Leak proof self securing container from single sheet

A generally leak proof open top self securing container for a human user and or their objects forms either a water craft or small toy boat or floating tackle tray; and pending a final size and or material which the no-parts container is formed of. The container comprises end walls (18) having hingedly connected interlocking flaps (20) having notches (22) that interlock with other notches (12) (13) (15) located within the edges of the side walls (10) to wedge-lock and laterally secure the end walls (18) between the interlocked locations and exteriorly located triangular shape hingedly-mated corner projections (24). No fastening parts, or adhesives, or tabs or interiorly located tab receiving apertures are required to retain the structural stability of the preferred embodiment. One alternative embodiment includes additional bend lines (5) extending the width to enable a compact folding. Alternative embodiments include a hingedly connected side wall strengthening flap (14) (16) having perforated portions (17) within the bend line (6) for optional removal. Final embodiments include closed cell floatation foam (40), flute channel plugs (44) (46) (48), side wall apertures (26), connecting rods (39), and elastic cords (36).

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Description
CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation in part and claims the benefit under U.S. patent application Ser. No. 11/288,463 filed Nov. 29, 2005, and is hereby incorporated by reference in its entirety.

Also disclosed is the provisional application Ser. No. 61/009,274 filed Dec. 27, 2007.

# 11/288,463 Nov. 29, 2005 Wagenknecht application # 592,545 Dec. 31, 2005 Wagenknecht disclosure # 601,175 May 24, 2006 Wagenknecht disclosure # 602,330 Jun. 15, 2006 Wagenknecht disclosure # 603,657 Jul. 17, 2006 Wagenknecht disclosure # 611,029 Jan. 11, 2007 Wagenknecht disclosure U.S. Pat. No. 7,309,364 Dec. 18, 2007 Wagenknecht 416/70R # 60/901,995 Feb. 13, 2007 Wagenknecht provisional # 61/009,274 Dec. 27, 2007 Wagenknecht provisional # 12/069,625 Feb. 12, 2008 Wagenknecht application

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable.

REFERENCE TO SEQUENCE LISTING

Not applicable.

BACKGROUND

1. Field of Invention

This invention relates to five sided, open top, generally leak-proof containers being formed from a single substrate, and which require no interiorly located tab receiving apertures or adhesives or fasteners to achieve or maintain a structural stability of the container in either its manufacturing, assembly, or use.

2. Description of Prior Art

Within prior art, the means for achieving or retaining the form and structural stability of a five sided open top generally leak proof container being formed from a single planar sheet substrate had included either adhesives or fasteners or tabs and interiorly located tab receiving apertures. Those containers which did include tabular appendages that interlocked with tab receiving apertures were not totally leak proof, as the apertures were usually located approximately intermediate the containers height.

Most generally leak proof containers being formed from a single planar sheet substrate which do not utilize interiorly located tab receiving apertures, and which do not require separate fasteners, will require at least one glued or adhesive taped area within the container, and so all strengths are totally dependent on the glue or adhesive tape to not break down when being saturated by water for long periods.

Water proof glues or adhesive tapes with oil based properties will not adhere to a containers wet surfaces when it needs to be assembled in a moist or rain soaked environment, or when assembled upon a waters surface.

Other than application Ser. No. 11/288,463, prior art lacked additional wall strength within at least two oppositely facing walls by not including up to four exteriorly located hingedly mated triangular shape projections.

Also not found, were two oppositely facing wedge-locked end walls which exhibit structural wall strength from solid or liquid weight stress loads from within or without the container; and whether upon land in a small scale for retaining a user's held objects, or either in a larger scale when on a water's surface and when containing the user themself.

Prior art mostly included folded flaps which abut the container's end walls for forming locking tabs or gluing or stapling. Prior art and including application Ser. No. 11/288,463 did not disclose an interlocking flap being hingedly connected to an end wall and comprising narrow notches within the flap which interlock with notches within a side wall as a means for forming and securing a structural stability of a part-less self securing generally leak-proof container.

Within single substrate five sided open top containers, there is not much lateral sidewall stability, and especially in the longer sidewalls of an elongate container, and particularly when the walls are up to ten feet long.

