Collapsible crate

Abstract

A collapsible crate, which has an especially sturdy construction, making it particularly suitable for containing and transporting large containers, such as one-gallon water or milk jugs, is disclosed. The crate may also be used for suspending file folders without the use of a rack onto which the file folders are suspended. The crate comprises a bottom panel, a top rectangular frame, two side panels pivotally connected at opposite ends of the frame, and front and back folding panels pivotally connected at their lower ends to opposite ends of the bottom panel and at their upper ends to corresponding opposite ends of the top frame, adjacent the side panels. The crate appears as a normal milk crate, but is collapsible to a very low profile by swinging the side panels up toward the frame, so that the side panels are substantially parallel to the bottom panel and co-planar with the frame, then allowing the front and back panels to fold inwardly to bring the top frame and bottom panel together, such that the crate structure is compressed into a compact configuration.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This patent application claims priority from U.S. Provisional Patent Application Ser. No. 60/449,202 filed Feb. 19, 2003 for COLLAPSIBLE CRATE, which application is incorporated herein by this reference thereto.

BACKGROUND OF THE INVENTION

[0002] 1. Field of the Invention

[0003] This invention relates generally to crates, and in particular to crates which are collapsible or foldable.

[0004] 2. Description of the Related Art

[0005] Containers having an open top for convenient storage and delivery of items have been designed as foldable for convenient storage of the containers themselves. See for example Saunders U.S. Pat. No. 3,796,342. Such containers, however, may have an unstable and heavy design, which uses too much material, making them costly and less than ideal -for delivery of heavy items, such as a plurality of one-gallon milk or water jugs.

SUMMARY OF THE INVENTION

[0006] The present invention provides a collapsible crate which has an especially sturdy construction, making it particularly suitable for containing and transporting large containers, such as one gallon water or milk jugs, and the like. The crate may also be used for suspending file folders without the use of a rack onto which the file folders are suspended. The crate comprises a bottom panel, a top rectangular frame, two side panels pivotally connected at opposite ends of the frame, and front and back folding panels pivotally connected at their lower ends to opposite ends of the bottom panel and at their upper ends to corresponding opposite ends of the top frame, adjacent the side panels. The crate appears as a normal milk crate, but is collapsible to a very low profile by swinging the side panels up toward the frame, so that the side panels are substantially parallel to the bottom panel and co-planar with the frame, then allowing the front and back panels to fold inwardly to bring the top frame and bottom panel together, such that the crate structure is compressed into a compact configuration.

OBJECTS OF THE INVENTION

[0007] It is an object of the present invention to provide a crate which is collapsible or foldable to a compact configuration.

[0008] It is another object of the present invention to provide a collapsible crate which has an especially sturdy construction, making it particularly suitable for containing and transporting large containers, such as one gallon water or milk jugs.

[0009] It is yet another object of the present invention to provide a collapsible crate which can be used for directly suspending file folders, without the use of an additional rack for suspending the folders.

BRIEF DESCRIPTION OF THE DRAWINGS

[0010] FIG. 1 is a perspective view of the crate of the present invention, shown in its functional state.

[0011] FIG. 2 is a perspective view of the crate of FIG. 1, containing six one-gallon water bottles.

[0012] FIG. 3 is a perspective view of the crate of FIG. 1, shown in its collapsed stated.Figure 4 is a perspective top view of the bottom panel of the crate of FIG. 1, shown disassembled from the crate.

[0013] FIG. 5 is a perspective view of the inner side of the lower and upper panel sections which form the front panel of the crate of FIG. 1, the front panel being identical to the back panel. The upper and lower sections are shown unconnected to each other and disassembled from the crate.

[0014] FIG. 6 is a perspective view of the top frame of the crate of FIG. 1, shown disassembled from the crate.

DESCRIPTION OF THE PREFERRED EMBODIMENT(S)

[0015] The detailed description set forth below in connection with the appended drawings is intended as a description of presently preferred embodiments of the invention and is not intended to represent the only forms in which the present invention may be constructed and/or utilized. The description sets forth the functions and the sequence of steps for constructing and operating the invention in connection with the illustrated embodiments. However, it is to be understood that the same or equivalent functions and sequences may be accomplished by different embodiments that are also intended to be encompassed within the spirit and scope of the invention.

