Reinforcement structures for a foldable, reusable storage container, storage containers incorporating the structures, and methods of making same

Abstract

A reinforced storage container assembly, formed by connecting plural storage containers end-to-end, includes a first storage container, a second storage container, a connector, and at least one reinforcement structure. The storage containers each have an open end formed by removal of an end wall, and are oriented with the open ends facing toward one another, and attached at the open ends by a connector. Each reinforcement structure includes an inner reinforcement panel, used singularly, and an outer reinforcing member used in combination with a stiffening member, modified stiffening member or reinforcing channel. Each reinforcement structure reinforces at least one corresponding side wall or the floor of the storage container assembly. Each reinforcement structure and attaching hardware are sufficiently recessed into a storage container side wall or floor to allow the storage container assembly to be collapsibly folded without interference between any of the side walls, floor, reinforcement structures, or hardware.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application claims priority under 35 U.S.C. 119(e) based on U.S. provisional patent application No. 60/705,852, filed Aug. 5, 2005.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to storage containers, and particularly to composite storage containers made using reinforcement structures, designed for adding strength and rigidity thereto. More particularly, the present invention relates to a relatively large, foldable reinforced storage container assembly formed by connecting two or more foldable storage containers in an end-to-end relationship, to connecting hardware for use in making such a composite storage container, and to methods of making such a composite storage container. The inventive composite storage container is made using specialized reinforcement structures adapted to reinforce and strengthen side walls of the large storage container assembly, for reliable use over a relatively long period.

2. Background Art

Storage containers, including reusable containers, are widely used in industrial settings. In particular, reusable industrial storage containers are commonly used in shipping parts for use on an assembly line or the like, in warehousing inventory, etc. A commonly used type of large, reusable plastic storage containers, which are foldably collapsible to approximately ⅓ of its normal size when not in use, are commercially available from the Ropak Corporation, and are described for example in the U.S. Pat. Nos. 4,923,079 and 6,145,682, the entire disclosures of which are hereby incorporated by reference. The collapsible nature of the storage containers is extremely desirable for reducing the space required to store and transport the containers when empty.

Many other types of storage containers are commercially available, including metal containers.

Further, there are situations where a particular, mass produced storage container does not have adequate capacity for a specific application thereof, and a user may wish to combine-connect two or more standard size storage containers together to form a larger capacity storage container assembly to meet a specific size requirement. Methods and apparatus previously proposed by applicant for connecting storage containers together, such as the reusable, collapsible Ropak containers, are discussed in U.S. Pat. Nos. 6,145,682 and 6,210,069, the entire disclosures of which are incorporated herein by reference.

For connecting the containers in the manners as previously proposed, an end wall of each container is removed, and then the open ends are joined together with appropriate fastening hardware such that the resulting large container has a single open space therein. Once connected, the side walls of the larger-capacity container assembly span typically twice the distance of the original side wall of a single container. As such, they may lack sufficient stiffness and strength to resist bowing outwardly when the container is filled with storage contents, particularly heavy and bulky materials, to be reliably folded and unfolded, etc., and therefore, these relatively unstable walls may hinder the purpose of creating larger capacity storage containers.

The applicant has previously implemented reinforcement measures, to strengthen a foldable storage container formed by connecting end-to-end two storage containers, which mainly included stiffening rails and brace members installed on side walls, and reinforcing braces installed on portions of inside corners of the container.

FIG. 1A of the present drawings represents one embodiment of a reinforced composite storage container assembly 10 according to the teachings of U.S. Pat. No. 6,145,682, commonly owned by the present applicant. The container assembly 10 of FIG. 1A is formed by connecting a first storage container 7 to a second storage container 9, with the containers arranged in an aligned end-to-end relationship. The container assembly 10 of FIG. 1A includes a pair of inverted channel-shaped reinforcing members 22, 24 disposed along the upper edges of the long side walls, and spanning between the upper edges of the joined containers to provide strength and rigidity to the assembled side wall. The container assembly 10 of FIG. 1A also includes an open end structure 19, in order to make an interior end portion thereof more accessible, to allow a user to remove individual parts more easily therefrom, as needed. The container assembly 10 also includes internal reinforcing braces 26, 28, formed of angle iron or the like, which are optionally used to reinforce the storage container 10 at the interior side corner sections of the open end structure 19.