Prior art and including application Ser. No. 11/288,463 also did not disclose any alternative embodiments using additional sidewall strengthening flaps, or double hinged strengthening flaps to further strengthen an extremely elongate containers weakest areas, and which are the intermediate portions of the two longest walls exterior edges which may tend to waiver laterally under pressure.

Prior art did not address or disclose a container retaining its leak proof form when in an almost fully disassembled and nearly planar state; and nor did prior art address or disclose the advantage of a hingedly connected interlocking flap to further strengthen an almost fully dis-assembled container by aiding to at least some degree a prevention of lateral twisting at each elongate end of the container.

Prior art did not disclose a manufacturers or users option of using elastic cords to instantly and partially pre-assemble a part-less self securing container before a final interlocking of a notched, hingedly connected end wall interlocking flap within a notch of a side walls upper perimeter edge.

Prior art did not address or disclose any leak proof container which is able or intended to be assembled upon a waters surface by a swimming human user, and without a need for any tabs or interiorly located tab receiving apertures, or separate fasteners, or adhesives, or glues, or tapes of any kind.

Summarily, there is no prior art of an open top, five sided, leak-proof, part-less, self securing container being formed of a single substrate to form a container for a human user and or their objects having wedge-locked end walls via hingedly connected end wall flaps to establish similar end wall strengths as this new concept of a part-less self securing leak-proof container being formed from one single sheet substrate.

SUMMARY

A generally leak proof open top self securing container with end walls (18) having hingedly connected interlocking flaps (20) having narrow notches (22) which interlock with V-shape notches (12), angled notches (13) or circular shape notches (15) located within the edges of the side walls (10) to wedge-lock and laterally secure the end walls (18) between the interlocked locations and exteriorly located triangular shape hingedly-mated corner projections (24). A first portion (1) of bend lines parallel the substrate's longest length, and are spaced inwardly to determine a side walls (10) height. A second portion (2) of bend lines parallel the substrate's shortest length to define the hingedly connected interlocking flaps (22). A third portion (3) of bend lines are parallel with and located further inwardly than the second portions (2) to perpendicularly and nearly abut or abut and conjoin the first portions (1) and so determine the height of an end wall (18). A fourth portion (4) of bend lines extend inwardly and angularly from approximate corner areas to locations where the first (1) and third (3) portions nearly abut or abut to define the triangular shape corner projections (24). No fastening parts, or adhesives, or tabs or interiorly located tab receiving apertures are required to retain the structural stability of the preferred embodiment. One alternative embodiment includes a fifth portion (5) of bend lines extending the width to enable a compact folding. Other embodiments include a sixth portion (6) of bend lines to define a hingedly connected side wall strengthening flap (14) to fold back onto the side wall being retained by a notch (22) of the interlocking flaps (20), and with one embodiment having a spoon or paddle shape strengthening flap (16) having perforated portions (17) within the bend line (6) for optional removal. A strengthening flap may be in any shape which adds at least some additional strength. Other embodiments include closed cell floatation foam (40), flute channel plugs (44) (46) (48), side wall apertures (26), connecting rods (39), portions of an end wall being angled (19) outwardly from the floor, and elastic cords (36). The container may be formed of most any material which is malleable or bendable at least once, and in any size appropriate for the manufacturer's intended use.

OBJECTS AND ADVANTAGES

A first object and goal of this invention is to form a self securing leak proof container having five sides and an open top, and while remaining structurally secure after being quickly assembled, and without having or requiring any interiorly located tabs or tab receiving apertures, or fasteners, or adhesives in either its manufacturing, assembly, or use.

Advantages of the first object include cost effective manufacturing, a quick assembly, and a sturdy structural stability of a generally leak proof container; and pending the substrate chosen according to the end use purpose.

A second object of this invention is to form a generally leak proof container in multiple sizes and different substrate materials of the preferred embodiment to contain a human user and or their objects.

Multiple advantages of the second object include a fast assembly of a generally leak proof container which may be marketed for many end use purposes including sandwich containers, foot baths, tool trays, food trays, emergency flood containers, pet litter boxes, etc. The multiplicity of end use purposes of this concept of a quick assembling generally leak proof container is understood to be distinct and irrelevant to any claims disclosed; yet is deemed by the writer to be worthwhile to convey to the reader the potential value of this new concept of a container which requires no fastening parts, or interiorly located tab receiving apertures, or adhesives in its manufacturing, assembly or use. Cost savings are obvious.

