of the crate.

Figures 2-10 illustrate steps for deploying the two pairs of sides 314α

and 3146, 316α and 3166 into their respective storage deployments. First, any

attachment feature that secures one of the sides to an adjacent side is

disengaged. The illustration here shows handles 322 configured in sides 314a

and 3146, however, substantially any disengageable attachment configuration,

as discussed below with regard to a second and third preferred embodiments,

may be used. Once disengaged from the adjacent sides 316α and 3166, side

3146 is folded inwardly, as seen in Figure 3, until it is received into recess 320,

as seen in Figure 4. Side 314Λ is then disengaged from the adjacent sides 316α

and 3166, and folded inwardly, as seen in Figure 5, until it is received into

recess 320 and resting on side 3146, as seen in Figure 6. It should be noted that

this sequence may be reversed and side 314α may be stored away first with

3146 resting on top.

Next, side 3166 is folded inwardly, as seen in Figure 7, until it is resting

on the upper surface 318 of the base 312, as seen in Figure 8. As illustrated in

Figure 8, when in the storage deployment, side 316b is preferably no longer

than one-half (V_L) of the length L of base 312 in order to add not more than

one side thickness to the thickness of the base in the overall thickness of the

storage configuration of the crate. In some applications sides 316α and 3166

may need to be longer than one-half (V2L) of the length L of base 312. For such applications, the present invention provides a foldable extension 352 hingedly

attached along the top edge of at least one of sides 316α and 3166. The foldable

extension 352 is attached by hinges 354, and is folded into the associated side

during the folding process of the side. A transverse recess 352α is preferably

provided in the base and/or folded sides to accommodate the foldable

extensions without adding significantly to the thickness of the folded

configuration.

Side 316α is then folded inwardly, as seen in Figure 9, until it is resting

on the upper surface 318 of the base 312, as seen in Figure 10. When both sides

316α and 3166 are in the storage deployment, substantially all of the upper

surface 318 of the base 312, recess 320, and sides 314α and 3146 are covered

by sides 316A and 3166.

In order for sides 314α and 3146 to be deployed in recess 320 that is

located between channels 326, as discussed below, it is necessary for sides

314α and 3146 to move away fonn the edge of base 312 , and preferably also to

be able to descend at least partially into the depth of recess 320. Further, it is

also preferable that the base region of the side, that is the region of the side that

abuts base 312, descend into the depth of recess 320, so as to allow each of the

side to lay parallel to the upper surface 318. Figures 11A- 11E illustrate a non-

limiting prefened hinged configuration for such interconnection of base 312

and sides 314α and 3146, and steps for deploying sides 314 and 3146 into

their respective storage deployments. It should be noted that other hinge

configurations may be suitable for this purpose. Such hinge configurations may include, but are not limited to, a slideable hinge, and a hinge pin associated

with a slot.

As illustrated, hinge bracket 370 provides rotation about two axes of

rotation, 360 and 362. When side 314α is folded inwardly, rotation about axis

362 allows the bottom edge of side 314α to move away from the edge of ba.se

312 in order to reach recess 320, as seen in Figure 11. Rotation about axis 360

allows side 316α to lay flat when received in recess 320, as seen in figure 11 C.

The "L" shape of bracket 370 allows the base region of the side to descend into

the depth of recess 320, so as to allow each of the sides 314α and 3146 to lay

parallel to the upper surface 318. The process is repeated when side 3146 is

brought into its storage deployment, as illustrated in Figures 11D and HE. It

will be understood that this discussion of the double hinge configuration is

intended only as an example of a hinged interconnection between the base 312

and sides 314 and 3146, and that other configurations that will provide

substantially the same results are possible. It should be noted that a crate in

which sides 314 and 3146 may be detached from base 312 for insertion into

recess 320 is within the scope of the present invention.

Crate 300 is preferably configured for handling by standard paLlet

handling equipment. To this end, as illustrated in Figure 1, base 312 preferably

has a pair of elongated channels 326 extending parallel to length L for

receiving tines of a forklift mechanism (forklift, pallet earner etc.). Channels

326 typically extend along the entirety of length L, allowing insertion of tines

from either end of the crate. Most preferably, at least a major portion of recess 320 is located between channels 326. Thus, considered from a different point of

view, crate 300 may be considered to have a thin base 312 in the region of

recess 320, with locally raised regions to provide the volume required for

channels 326. It will thus be understood that the usable volume of the inside of

the crate is fully maximized by making all volume other than that required for

channels 326 available for loading with produce.