Another embodiment of the applicant's previously reinforced storage container assembly disclosed in U.S. Pat. No. 6,210,069, is shown in FIGS. 1B-1D of the present drawings. In FIG. 1B, each of a pair of containers 42 has an end wall 17 thereof removed. In FIG. 1C, the containers 42, 42 are shown inverted for purposes of ease in assembly. The open ends of the two containers 42, 42 are disposed facing each other, and the bottoms of the containers 42, 42 are connected together using connecting blocks 100 and bolts 45. In the embodiment of FIGS. 1B-1D, the blocks fit partially into recesses 15 formed into one container and partially into corresponding recesses formed the other container, and have ends thereof secured with nuts (not shown). In FIG. 1D, exterior surfaces of the respective side walls 60, 62 of the joined containers 42, 42 have recesses 64, 66 formed therein with a router or the like, and then a reinforcing bar 56 is fitted in each pair of the recesses 64, 66 and secured to the container side walls with bolts or the like, as is discussed more fully in U.S. Pat. No. 6,210,069.

Although applicant's previously proposed, reinforced, combined container assemblies discussed above and in greater detail in U.S. Pat. Nos. 6,145,682 and 6,210,069 function appropriately for their intended purposes, a need still exists in the art for improved reinforcement of the combined storage containers, especially as the overall size thereof increases. For example, applicant has determined that over an extended period of use, the lengthy side walls of the combined container assembly may become warped or damaged, particularly when the empty container is being collapsed/folded even with the known reinforcing structures. Factory workers tend to quickly fold the side walls of an empty container by simply kicking the side walls flat, after connecting pins at opposite ends thereof have been retracted.

Although the known reinforcing structures have relatively high strength and rigidity, these structures my become warped or displaced by such rough handling over time, especially along the joined interfaces of the connected containers, where stress tends to be concentrated. Further, in storage containers having a side wall height of more than 36 inches, the problem tends to be greater.

SUMMARY OF THE INVENTION

The present invention has been developed to fulfill the discussed need, and to correspondingly overcome limitations of the known structures. In a first embodiment thereof, the present invention provides a reinforced storage container assembly formed by connecting two or more storage containers end-to-end, where the assembly includes a first storage container, a second storage container, connecting hardware for connecting the two containers, and at least one reinforcement structure.

The reinforcement structures used for reinforcing both collapsibly foldable and non-collapsible storage containers include inner and outer reinforcing members, stiffening rails, modified stiffening rails and reinforcing channels. A first illustrative embodiment of the present invention provides a reinforced composite storage container assembly having outer reinforcing members disposed on outer portions of side walls thereof, and used in combination with at least one stiffening member, modified stiffening member or reinforcing brace for reinforcing the side walls of the storage container.

The outer reinforcing members may be T-shaped in cross section, and may be made of metal, such as steel plate. In the first embodiment, the outer reinforcing member includes a V-shaped stem formed of angle iron having a first end portion and a second end portion, and a flat plate attached by means of welding to the first end portion of the stem such that a triangular cross section is formed at the first end portion, where the flat plate is attached to the V-shaped stem. In the depicted embodiment, the flat plates are rectangular in shape. The flat plate includes a plurality of attachment holes formed therethrough for attaching the outer reinforcing member to the side wall of a storage container having corresponding holes formed therethrough.