One additional advantage of the second object is how the structure when made of a ½ inch thick substrate; and in a size of 2 foot by 10 foot with 1 foot high side walls is able to support two human users, an electric battery, a trolling motor under power, and other items totaling well over 400 pounds while on a waters surface.

A third object of this invention is to wedge-lock an end wall between exteriorly located hingedly mated triangular shape projections and locations of interlocking between notches within the side walls and an end walls notched and hingedly connected interlocking flap, and with the planar surface of the interlocked flap being angular to the planar surface of the end wall.

The advantages of the third object is an end wall which cannot laterally waiver in any direction, and portions of the side walls being adjacent the location of interlocking which also cannot laterally waiver in any direction, and portions of the side walls being near the interlocking location which still cannot laterally waiver in their elongate direction; yet will still resist excessive wavering in directions perpendicular to their elongate length. The difference in angle between the interlocked flap and end wall provides much added strength.

For clarity of explanations; references to any elongate direction shall refer to a longest length of a container which is not absolutely square in its dimensions excluding height; and wherein the longest dimension refers to the side wall(s) and a shortest dimension refers to an end wall(s). The greatest amount of any lateral wavering of a side wall is located intermediate the two end walls, while yet still only wavering in directions perpendicular to the elongate length.

A fourth object of this invention within an alternative embodiment is to provide a reinforced side wall(s); wherein a strengthening flap is hingedly connected to fold back onto the side wall, or angularly to a planar surface of the side wall, and with the option of the notch of an end wall's interlocking flap retaining a side wall strengthening flap abuttingly or adjacent to the side walls either exteriorly or interiorly to the containers cavity area.

Advantages of the fourth object providing a strengthened elongate side wall(s) are easily seen when a container has a cavity area being 26 inches wide by 10 feet long, and with 11 inch high side walls, and wherein an intermediate area of the extremely long side walls edges are the weakest location. When the container is formed of a light weight paper board or foam plastic, and in a size ratio more proportioned to a round sandwich, the side wall strengthening flaps still provide additional strength in locations intermediate the container's longest dimension. The side wall strengthening flaps provide additional strength, and whether angled to the planar surface of the side wall, or whether abuttingly flush with the side wall.

A fifth object of this invention is to take further advantage of the side wall strengthening flaps by incorporating the shape of a folding paddle blade. The folding paddle is listed as U.S. Pat. No. 7,309,364 by Wagenknecht, et al filed on Nov. 22, 2006. The strengthening flaps within any embodiment may be perforated in the hinged bend line for their optional removal.

Advantages of the fifth object where the side wall strengthening flaps are in a shape of a removable folding paddle include the ability to stack and store multiple emergency leak proof containers and their attached means of propulsion in a flat planar form without a need for any tools, parts, fasteners, or adhesives required in the assembly of either the container or the serratingly attached strengthening flaps. Stackability and compactness within any product has merit.

An end user who is initially protecting their valuables within a flood situation may alternatively use the same container as an emergency escape container while additionally having the option of using the sidewall strengthening flaps as a means of propulsion for the emergency escape leak proof container.

It is a sixth object of this invention to have a plurality of apertures not located interiorly or intermediate a side walls height; but just adjacent a side walls uppermost perimeter edge to not greatly affect the ability of the container to remain leak proof. The apertures may be completely cut out, or partially cut with a portion remaining intact to form a flap which is pushed through by the user to expose the aperture.

Advantages of the sixth object including apertures near a side walls uppermost perimeter edge provide an end user many options.

After tearing off the serratingly attached sidewall strengthening flaps of this embodiment, the user may then fold the strengthening flaps and then thread the folded strengthening flaps through the apertures; wherein the apertures will serve as oar lock apertures.

Further advantages of the apertures include an end users option of threading a shovels handle, or a similar rod, through two oppositely facing apertures, wherein two opposing persons may grip the rod to carry or drag heavy items such as sand for sandbagging around a soon to be flooded home and such.