Figures 12A-18 show a second preferred embodiment of a knock-down

crate, generally designated 10, constructed and operative according to the

teachings of the present hrvention. Generally speaking, crate 10 is formed from

a base 12 and a set 14 of sides 16α, 166, 16c and 16d. An upper surface 18 of

base 12 features an elongated recess 20 extending substantially the entirety of a

length L of the base and sized for receiving set of sides 14.

The sides are configured to be detachably engageable with base 12 with

a first pair 16α and 16c parallel to the length L of base 12 and a second pair 166

and 16d parallel to a breadth or width W of base 12 such that, when sides 16a,

166, 16c and 16d are engaged with base 12, the base and the sides define a

four-sided crate 10 as shown in Figure 13 with recess 20 contributing to an

internal volume of the crate. When the crate is unloaded and the sides are

detached from the base, the set 14 of sides 16α, 166, 16c and 16d are received

so as to be substantially contained within recess 20 to fonn the knocked-down

configuration of Figure 14 for compact transportation.

It will be immediately appreciated that the crate of the present invention

offers profound advantages over conventional knock-down crates. Specifically, in the assembled configuration of Figure 13, recess 20 contributes significantly

to the usable internal volume of the crate, thereby maximizing transport

volume. In the knocked-down state of Figure 14, all parts of the crate are

configured in a single compact block which is easily handled and can be

efficiently stacked with other similar crates to ensure minimum volume for

return transportation or storage of the crate when not in use. These and other

advantages of the present invention will be better understood from the

following detailed description.

Turning now to the features of crate 10 in more detail, it is a prefened

feature of certain implementations of the present invention that the crate is a

square crate, i.e., that length L is substantially equal to breadth W. In most

preferred cases, all four sides are then made interchangeable such that the user

can assemble the crate with each side located arbitrarily along any edge of the

base. In order to fonn a usable crate, it is clearly necessary to achieve load-

bearing engagement between adjacent sides of the assembled crate and between

each side and the base. Thus, each of sides 16a, 166, 16c and 16d includes

attachment features 22, 24 for attachment to two adjacent sides. Figure 15

illustrates two interconnected sides 16c and 16d, with their available

attachment features clearly visible. The attachment features are shown here

schematically as complementary rectangular-section interlocking tabs with

through-bores for receiving a bolt element to lock the sides together and to the

base. Most preferably, attachment features 22, 24 are further configured such that pairs of the sides are doubly-interlockable to forai a unit 14 with the pair

of sides associated in close parallel relation. Figures 16A and 16B show such a

unit 14α prior to and after interconnection. Figure 17 shows a cut-away view of

crate 10 partially assembled with one unit 14α stored in recess 20. Two such

units together make up an easily handled set 14 of sides for insertion into recess

20 as shown in Figure 18.

It should be appreciated that the attachment features shown here are

represented schematically. Various engagement configurations for removably

engaging sides with a base and with each other to form a knock-down crate are

known in the art. The specific choice of engagement configuration, other than

certain features discussed explicitly herein, does not constitute part of the

present invention per se and for conciseness will not be described here in detail.

By way of non-limiting examples, the various engagement and locking

configurations described in the aforementioned U.S. Patent No. 6,142,329 to

Dotan, and/or U.S. Patent Application Publication No. 2002/0084274 to Dotan

are considered suitable for implementation of the present invention.

Optionally, a locking anangement (not shown) may be provided to

retain set of sides 14 within recess 20 to ensure that the set of sides do not

become dislodged during handling. Most preferably, at least one locking

element used for interlocking the sides when assembled also functions to

selectively lock the set of sides within recess 20 when in the knock-down

configuration. Such an implementation is well within the capabilities of one

ordinarily skilled in the art. In most prefened implementations, base 12 and sides 16α, 166, 16c and

16d are all fonned primarily from molded plastic material. It should be noted,

however, that implementations of the crate structure described using materials

other than molded plastics also fall within the broad scope of the present

invention. The various components of the crates of the present invention are

illustrated here schematically and simplistically for clarity of presentation. The

geometrical patterns shown here on the sides of the crates are non-functional

and are included merely to facilitate visual differentiation between the inward-

facing and outward-facing surfaces. It will be understood by one ordinarily

skilled in the art that the various components will typically be implemented

with various structures of reinforcing ribs and/or other functional or decorative

features which do not per se constitute part of the present invention.