[0016] The present invention provides a collapsible crate 1 comprising a bottom panel 2, a top rectangular frame 3, two side panels, 4 and 5, pivotally connected at opposite ends of the frame 3, and front and back folding panels, 6 and 7, pivotally connected at their lower ends, 8 and 9, to opposite ends of the bottom panel 2 and at their upper ends, 10 and 11, to corresponding opposite ends of the top frame 3, adjacent the side panels. The crate 1 is foldable or collapsible to a low profile (see FIG. 3) by swinging the side panels 4, 5 up toward the frame 3, so that the side panels are substantially parallel to the bottom panel 2 and co-planar with the frame 3, then allowing the front and back panels 6, 7 to fold inwardly, bringing the top frame 3 and bottom panel 2 together, such that the crate structure is compressed into a compact configuration. The side panels 4, 5 may overlap at their bottom ends 12, 13, depending on the length of the panels.

[0017] The crate 1 has an especially sturdy construction, making it particularly suitable for containing and transporting large containers, such as water or milk jugs, as shown in FIG. 2. The panels of the crate 1 are preferably constructed from plastic forming a mesh pattern for a low material, lightweight, and cost effective construction. FIGS. 4 through 6 illustrate the bottom and front panels, and top frame of the crate, with each member shown separate from the crate, and without the mesh pattern, for purposes of illustration.

[0018] The bottom panel 2 of the crate 1 is a piece which includes a base 15 which forms a bottom support for the crate 1, and a shallow border wall 14 extending orthogonal and upwardly from the base 15 forming a low perimeter wall around the base. The border wall 14 comprises opposite side walls, 16 and 17, and opposite front and back walls, 18 and 19, as shown in the figure. The side walls 16, 17, each includes a pair of apertures, 20 and 21, receptively, wherein each aperture is proximal to a corner of the border wall 14, for receiving a hinge pin from an adjacent lower side end of the front and back folding panels 6, 7. The front and back walls 18, 19, each include hinge notches or recesses, 22 and 23, which extend inwardly from each wall, for pivotally connecting at the lower ends 8, 9 of the front and back folding panels 6, 7, via metallic hinge pins. Additionally, central hinge coupling panels 32, 33, form receiving panels which pivotally interconnect with pin rods formed on the lower ends 8, 9 of the front and back panels 6, 7.

[0019] The front panel 6, which is identical to the back panel, is illustrated in FIG. 5. The panel 6 includes upper and lower panel sections, 24 and 25, respectively, which are shown unattached in the figure for illustration purposes. The panel sections 24, 25, include mating hinge notches 26, 27, at their lower and upper edges, 28, 29, respectively, which are pivotally interconnected via hinge pins (not shown), to form the foldable panel 6.

[0020] Also, the upper section 24 includes L-shaped extending panels 36, for engagement with corresponding receiving grooves 37 on the lower section 25. The engagement between the panels 36 and grooves 37, prevents the lower and upper sections from folding outwardly and lends sturdiness to the crate structure when the crate is in its unfolded or upright configuration.

[0021] Additionally, the lower panel section 25 includes hinge notches or recess 31 at its lower end 8 which interconnect with mating hinge notches or recesses 22 on the top frame. Additionally, medial pin rods 34 are formed at the lower section 8 which pivotally interconnect with the pin receiving panels 32 of the bottom panel 2. Likewise, the upper panel section 24 includes hinge notches or recesses 30 at its upper end 10, and pin rods 35 which interconnect with the notches or recesses and pin receiving panels formed on the top frame 3, similar to the notches or recesses 22 and panels 32.

[0022] The upper and lower panel sections 24, 25, further include side L-shaped panels, 38 and 39, for engagement with recesses on the side panels, 4 and 5, when the crate is in its unfolded configuration, lending further stability to the crate structure.

[0023] The top frame 3 of the crate 1 is shown in FIG. 6, and includes front and back frame walls, 40 and 41, and side walls, 42 and 43. The walls 40, 41 include hinge notches or recesses similar to the notches or recesses, 22 and 23, on the bottom panel, and hinge coupling panels forming pin receiving panels, similar to the panels 32 and 33 of the bottom panel 2, for pivotally coupling to the upper ends 10, 11 of the front and back panels 6, 7.

[0024] The front and back walls 40, 41 each includes a pair of apertures, formed in recessed portions proximal the corners of the top frame 3. (The aperture and recessed portions 43 are shown in the figure only for the front wall 40). The aperture on the walls 40, 41 are similar to the apertures 20 and 21, and receive a hinge pin from an adjacent upper side of the side panels 4, 5, forming a pivotal coupling with the side panels. The side panels further include a central pin rod, similar to the pin rods on the front and back panels, which pivotally couple with central pin receiving panel on the side walls 42, 43 of the top frame 3.