As described earlier, a reinforced storage container assembly is formed by connecting two or more storage containers end-to-end, with intermediate walls thereof removed. Such connection of two storage containers into a large storage container may form a V-shaped groove between abutted side walls, on outer portions of the side walls. In order to create a reinforced storage container assembly, the V-shaped stem of the outer reinforcing member is disposed in the V-shaped groove formed between abutted walls of the storage container. A second end portion of the V-shaped stem of the outer reinforcing member is secured on the upper portion of the side wall of the container, using at least one stiffening member, modified stiffening member or reinforcing channel. The first end portion of the V-shaped stem, having the flat plate attached thereto, where the flat plate has a plurality of attachment holes formed therein, is secured on the lower portion of the side wall of the storage container using suitable fasteners, which may be a plurality of nuts and bolts.

The provided reinforced storage container assembly can either be collapsibly foldable or may be formed from non-collapsible storage containers. In collapsibly foldable reinforced storage containers having a folding line, the outer reinforcing members are installed on the outer portion of the side walls above the folding line. In non-collapsible reinforced storage containers, the outer reinforcing members may be installed at any level.

In one aspect of the invention, a reinforced storage container assembly formed by connecting two storage containers end-to-end, with intermediate walls thereof removed, includes the outer reinforcing members used in combination with the stiffening rails. The outer reinforcing members are disposed along the height on outer portions of abutted side walls, with a second end portion of the stem attached to very top edge of the side walls and the first end portion having the flat plate attached to the container above the folding line of the side walls. The stiffening member is attached to abutted side walls for reinforcing and interconnecting the storage containers together. The stiffening member, being substantially U-shaped in cross section, is adapted to securely receive the upper edge portions of the side walls, and the second end portion of the stem of the outer reinforcing member therein.

In another aspect of the invention, the reinforced storage container assembly includes outer reinforcing members used in combination with modified substantially U-shaped stiffening rails. The modified stiffening member includes elongated elements for receiving the second end portion of the stem of outer reinforcing member which is not extended up to very top edge of the side wall. In other words, the second end portion of the stem may placed below the very top edge of the side wall and, such placement of the second end portion is received by the elongated elements of the modified stiffening rails. Alternatively, the second end portion may be extended up to the very top edge of side wall. The attachment of the outer reinforcing member to the modified stiffening member generally includes disposing a portion of the second end portion of the stem between the elongated element of the modified member and the side wall.

In yet another aspect of the invention, the reinforced storage container assembly includes an outer reinforcing members used in combination with reinforcing channels mounted along substantial length portions of side walls. The reinforcing channel includes a longitudinal channel that may be made of metal. The reinforcing channel is designed for reinforcing side walls and also for securing the second end portion of the stem of outer reinforcing member therein. The second end portion of the stem is not required to be extended up to very top edge of the side wall of the storage container. Alternatively, as the second end portion is placed beneath the reinforcing channel thereby allowing the second portion of the stem to be extended up to very top edge of the side wall.

In another aspect of the invention, a reinforced storage container assembly includes inner reinforcement panels mounted on portions of container floor and inside side walls, and outer reinforcing members mounted on outer portions of side walls. The outer reinforcing members are used in combination with at least on of the stiffening member, modified stiffening member, and the reinforcing channel. Alternatively, the reinforced storage container assembly may only include inner reinforcement panels.

The inner reinforcement panels may have a generally L-shaped cross section, and may also be made of metal. Each inner reinforcement panel includes a vertical portion, a horizontal portion attached to the vertical portion at one end, and a plurality of attachment holes formed therethrough the vertical portion for fastening the inner reinforcement panel to the side walls of the storage container. The inner reinforcement panels are designed to receive portions of container floor and inner side walls. The inner reinforcement panel is disposed on inside of collapsibly foldable storage container at a seam between two containers at the very bottom of side wall below a folding line. Generally, one inner reinforcement panel is used for each junction of side walls at the seam between two containers. Also, the inner reinforcement panel may be used at a seam between two non-collapsible storage containers. Additionally, inner reinforcement panels may be used for reinforcing side walls or end walls of a storage container.

The present invention provides a reinforced storage container assembly formed by connecting two or more storage containers end-to-end with one or more reinforcing structures which are durable and easy to install.