Furthennore, depending upon the type of produce to be transported and the

desired drainage characteristics of the crate, the base and walls may be made

either solid or with drainage and ventilation openings, as is known in the art.

Crate 10 is preferably configured for handling by standard pallet

handling equipment. To this end, base 12 preferably has a pair of elongated

channels 26 extending parallel to length L for receiving tines of a forklift

mechanism (forklift, pallet canier etc.). Channels 26 typically extend along the

entirety of length L, allowing insertion of tines from either end of the crate.

Most preferably, at least a major portion of recess 20 is located between

channels 26. Thus, considered from a different point of view, crate 10 may be

considered to have a thin base 12 in the region of recess 20, with locally raised regions to provide the volume required for channels 26. It will thus be

understood that the usable volume of the inside of the crate is fully maximized

by making all volume other than that required for channels 26 available for

loading with produce. Furthennore, since the sides are stored between the

regions of base 12 containing channels 26, nothing overlies the regions of the

base 12 containing channels 26 in the collapsed state, making the height of the

crate in its collapsed state significantly less than that of "fold-down" crates of

similar dimensions.

According to the second prefened embodiment of the present invention

shown here, elongated recess 20 is a closed-ended recess tenninating at two

end walls 28. As a result, the length of recess 20 is slightly less than the

external length L of base 12. To ensure that sides 16 , 166, 16c and 16d fit

within recess 20, each side preferably includes one corner portion of the

assembled crate, with part of the adjacent side or at least engagement features

for the adjacent side extending laterally from the corner portion. As a result, the

length of each side is less than the external length, dimension of the assembled

crate by the thickness of one corner portion, preferably at least equal to a

thickness of the crate side. Thus, if end walls 28 have a thickness no more than

about half the thickness of sides 16a, 16b, 16c and 16d, the sides can be

accommodated within recess 20.

Turning now to Figures 19A-21, there is shown a third prefened

embodiment of a crate, generally designated 10O, constructed and operative

according to the teachings of the present invention. Crate 100 is structurally and functionally similar to crate 10 described above. For clarity and

conciseness, features of crate 100 analogous to those of crate 10 are labeled

with reference numerals greater by 100 than the numeral used for the analogous

feature of crate 10. Crate 100 differs from crate 10 primarily in that recess 120 is here an

open-ended recess extending the entirety of length L. In order to ensure closure

of the sides of the assembled crate, at least one pair of sides 1166 and 116d

each features a downwardly projecting tab 130 configured to substantially close

an end of recess 120 when the side is engaged with base 112 as shown in

Figure 20. Most preferably, base 112 features an engagement indentation 132

(Figure 8 A) across each end of recess 120 with which downwardly projecting

tabs 130 engage when assembled to provide mecbanical support to the tabs.

As mentioned earlier, it is considered advantageous that the crates of the

present invention employ four interchangeable sides, thereby allowing a user to

assemble the crate with each side engaged along an arbitrarily chosen edge of

the base. Parenthetically, it should be noted that the term "interchangeable" as

used herein refers to sides having functionally equivalent features to the extent

that inadvertent swapping of two sides does not significantly impact the

function of the assembled crate. Interchangeability does not necessarily imply

that the sides are identical or indistinguishable.

In this embodiment, interchangeability of^" the sides may be achieved by

providing a pair of slots 134 extending parallel to length L and configured for

receiving downwardly projecting tabs 130 of the sides deployed parallel to length L. The engagement of tabs 130 within slots 134 also adds structural

strength to the assembled crate. In order to allow sides 116α and 116c to be

located at the outer edge of base 112, tabs 130 are most preferably slightly

thinner than the main upper portion of the sides and slightly set back from the

plane of the outer surface of the side.

Clearly, in an alternative implementation (not shown), tabs 130 may

have a thickness equal to that of the main upper portion of the sides, the tabs

being received in a conesponding external recess formed in the external

surfaces of the base parallel to the length L. In all other respects, the structure and function of crate 100 will be

understood by analogy to that of crate 10 described herein.