[0025] Additionally, the pivot axes of the side panels 4, 5, are located above the pivot axes of the front and back panels 6, 7 on the top frame 3. This allows the crate 1 to be folded by pivotally swinging the side panels 4, 5, upwards towards the top frame before folding the front and back panels 6, 7 inwardly to cause the frame to collapse to a compact configuration, as shown in FIG. 3. Thus, the crate 1 can be used for delivery, then stored for later use, in its folded configuration, such that it takes up minimal space.

[0026] The top frame may further include inner slots 44 on the front and back walls 40, 41, Thus, the crate is sturdy, and can be used for delivery of milk and water jugs, and other similar items, and as a file box. The multiple possible uses for the crate make it an ideal gimmick item, which can be utilized by a seller to deliver items, such as water or milk,hereby the customer is allowed to keep the crate. Thus, the customer may be encouraged to purchase items which are delivered in the crate, if allowed to keep the crate.

[0027] While the present invention has been described with regards to particular embodiments, it is recognized that additional variations of the present invention may be devised without departing from the inventive concept.

Claims

1. A collapsible container having a first upright position for holding items and a second folded compact position for storage, wherein said container comprises:

a. a bottom panel 2;

b. a top frame 3;

c. two side panels 4, 5, said side panels being pivotally connected to opposite ends of the top frame 3;

d. a front folding panel 6 comprising upper 10 and lower 8 ends and pivotally connected upper 24 and lower 25 panel sections, said front folding panel 6 being pivotally connected to the top frame 3 at its upper end 10 and being pivotally connected to the bottom panel 2 at its lower end 8;

e. a back folding panel 7 comprising upper 11 and lower ends 9 and pivotally connected upper 24 and lower 25 panel sections, said back folding panel 7 being pivotally connected to the top frame 3 at its upper end 11 and being pivotally connected to the bottom panel 2 at its lower end 9;

f. at least one L-shaped extending panel 36 formed integral with the upper panel section 24 of the front folding panel 6;

g. at least one L-shaped extending panel 36 formed integral with the upper panel section 24 of the back folding panel 7;

h. at least one receiving groove 37 formed in the lower panel section 25 of the front folding panel 6; wherein said receiving groove 37 engages the L-shaped extending panel 36 of the front folding panel 6 when the container 1 is in the upright position; and

i. at least one receiving groove 37 formed in the lower panel section 25 of the back folding panel 7; wherein said receiving groove 37 engages the L- shaped extending panel 36 of the back folding panel 7 when the container 1 is in the upright position; wherein

engagement between the L-shaped extending panels 36 and receiving grooves 37 prevents the lower 24 and upper 25 panel sections of the front 6 and back 7 folding panels from folding outward when the container 1 is in the upright position, and wherein

the container 1 can be folded into the compact position by pivotally swinging the side panels 4,5 towards the top frame 3 and folding the front 6 and back 7 folding panels inward to cause the container 1 to collapse to the compact position.

2. A collapsible container comprising The container of claim 1, wherein:

the bottom panel 2 comprises a base 15 and a shallow border wall 14 extending orthogonal and upward from the base 15, and wherein said border wall 14 comprises opposite first and second side walls 16, 17 and opposite back and front walls 18, 19.

3. The collapsible container of claim 2, wherein the front wall 18 comprises a central hinge coupling panel 32 that pivotally connects with a pin rod formed on the lower end 8 of the front folding panel 6.

4. The collapsible container of claim 2, wherein the back wall 19 comprises a central hinge coupling panel 33 that pivotally connects with a pin rod formed on the lower end 9 of the back folding panel 7.

5. The collapsible container of claim 2, further comprising a first aperture 20a and a second aperture 20b disposed in the first sidewall 16, and a first aperture 21a and a second aperture 21b disposed in the second sidewall 17, each of said apertures 20a, 20b, 21a, 21b being disposed proximal to a corner of the border wall 14.

6. The collapsible container of claim 5, further comprising first and second hinge pins disposed respectively in the first 20a and second 20b apertures of the first sidewall 16, wherein the first hinge pin is connected to the front folding panel 6 and the second hinge pin is connected to the back folding panel 7.