For a more complete understanding of the present invention, the reader is referred to the following detailed description section, which should be read in accordance with the accompanying drawings. Throughout the following description, like numbers refer to like parts.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a perspective view of a composite prior art reinforced collapsibly foldable storage container, formed by connecting two storage containers together, including stiffening rails installed on top of the side walls thereof, and reinforcing members installed on inside corners of the container.

FIG. 1B is a perspective view of a foldable prior art storage crate, showing a side wall of the storage crate being removed.

FIG. 1C is a cutaway perspective view of two inverted prior art storage crates being interconnected using specialized connecting blocks; and

FIG. 1D is a perspective view of a foldable prior art storage crate assembly.

FIG. 2 is a perspective view of a reinforced foldable storage container assembly according to a first illustrative embodiment of the present invention.

FIG. 3 is another view an outer reinforcing member and a stiffening member disposed on a side wall of the container of FIG. 2, to form a reinforced storage container.

FIG. 4A is a front plan view of an outer reinforcing member, used in constructing the composite storage container of FIGS. 2-3.

FIG. 4B is a top plan view of the outer reinforcing member of FIG. 4A.

FIG. 5 is an end plan view of a stiffening rail used to reinforce upper side wall edges of the storage container assembly of FIG. 2;

FIG. 6 is a perspective view of a reinforced foldable storage container assembly according to a second illustrative embodiment of the present invention.

FIG. 7 is a sectional view of the reinforced storage container assembly of FIG. 6, showing an outer reinforcing member used in combination with modified stiffening rails.

FIG. 8 is a perspective view of a reinforced foldable storage container assembly according to a third illustrative embodiment of the present invention.

FIG. 9 is sectional view of the reinforced storage container assembly of FIG. 8, showing an outer reinforcing member used in combination with reinforcing channels.

FIG. 10 is a perspective view of a reinforced foldable storage container assembly according to a fourth illustrative embodiment of the present invention, in which outer reinforcing members are used in combination with reinforcing channels and inner reinforcement panels.

FIG. 11 is a side plan view an of inner reinforcement panel used in constructing the container assembly of FIG. 10.

FIG. 12 is a perspective view of a rectangular stabilizing washer according to the present invention; and

FIG. 13 is a cross-sectional view of portions of two interconnected storage containers, showing two of the stabilizing washers of FIG. 12 in use.

DETAILED DESCRIPTION

Referring now to FIGS. 2-3 of the drawings, a reinforced collapsible storage container assembly, in accordance with a first illustrative embodiment of the present invention, is shown generally at 100. The reinforced container assembly 100 in the depicted embodiment is a modified and improved version of a collapsible plastic storage container originally sold by the ROPAK Corporation of Fullerton, Calif. as a ROPAK brand foldable crate, and is made up of two storage containers joined end-to-end with the intermediate walls thereof removed, for a larger capacity container. Further information about these commercially available products can be found at the web site http://www.linpacmh.com/products.html.

The reinforced storage container assembly 100, formed by connecting two or more storage containers end-to-end, includes a first storage container 102, a second storage container 104, a connector, and one or more reinforcement structures, to be described in further detail herein.

The reinforced storage container assembly 100 includes a floor 116, a first end wall 118 pivotally attached to the floor 116 via a first hinge pivot pin (not shown), forming a folding line 119 for the first end wall 118, and disposed at a first height above the floor 116. The reinforced storage container assembly 100 also includes a second end wall 117 pivotally attached to the floor 116 opposite the first end wall 118. The second end wall 117 is pivotally foldable into the container 100, as shown by the two-headed arrow in FIG. 2, to lie flush against the floor 116 when in a closed configuration thereof.

The reinforced container also includes a first side wall 112 pivotally attached to the floor 116 via a second hinge pivot pin (not shown) and disposed at a second height above the floor 116, where the second height is above the first height of the first hinge pivot pin. The connection between the first side wall 112 and the floor 116 forms a folding line, adjacent the second hinge pivot pin, to allow the side wall 112 to fold down on top of the already collapsed end walls 117, 118. The reinforced container 100 further includes a second side wall 114, pivotally attached to the floor 116 opposite the first side wall 112. The second side wall 114 is joined to the floor 116 via a third hinge pivot pin (not shown) forming a folding line 115 which is disposed at substantially the same height as the second pivot pin.