Refening now again generically to both embodiments of a crate

according to the teachings of the present invention, the sides and base are

preferably configured to allow stacking of the crate with other similar crates in

both the assembled crate configuration and the knock-down compact

configuration. To this end, the upper and lower edges of sides 16α, 166, 16c

and 16d, and upper and lower peripheral regions of base 112 are preferably

fonned with complementary alignment projections 20O and recesses 202

(Figure 24A). Aligmnent projections 200 and recesses 202 are positioned and

configured such that, when the sides are engaged with the base to fonn the

four-sided crate (Figure 24B), alignment projections 200 and recesses 202 on

the upper edges of the sides and on the lower peripheral region of the base

serve to align the four-sided crate with similar crates (not shown) placed above and below the crate, and when the sides are received within recess 20 (Figure

24C), aligmnent projections 200 and recesses 202 on the upper and lower

peripheral regions of the base serve to align the base with similar bases (not

shown) placed above and below the base. At this point, the use of crates 10 and 100 will be clearly understood.

Specifically, the crate is deployed in its deployed "crate configuration" and

loaded with produce at a loading location. It will be noted that, as shown in

Figure 22, at least part of the produce 204 lies within the elonga-ted recess 20,

thereby contributing to the total volume of produce which can be transported

within the crate. Then, after transporting the produce in the crate to an

unloading location, the produce is unloaded from the crate and the crate is

disassembled and the walls stored in the recess to produce the "knock-down

configuration" as shown in Figure 23. The crate is then compact and

conveniently handled, with the four sides located substantially within elongated

recess 20, for transport to a next loading location. Most preferably, in a crate

having aligmnent features as described with reference to Figures 24A-24C, the

crate is stacked with other similar crates when in the crate configuration such

that the aligmnent projections and recesses on the upper edges of the sides and

on the lower peripheral region of the base serve to align the crate with the other

similar crates placed above and below the crate, and is stacked when in the

knock-down configuration with other similar crates such that the aligmnent

projections and recesses on the upper and lower peripheral regions of the base serve to align the crate with the other similar crates placed above and below the

crate.

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.

Claims

WHAT IS CLAIMED IS:

1. A knock-down crate comprising:

(a) a base having a length, a breadth, and an upper surface; and

(b) a first pair of sides associated with said base and configured to alternate between a first deployment parallel to said length and a storage deployment, and a second pair of sides associated with said base configured to alternate between a first deployment parallel to said breadth and a storage deployment,

wherein said upper surface of said base features an elongated recess extending

substantially the entirety of said length, said recess being sized for receiving at

least one of said first and second pairs of sides, such that, when said first and

second pairs of sides are deployed in said first deployment, said base and said

sides define a four-sided crate with said recess contributing to an internal

volume of said crate, and when said first and second pairs of sides are deployed

in said storage deployment, at least one of said first and second pairs of sides is

receivable so as to be substantially contained within said recess for compact

transportation.

2. The knock-down crate of claim 1, wherein association of said first

and second pairs of sides with said base includes hinged interconnection of at

least one of said first and second pairs of sides with said base such that said at

least one of said first and second pairs of sides is rotatable between said first

deployment and said storage deployment.

3. The knock-down crate of claim 2, wherein both said first and second

pairs of sides are hingedly interconnected to said base.

4. The knock-down crate of claim 2, wherein one of said first and

second pairs of sides is receivable so as to be substantially contained within

said recess and the other of said first and second pairs of sides covers said

recess.

5. The knock-down crate of claim 2, wherein said at least one of said

first and second pairs of sides having said hinged interconnection includes at

least said first pair of sides, and said first pair of sides is hingedly interconnect

so as to allow each side of said pair to move away from an edge of said base

when deployed in said recess.

6. The knock-down crate of claim 5, wherein said hinged

interconnection allows a base region of said each side to descend into a depth

of said recess, so as to allow each of said sides of said first pair to lie parallel to

said upper surface.

7. The knock-down crate of claim 2, wherein at least one of said first

and second pairs of sides includes attachment features configured so as to

disengagably attach adjacent sides one to another when said first and second

pairs of sides are deployed in said first deployment.

8. The knock-down crate of claim 4, wherein said pair of sides that

covers said recess folds such that each side of said pair folds over no more than

half of one of said length and said breadth.