7. The collapsible container of claim 2, further comprising third and fourth hinge pins disposed respectively in the first 21a and second apertures 21b of the second sidewall 17, wherein the third hinge pin is connected to the front folding panel 6 and the fourth hinge pin is connected to the back folding panel 7.

8. The collapsible container of claim 2, wherein each of the upper panel sections 24 comprises a first mating hinge notch 26 at their respective lower edges 28 that pivotally connects with a second mating hinge notch 27 disposed at the respective upper edges 29 of each of the lower panel sections 25.

9. The collapsible container of claim 2, further comprising a pair of hinge notches 23a, 23b disposed in the back wall 19, wherein each hinge notch, 23a, 23b connects pivotally with the back folding panel 7 via a hinge pin.

10. The collapsible container of claim 2, further comprising a pair of hinge notches 22a, 22b disposed in the front wall 18, wherein each hinge notch, 22a, 22b connects pivotally with the front folding panel 6 via a hinge pin.

11. The collapsible container of claim 2, further comprising at least one central hinge coupling panel 33 disposed in the back wall 19, wherein said central hinge coupling panel 33 pivotally connects with the back folding panel 7.

12. The collapsible container of claim 2, further comprising at least one central hinge coupling panel 32 disposed in the front wall 18, wherein said central hinge coupling panel 32 pivotally connects with the front folding panel 6.

13. The collapsible container of claim 1, wherein the top frame 3 comprises a front frame wall 40, a back frame wall 41 and a first sidewall 42 and a second sidewall 43.

14. The collapsible container of claim 13, further comprising at least one hinge notch 22 and at least one hinge coupling panel 23 disposed in the back frame wall 41, wherein said hinge notch 22 and hinge coupling panel 23 interface pivotally with the back folding panel 7.

15. The collapsible container of claim 13, further comprising at least one hinge notch 22 and at least one hinge coupling panel 23 disposed in the front frame wall 40, wherein said hinge notch 22 and hinge coupling panel 23 interface pivotally with the front folding panel 6.

16. The collapsible container of claim 2, further comprising a first and a second recessed portion 45a, 45b each comprising an aperture and being formed in the front frame wall 40, said first and second recessed portions 45a, 45b being disposed adjacent a corner of the top frame 3 wherein the first recessed portion 45a pivotally connects to an upper edge of the first side panel 4 and the second recessed portion 45b pivotally connects to an upper edge of the second side panel 5.

17. A collapsible container having a first upright position for holding items and a second compact position for storage, comprising:

a. atop frame 3;

b. a bottom panel 2;

c. a first side panel 4 pivotally connected to the top frame 3;

d. a second side panelS pivotally connected to the top frame 3;

e. a front folding panel 6 comprising upper 10 and lower 8 ends and pivotally connected upper 24 and lower 25 panel sections, said front folding panel 6 being pivotally connected to the top frame 3 at its upper end 10 and being pivotally connected to the bottom panel 2 at its lower end 8;

f. a back folding panel 7 comprising upper 11 and lower ends 9 and pivotally connected upper 24 and lower 25 panel sections, said back folding panel 7 being pivotally connected to the top frame 3 at its upper end 11 and being pivotally connected to the bottom panel 2 at its lower end 9;

g. at least one L-shaped extending panel 36 formed integral with the upper panel section 24 of the front folding panel 6;

h. at least one L-shaped extending panel 36 formed integral with the upper panel section 24 of the back folding panel 7;

i. at least one receiving groove 37 formed in the lower panel section 25 of the front folding panel 6; wherein said receiving groove 37 engages the L-shaped extending panel 36 of the front folding panel 6 when the container 1 is in the upright position; and

j. at least one receiving groove 37 formed in the lower panel section 25 of the back folding panel 7; wherein said receiving groove 37 engages the L-shaped extending panel 36 of the back folding panel 7 when the container 1 is in the upright position; wherein

engagement between the L-shaped extending panels 36 and receiving grooves 37 prevents the lower 24 and upper 25 panel sections of the front 6 and back 7 folding panels from folding outward when the container 1 is in the upright position.

18. The collapsible container of claim 17, wherein the container 1 can be folded into the compact position by pivotally swinging the first and second side panels 4, 5 towards the top frame 3 and folding the front 6 and back 7 folding panels inward to cause the container 1 to collapse to the compact position.