As discussed earlier, a reinforced collapsibly foldable storage container assembly 100 is generally made up of two storage containers 102, 104 joined end-to-end, with the intermediate walls thereof removed, to define a larger capacity container. When using these commercially available ROPAK brand containers, the end-to-end joining of two containers 102, 104 forms an inwardly extending V-shaped groove 122 facing outwardly at the seam between the containers 102, 104, located substantially in the middle of the assembly, along the height of the container on an outside portion of the side walls 112, 114 thereof.

The reinforced storage container assembly 100, in accordance with the first embodiment of the present invention, also includes a pair of outer reinforcing members 124, 126 (FIGS. 3 and 7), with a portion of each the reinforcing members, respectively, disposed in the V-shaped grooves 122 on respective outer surfaces of the opposite side walls 112, 114. The reinforcing members 124, 126 are installed in combination with stiffening rails 128, 130 installed on the top portions of the side walls, respectively, as shown in FIG. 2.

The outer reinforcing members 124, 126 shown generally in FIGS. 2 and 3, and more specifically in FIGS. 4A-4B, have a generally inverted T-shape, and may be made of metal, such as iron or steel plate. Each outer reinforcing member 124, 126 includes a stem portion 132 and an anchor plate 134 welded to, or otherwise rigidly affixed to the stem portion. As seen best in FIG. 4A, the stem portion 132 in the depicted embodiment has a V-shaped cross-section. The stem portion 132 may be formed of angle iron, and has a first end 136 and a second end 138. The anchor plate 134 is attached across the first end 136 of the V-shaped stem portion 132, such as by welding, forming a triangular cross section, as shown in FIG. 4B. The flat anchor plate 134, which may be formed in a rectangular shape and may be made of metal, has a plurality of attachment holes 140 formed therethrough for receiving fasteners, such as nuts and bolts, to permit fastening of the reinforcing member to a corresponding side wall.

The cross-sectionally V-shaped stem portion 132 of the outer reinforcing member 124 126 is disposed outside of the corresponding side wall 112, 114 in the V-shaped groove 122 which, as previously noted, is formed on an outside portion of the wall when the two storage containers are joined together. The free second end 138 of the V-shaped stem portion 132 is arranged close to the top edge of the corresponding side wall 112, 114, and the tip of the second end 138 is covered by a central area of a corresponding stiffening member 128 or 130, as shown.

Each outer reinforcing member 124, 126 is attached to its corresponding side wall 112, 114 above the folding line 113, 115 of the side wall, using fasteners such as nuts and bolts, which extend through holes (not shown) drilled in the side wall, and also through the holes 140 formed in the anchor plate.

Referring now to FIG. 5, it will be seen that the stiffening rails 128, 130, in the first embodiment of the invention, have a generally inverted U-shape when viewed in cross-section, with opposed vertical walls 102, 104 of the stiffening rail having approximately the same height dimension as, or being incrementally longer than, the width of the top connecting web portion 106 thereof, as shown.

Optionally, the reinforced storage container assembly 100 may include reinforcing braces 125, 127 (FIG. 10) installed on inside portion of the corners of storage container, for providing additional reinforcement to the container. These reinforcing braces 125, 127 are similar in construction to the stem portion 132 of the reinforcing member 124.

The outer reinforcing members 124, 126 are particularly advantageous for reinforcing tall storage containers, e.g., containers having a height of 36 inches and above. It may be noted that the storage containers come in various sizes. The outer reinforcing member 124, 126 can be made in various lengths, as needed, according to the height and length of the containers needing reinforcement. The reinforcing of the side walls 112, 114 using outer reinforcing members 124, 126 to add strength and rigidity to the side walls 112, 114 is very important, particularly when the side walls 112, 114 are foldably collapsed (when container is empty) for returning the empty containers 100.