9. The knock-down crate of claim 8, wherein said other of said first and

second pairs of sides includes a foldable extension portion along a top region of

at least one side of said pair of sides.

10. The knock-down crate of claim 2, wherein said length is

substantially equal to said breadth.

11. The knock-down crate of claim 1, wherein said elongated recess is a

closed-ended recess terminating at two end walls.

12. The knock-down crate of claim 11, wherein each side of one of said

first and second pair of sides has a length no greater than a length of said

closed-ended recess.

13. The knock-down crate of claim 1, wherein association of said first

and second pairs of sides with said base is a detachable engagement such that

said first and second pairs of sides, when detached from said base, are

receivable so as to be substantially contained within said recess to attain said

storage deployment.

14. The knock-down crate of claim 13, wherein said length is

substantially equal to said breadth.

15. The knock-down crate of claim 14, wherein said first pair of sides

and said second pair of sides are interchangeable.

16. The knock-down crate of claim 13, wherein said elongated recess is

an open-ended recess extending the entirety of said length.

17. The knock-down crate of claim IS, wherein at least said second pair

of sides each features a downwardly projecting tab configured to substantially

close an end of said open-ended recess when said side is engaged with said

base.

18. The knock-down crate of claim 1 7, wherein said first pair of sides

and said second pair of sides are interchangeable, said base including a pair of

slots extending parallel to said length and configured for receiving said

downwardly projecting tab of said first pair of sides.

19. The knock-down crate of claim 13, wherein said elongated recess is

a closed-ended recess tenninating at two end walls.

20. The knock-down crate of claim 19, wherein each side of said first

and second pair of sides has a length no greater than a length of said closed-

ended recess.

21. The knock-down crate of claim 13, wherein each side of said first

and second pairs of sides includes attachment features for attachment to two

adjacent sides, and wherein said attachment features are further configured

such that each pair of said sides are doubly-interlockable to fonn a unit with

said pair of sides associated in close parallel relation.

22. The knock-down crate of claim 13, wherein upper and lower edges

of said first and second pairs of sides and upper and lower peripheral regions of

said base are formed with complementary aligmnent projections and recesses

such that, when said first and second pairs of sides are engaged with said base

to fonn said four-sided crate, said alignment projections and recesses on said

upper edges of said sides and on said lower peripheral region of said base serve

to align said four-sided crate with similar crates placed above and below said

four-sided crate, and when said first and second pairs of sides are received

within said recess, said aligmnent projections and recesses on said upper and

lower peripheral regions of said base serve to align said base with similar bases

placed above and below said base.

23. The knock-down crate of claim 22, wherein said base and said first

and second pairs of sides are all fonned primarily from molded plastic material.

24. The knock-down crate of claim 1, wherein said base has a pair of

elongated channels extending parallel to said length for receiving tines of a

forklift mechanism.

25. The knock-down crate of claim 24, wherein a major part of said

recess lies between said elongated channels.

26. A method for using a knock-down crate to transport produce from a

loading location to an unloading location, the method comprising the steps of:

(a) providing a knock-down crate having:

(i) a base with an upper surface including an elongated recess, and

(ii) four sides deployable in a crate configuration wherein said four sides are engaged with said base and each other to fonn a four-sided crate, said four sides being further deployable in a knock-down configuration wherein said four sides are deployed in a storage deployment with at least two of said four sides received substantially within said elongated recess;

(b) deploying said crate in said crate configuration;

(c) loading said crate at the loading location with produce, at least part of the produce lying within said elongated recess;

(d) transporting the produce in said crate to the unloading location; (e) unloading the produce from said crate; and

(f) deploying said crate in said knock-down configuration with at least two of the four sides located substantially within said elongated recess for transport to a next loading location.

27. The method of claim 26, wherein upper and lower edges of said sides

and upper and lower peripheral regions of said base are fonned with

complementary alignment projections and recesses, the method further

comprising:

(a) stacking said crate when in said crate configuration with other similar crates such that said alignment projections and recesses on said upper edges of said sides and on said lower peripheral region of said base serve to align said crate with the other similar crates placed above and below said crate; and

(b) stacking said crate when in said knock-down configuration with other similar crates such that said alignment projections and recesses on said upper and lower peripheral regions of said base serve to align said crate with the other similar crates placed above and below said crate.