19. A method for folding a collapsible container comprising a top frame, a bottom panel, a first side panel and a second side panel, a front folding panel and a back folding panel, comprising the steps of:

a. applying pressure to the first side panel 4 to pivotally swing the first side panel 4 towards the top frame 3;

b. applying pressure to the first second panel 5 to pivotally swing the second side 5 panel towards the top frame 3;

c. applying pressure to the front folding panel 6 to fold the front folding panel 6 inward; and

d. applying pressure to the back folding panel 7 to fold the back folding panel 7 inward to cause the container 1 to collapse to a compact configuration; wherein

the pivot axes of the first and second side panels 4, 5 are disposed above the pivot axes of the front folding panel 6 and back folding panel 7.

20. A collapsible container comprising:

a. a bottom panel 2, wherein said bottom panel 2 comprises a base 15 and a shallow border wall 14 extending orthogonal and upwardly from the base 15; said shallow border wall 14 comprising a first sidewall 16 and second sidewall 17 disposed opposite to one another, and a back wall 18 and a front wall 19 disposed opposite to one another;

b. a front folding panel 6 comprising an upper panel section 24 and a lower panel section 25, wherein said upper panel section 24 comprises a first mating hinge notch 26 that pivotally connects with a second mating hinge notch 27 disposed in the lower panel 25;

c. a pair of hinge notches 22a, 22b disposed in the front wall 16, wherein each hinge notch pivotally connects to the front folding panel 6;

d. a back folding panel 7 comprising an upper panel section 24 and a lower panel section 25, wherein said upper panel section 24 comprises a first mating hinge notch 26 that pivotally connects with a second mating hinge notch 27 disposed in the lower panel 25;

e. a pair of hinge notches 23a, 23b disposed in the back wall 19 wherein each hinge notch pivotally connects to the back folding panel 7;

f. at least a first aperture and a second aperture disposed in the first sidewall, and at least a first aperture and a second aperture disposed in the second sidewall, each of said apertures being disposed proximal to a corner of the border wall;

g. first and second hinge pins disposed respectively in the first and second apertures of the first sidewall, wherein the first hinge pin is connected to the front folding panel 6 and the second hinge pin is connected to the back folding panel 7;

h. third and fourth hinge pins disposed respectively in the first and second apertures of the second sidewall, wherein the third hinge pin is connected to the front folding panel 6 and the fourth hinge pin is connected to the back folding panel 7;

i. at least one central hinge coupling panel 33 disposed in the back wall 19, wherein said central hinge coupling panel 33 pivotally connects to the back folding panel 7;

j. at least one central hinge coupling panel 32 disposed in the front wall 18, wherein said central hinge coupling panel 32 pivotally connects with the front folding panel 6;

k. at least one L-shaped extending panel 36 formed integral with the upper section 26 of the front folding panel 6 and at least one L-shaped extending panel 36 formed integral with the upper section 26 of the back folding panel 7;

l. at least one recess 37 formed integral with the bottom section 25 of the front folding panel 6; wherein said recess 37 interfaces with the L-shaped extending panel 36 of the front folding panel 6;

m. at least one recess 37 formed integral with the bottom section 25 of the back folding panel 7, wherein said recess 37 interfaces with the L-shaped extending panel 36 of the back folding panel 7;

n. a top frame 3 comprising a front frame wall 40 a back frame wall 41, and a first sidewall 42 and second sidewall 43 disposed opposite to one another;

o. at least one hinge notch 22 and at least one hinge coupling panel 23 disposed in the back frame wall 41, wherein said hinge notch 22 and hinge coupling panel 23 interface with the back folding panel 7;

p. at least one hinge notch 22 and at least one hinge coupling panel 23 disposed in the front frame wall 40, wherein said hinge notch 22 and hinge coupling panel 23 interface with the front folding panel 6;

q. a first and a second recessed portion 45a, 45b each comprising an aperture and being formed in the front frame wall 40, said first and second recessed portions 45a, 45b being disposed adjacent a corner of the top frame 3, wherein the first recessed portion 45a pivotally connects to an upper edge 10 of the first side panel 4 and the second recessed portion 45b pivotally

connects to an upper edge 11 of the second side panel 5; wherein the pivot axes of the side panels 4, 5 are disposed above the pivot axes of the front folding panel 6 and back folding panel 7 and the container can be folded by pivotally swing the side panels towards the top frame and then folding the front folding panel and back folding panel inward to cause the frame to collapse to a compact configuration.