Referring now to FIGS. 6-7, a reinforced collapsible storage container assembly 150 in accordance with the second illustrative embodiment of the present invention is shown. The storage container assembly 150 of FIGS. 6-7 is similar to the storage container assembly 100 according to the first embodiment, as described herein, except that the stiffening rails 158, 160 in this embodiment have side sections 162, 164 which extend downwardly to a significantly greater extent than the side sections of the stiffening rails 128, 130 according to the first embodiment. The side sections 162, 164 of the stiffening rails 158, 160 may be taller than the width of the connecting portion 165 at the top of the stiffening member. In one embodiment, the side sections 162, 164 of the stiffening rails 158, 160 may be approximately twice as tall as the width of the connecting portion 165 at the top of the stiffening member.

The composite storage container assembly 150 is formed by joining two storage containers end-to-end with the intermediate walls thereof removed, and includes a first storage container, a second storage container, a connector, and outer reinforcing members 124, 126 used in combination with the modified stiffening rails 158, 160. The modified stiffening members 158, 160 are designed to receive and securely restrain the second end 138 of the V-shaped stem portion 132 of the outer reinforcing member 124, 126, as shown in FIGS. 6 and 7, in a situation where the stem portion has not been extended up to the very top portion of the side wall 112 or 114.

The modified stiffening rails 158, 160 are substantially U-shaped in cross section, similar to that of the stiffening rails 128, 130 of the first embodiment. However, the modified stiffening member 158, 160 further include elongated side sections 162, 164 designed for securely holding the second end portion 138 of the V-shaped stem portion 132 of the outer reinforcing member 124, 126 beneath the elongated element as shown in FIG. 7. In this embodiment, the second end 138 of the stem portion 132 of outer reinforcing member is not required to be extended up to a very top edge of corresponding side wall, and it may be placed below the top edge, unlike the first embodiment of the present invention in which the second end of the reinforcing member must be extended up close to the top edge of the side walls. The elongated side sections 162, 164 of the modified stiffening rails 158, 160 may further provide reinforcement to the side walls of container, as they extend substantially below the top edges of the side walls.

Additionally, the reinforced container may include reinforcing brace members 125, 127 installed on inner corner portions along the height of the container, similar to those shown in FIG. 2.

As shown in FIGS. 8 and 9, the present invention also contemplates a reinforced collapsible storage container assembly 180 according to a third embodiment, where the assembly is formed by joining two conventional storage containers end-to-end with the intermediate walls thereof removed. The reinforced collapsible storage container assembly 180, according to the third embodiment hereof, includes a first storage container, a second storage container, a connector, and outer reinforcing members 124, 126 used in combination with recessed horizontal reinforcing bars 168, 170 as shown in FIGS. 8 and 9.

The V-shaped stem portion 132 of the outer reinforcing member 124, 126 is disposed on outer portions of the side walls 112, 114 in the V-shaped groove 122 between side walls, formed by joining two storage containers. The second end 138 of the stem portion 132 is secured by the reinforcing bar 168, 170 disposed on the outer portion of the side wall 112, 114. The first end 136, of the stem portion 132 of the outer reinforcement member, having a flat plate 134 attached thereto, is secured on the vertically intermediate portion above the folding line 115 of the side walls 112, 114 in a similar manner as discussed above in connection with the first embodiment.

Each reinforcing bar 168, 170 includes a longitudinal rod, which may be made of metal. The length and the shape of the reinforcing channels may be varied according to the container size and strengthening requirements. The reinforcing bar 168, 170 is generally fixed on to the outside portion of a side wall along a substantial length portion of a side walls 112, 114 at a vertically intermediate portion thereof, and disposed in a recessed channel formed on the side wall of the storage container 100 between integral reinforcing ribs of the wall. The reinforcing bars 168, 170 may be disposed at any vertically intermediate portion of the side walls above the folding line such that it does not interfere with the folding of side walls of collapsible storage container 100. The reinforcing bars 168, 170 are designed to reinforce their respective associated side walls, and to securely restrain a portion of the second end portion 138 of the V-shaped stem portion 132 of the outer reinforcing members 124, 126 installed on outer portion of the side walls.

