Container with cutaway corners

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

FIELD OF THE INVENTION

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.

BACKGROUND OF THE INVENTION

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.

SUMMARY OF THE INVENTION

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.

BRIEF DESCRIPTION OF THE DRAWINGS

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.

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 1A-1A of FIG. 1;

FIG. 1B is a cross-sectional view of a portion of a stack of containers shown in FIGS. 1 and 1A;

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 2A-2A of FIG. 2.;

FIG. 2B is a cross-sectional view of a portion of the container shown in FIGS. 2 and 2A 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 3A-3A of FIG. 3;

FIG. 3B is a cross-sectional view of a portion of the container shown in FIGS. 3 and 3A 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 2A 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 2A 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 3A 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; and

FIG. 6 is a perspective view of the tray shown in FIGS. 1 and 1A, showing a first side wall being bent into position.

DETAILED DESCRIPTION OF THE INVENTION

Referring to FIG. 1, there is illustrated a container or tray 10 according to one embodiment of the present invention. 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.

As shown in FIG. 1A, the side walls, 14, 16, 18 and 20 are not attached to each other. Hence, the container 10 has open or cutaway corners 24. Although one configuration or shape of openings at the corners 24 is illustrated, the open corners 24 may be other sizes or shapes. 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 1A. The side walls 14, 16, 18 and 20 have upper edges 30, 32, 34 and 36, respectively. Although the upper edges of the side walls are illustrated as being co-planar due to the side walls being the same height, 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.

As shown in 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. Due, at least in part to the inherent nature of the thermoplastic material from which the container 10 is made, 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. Although 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. 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 10a comprises a base 12a and a plurality of side walls 14a, 16a, 18a and 20a, all extending upwardly from the perimeter of the base 12a and being perpendicular to the base 12a. The base 12a and side walls 14a, 16a, 18a and 20a define an interior 21a of the container 10a for storing or displaying products or items (not shown). The side walls 14a, 16a, 18a, 20a each are illustrated with at least one aperture or hole 22a used as handles for transporting the container 10a. 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 10a.

As shown in FIG. 2, the side walls 14a, 16a, 18a and 20a are not attached to each other. Hence, the container 10a has open or cutaway corners 24a. Although one configuration or shape of openings at the corners 24a is illustrated, the open corners 24a may be other sizes or shapes. The side walls 14a, 16a, 18a, and 20a are connected to the base 12a along a fold line 27a and each side wall forms a right angle 28a with the base 12a. See FIGS. 2 and 2A. The side walls 14a, 16a, 18a and 20a have upper edges 30a, 32a, 34a and 36a, respectively.

The base 12a of the container 10a shown in FIGS. 2, 2A and 2B has a plurality of aligned tabs 40 formed by C-shaped cuts 42 through the base 12a. The tabs 40 are located generally near the intersection between the base 12a and the side walls 14a, 16a, 18a and 20a. Although 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 10a to allow multiple containers to be nested and stacked together.

As shown in FIG. 2B, when a second container 11a like the container 10a, having a base 13a and sidewalls 15a is nested inside the interior 21a of the outer container 10a, the side walls 14a, 16a, 18a and 20a of the outer container 10a flex outward about a flex or pivot point 26a along the base 12a. See FIG. 2B. Due, at least in part due to the position of the tabs 40, an outer portion 44 of the base 12a, along with the side walls flexes or pivots about a pivot point 19a. FIG. 2B also shows a third tray or container 17a having a base 19a and sidewalls 23a nested or nestably stacked within the second container 11a. The second and third containers 11a and 17a 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 14a, 16a, 18a and 20a of the container 10a return to their position shown in FIG. 2A after the containers 11a and 17a are taken out or removed from the interior 21a of the container 10a. Although two containers 11a and 17a are shown nestably stacked inside container 10a, 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 10b comprises a base 12b and a plurality of side walls 14b, 16b, 18b and 20b, all extending upwardly from the perimeter of the base 12b and being perpendicular to the base 12b. The base 12b and side walls 14b, 16b, 18b and 20b define an interior 21b of the container 10b for storing or displaying products or items (not shown). The side walls 14b, 16b, 18b, 20b each are illustrated with at least one aperture or hole 22b used as handles for transporting the container 10b. 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 the container 10b.

As shown in FIG. 3, the side walls 14b, 16b, 18b and 20b are not attached to each other. Hence, the container 10b has open or cutaway corners 24b. Although one configuration or shape of openings at the corners 24b is illustrated, the open corners 24b may be other sizes or shapes. The side walls 14b, 16b, 18b, and 20b are connected to the base 12b along a fold line 27b and each side wall forms a right angle 28b with the base 12b. See FIGS. 3 and 3A. The side walls 14b, 16b, 18b and 20b have upper edges 30b, 32b, 34b and 36b, respectively.

The base 12b of the container 10b shown in FIGS. 3, 3A and 3B has a plurality of aligned generally rectangular openings 46 created by removing material from the base 12b. The openings 46 are located generally near the intersection between the base 12a and the side walls 14a, 16a, 18a and 20a. Although 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 10a to allow multiple containers to be nested and stacked together.

As shown in FIG. 3B, when a second container 11b like the container 10b, having a base 13b and sidewalls 15b is nested inside the interior 21b of the outer container 10b, the side walls 14b, 16b, 18b and 20b of the outer container 10b flex outward about a flex or pivot point 19b along the base 12b. See FIG. 3B. Due, at least in part due to the position of the openings 46, an outer portion 48 of the base 12b, along with the side walls flexes or pivots about a pivot point 26b. FIG. 3B also shows a third tray or container 17b having a base 19b and sidewalls 23b nested or nestably stacked within the second container 11b. The second and third containers 11b and 17b 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 10b is made, the side walls 14b, 16b, 18b and 20b of the container 10b return to their position shown in FIG. 3A after the containers 11b and 17b are taken out or removed from the interior 21b of the container 10b. Although two containers 11b and 17b are shown nestably stacked inside container 10b, 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. 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 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. Once the blank 50 is sufficiently heated, as shown in FIG. 5, the side wall 14 is bent upward along the fold line 27 thereby creating a side wall 14 perpendicular to the base 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 the other side walls 16, 18 and 20 until a container or tray is completely formed.

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 10a is formed. As shown in FIG. 4A, 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.

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 the container 10b is formed. As shown in FIG. 4B, 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.

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

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.