In the embodiment of FIGS. 8-9, the second end portion 138 of the outer reinforcing members 124, 126 can either be extended up to very top edge of the side wall, or can be placed below that top edge, as shown in FIGS. 8 and 9, depending on the placing of the reinforcing bar 168, 170 on the side walls 112, 114. The securing of the stem by the reinforcing channel is generally achieved by placing the stem of the outer reinforcing member beneath the reinforcing bar 168, 170 disposed on the side walls 112, 114 of the storage container 100. Alternatively, the second end portion of the stem portion 132 of outer reinforcing member 124, 126 may be fixedly attached to its associated reinforcing bar 168, 170.

In another aspect of the third embodiment, the reinforced storage container includes only reinforcing channels attached to the side walls of the storage container below and above the folding line of the respective side walls, and does not include outer reinforcing members.

Now referring to FIG. 10, in accordance with the fourth illustrative embodiment of the present invention, a reinforced collapsible storage container assembly 100 formed by joining two storage containers includes a first storage container 102, a second storage container 104, a connector, inner reinforcement panels 174, 176, and outer reinforcing members 124, 126 used in combination with at least one of the stiffening rails 128, 130, modified stiffening member 158, 160 and reinforcing bars 168, 170. The reinforced storage container 100 may additionally include reinforcing braces 125, 127 placed on inside corners of the container 100.

Similar to that of the first and second embodiments, the outer reinforcing member 124, 126 is disposed in the V-shaped groove 122, formed between side walls on outside portion by joining two storage containers 102, 104 above the folding line 15 of side walls. The V-shaped stem having a second end portion 138 of 132 is secured by at least one of the stiffening rails 128, 130, modified stiffening member 158, 160, and reinforcing bars 168, 170, and the stem further includes a first end portion having flat attached thereto is further attached to the side walls 112, 114 using fastening hardware including nuts and bolts. When stiffening member 128, 130 are used to receive the second end portion of the stem therein, second end portion of the stem must be extended up to the very top edge of the side wall. When either modified stiffening member 158, 160 or reinforcing bars 168, 170 are used for receiving and securing the second end portion 138 of the stem portion 132 may be placed below the very top edge of the side wall 112, 114.

The inner reinforcement panels 174, 176 used for reinforcing side walls 112, 114 are generally disposed inside the storage container at an intermediate position below the folding line 115 and are flushed against portions of side walls 112, 114 and container floor 116 as generally shown in the FIG. 10 (seen only on one side wall of the storage container).

The inner reinforcement panels 174, 176 as seen in FIGS. 10 and 11, are substantially an L-shaped in cross-section and may be made of metal, such as stock steel plate. The inner reinforcement panel 174, 176 includes a vertical portion 178, a horizontal portion 180 attached to the vertical portion 178 at bottom, a plurality of attachment holes 182 formed therethrough the vertical portion 178 for fastening the inner reinforcement panel 174, 176 to the inner side walls of the storage container 100.

The inner reinforcement panels 174, 176 are designed to receive portions of container floor 116 and portions of inner side walls 112, 114. It desirable to flush the inner reinforcement panel 174, 176 with the portions of side wall 112, 114 on the container floor 116 so that when folding the container it allows easy collapsing of the side walls 112, 114. Attachment bolts are placed through the plurality of the attachment holes 182 formed on vertical surface 178 of the inner reinforcement panel 174, 176 and then through the receiving holes formed therethrough side walls 112, 114. The attachment bolts extend beyond the outer surface of side wall for tightening the nuts for flushing the inner reinforcement panels against inside portions of side walls 112, 114 and container floor 116. The inner reinforcement panels 174, 176 may also include recesses concentrically formed about each attachment hole 182, thereby permitting head of the attachment bolts to be recessed flush with or beyond the vertical surface 178 of the corresponding inner reinforcement panel 174, 176. Alternatively, the inner reinforcement panel 174, 176 may not have any recesses formed thereon.

Although the present invention has been described herein with respect to specific embodiments thereof, the foregoing description is intended to be illustrative, and not restrictive. Many modifications may be made to the described embodiments without departing from the scope hereof. All such modifications, which fall within the scope of the appended claims, are intended to be within the scope and spirit of the present invention.

Claims

1. A collapsible, reinforced storage container assembly formed by connecting two or more storage containers, said reinforced storage container assembly comprising:

a first storage container having an open end formed by removal of an end wall thereof;

a second storage container having an open end formed by removal of an end wall, said second storage container open end abutted against said first storage container open end;

a plurality of fasteners interconnecting a base portion of said first storage container and a base portion of said second storage container, for connecting said base portions together;

a stiffening member attached to abutted side walls of said first and second storage containers and interconnecting said side walls together, the stiffening member extending longitudinally of the reinforced storage container assembly and being disposed proximate upper edge portions of said side walls; and

a reinforcing member extending along a junction between said abutted side walls of said first and second storage containers and operatively engaging said stiffening member.

2. The collapsible, reinforced storage container assembly of claim 1, wherein said junction between said abutted side walls is recessed inwardly from outer surfaces of said side walls, and said reinforcing member includes a first portion that fits in said recessed junction such that an outer surface of said first portion is substantially flush with said outer surfaces of said side walls.

3. The collapsible, reinforced storage container assembly of claim 2, wherein said reinforcing member includes a second portion connected to one end of the first portion, the second portion extends substantially perpendicular to the first portion and is fixed to said abutted side walls, and an opposite end of said first portion operatively engages said stiffening member such that the opposite end is prevented from moving relative to said abutted side walls.

4. The collapsible, reinforced storage container assembly of claim 1, wherein said reinforcing member is substantially T-shaped, with a stem portion thereof extending along the junction between said abutted side walls substantially flush with outer surfaces of the side walls, and a crossing portion thereof disposed at a lower end of the stem portion and fixed to said abutted side walls.

5. The collapsible, reinforced storage container assembly of claim 4, wherein an upper end of said stem portion operatively engages said stiffening member such that the upper end is prevented from moving relative to said abutted side walls.

6. The collapsible, reinforced storage container assembly of claim 5, wherein said stiffening member is substantially U-shaped in cross section opening downwardly, and securely receives the upper end of the stem portion therein.

7. The collapsible, reinforced storage container assembly of claim 6, wherein said stiffening member also receives upper edge portions of said side walls therein.

8. The collapsible, reinforced storage container assembly of claim 1, wherein said abutted side walls of said first and second storage containers are foldable along longitudinally extending fold lines thereof, and said reinforcing member being disposed above said longitudinally extending fold lines.

9. The collapsible, reinforced storage container assembly of claim 1, wherein said stiffening rails are formed of metal.

10. The collapsible, reinforced storage container assembly of claim 1, further comprising a third stiffening member attached to lower inner surfaces of said abutted side walls of said first and second storage containers and interconnecting said side walls together, said reinforcing member engaging outer surfaces of the side walls.

11. The reinforced storage container assembly of claim 9, said stiffening member having a plurality of holes formed therethrough, further comprising a fastening hardware including a plurality of bolts and nuts, each said hole for receiving one said bolt therethrough, for bolting said stiffening member to corresponding said side wall.

12. The reinforced storage container assembly of claim 11, wherein the stiffening member vertically compresses portions of said side walls to which it is attached, such that the top surface of said stiffening member is flush with the portion of the top surface of corresponding said side wall not covered by said stiffening member.

13. The reinforced storage container assembly of claim 11, said stiffening member further having a plurality of recesses formed therein, each recess concentrically located about a corresponding one of said holes, for receiving a bolt head therein.

14. The reinforced storage container assembly of claim 11, wherein each head of a stiffening member attachment bolt having a height no greater than the depth of corresponding said recess.