One end wall of the container may be unlocked and unfolded downward to where it is flat with the grounds surface for raking sand into the container before re-interlocking the end wall for transport of the sand. When the container has at least 4 apertures, up to 8 persons may surround the container for carrying extremely heavy loads such as water or sand. The 4 exteriorly projecting triangular shape flaps may serve as secure hand holds for up to 4 persons, but the rod threaded hand holds will prevent a container from buckling or twisting in the center area of the container when under extreme weight loads.

Further advantages of the sidewall apertures include options of tying multiple containers together with ropes or fasteners, or to form a large raft by threading rods completely through the apertures of two or more containers. When the side walls of two containers abut each other, and when appropriately sized rods are threaded through the apertures of both containers, the two containers then form at least one dual compartment container with minimal lateral twisting.

It is a seventh object of this invention to utilize other material substrates in addition to a paperboard or light weight plastic; and wherein an extremely durable and waterproof substrate such as a corrugated polymer plastic may serve as the containers material substrate for containers being larger than a sandwich container.

A thickness of corrugated plastic sheet is measured by its manufacturers according to its wall thickness. Two planar walls are conjoined by a plurality of elongate paralleling ribs, and with both walls and ribs being generally the same thickness. A 4 mil wall equals an approximate 3/16 inch plus thick substrate. A 6 mil wall equals an approximate ¼ inch thick substrate. A 10 mil wall equals an approximate ½ inch thick substrate.

Corrugated plastic sheets are also available with a lamination of U.S. Coast Guard approved closed cell foam on either one or both sides of the substrate. The laminated foam can be anywhere between 1/16 inch to ¼ inch thick.

One best advantage of the polypropylene corrugated plastic embodiment is within the polypropylene plastics own material properties. The materials water absorption within 24 hours is described by one major manufacturer as being only 0.02%; and with any flute channel being pluggable for additional floatation.

Yet, the material floats without an absolute need for sealing or plugging any of its elongate flute channel apertures. A heavy moving current may drag an unassembled container slightly downward from the water's surface, but within a lake or flooded area without fast moving currents, the unassembled container will float to the surface for a swimming user to assemble while in the water.

Further advantages of the seventh object include a 160 pound user being able to forcefully lean back against the described wedge-locked end wall with both hands in the air, and while the container is on a water's surface, and when the container is formed of an appropriate thickness of corrugated plastic. Same applied stresses and even more have proven the end wall's wedge-locked strength, and including an electric trolling motor being under full power, and with no added reinforcements applied to a 10 mil, ½ inch thick end wall.

Any inward stresses or pressures placed on the end walls in an inwardly direction toward the container's cavity area have proven equally resistant to any lateral shift or bending of the wedge-locked end wall. Side wall areas at and near the end wall prove equally resistant to any lateral wavering. Only side wall areas intermediate the length of a container may begin to waiver under stress, and yet are much improved with the previously described side wall strengthening flaps.

Further advantages involve prototype testing of the corrugated plastic embodiments floatability with a user on the water in a container having a cavity area of 2 feet by 8 feet, and with both end wall interlocking flaps disengaged. As a user holds both sidewalls and pushes them equally downward to within an inch of the waters surface, water pressures exterior to the containers cavity area force the walls upwardly to form a rectangular shaped saucer-like form. As the user pulls both sidewalls inwardly, the end walls shift upwardly while the container regains its normal assembled shape, and remains afloat as the user releases one of the two sidewalls to reach forward or backward to re-interlock the notched interlocking flap within the notch of the elongate sidewall.

This advantage of the container still remaining afloat while the container is in an almost planar and unassembled state was discovered during one of many proto testings where a first interlocking flap was accidentally disengaged, and where the container stayed afloat to allow the still floating passenger to reach forward to re-engage the interlocking flap with one hand. Both interlocking flaps were then soon disengaged to further explore the container's floatability in the previously described rectangular saucer-like form.

Once the corrugated plastic material is bent at the slit formed hinge line between the interlocking flap and the end wall, residual memory within the plastic material tends to keep the bend at least to some degree. The strengthening difference in planar surface angles between each end wall and its hingedly connected interlocking flap cooperates with all other side wall pre-bends and adjacently located difference in planar surface angles, and each corners triangular shape projection pre-bends and adjacently located difference in planar surface angles, and the users weight load, and the waters surface to maintain the containers partially assembled rectangular saucer-like floating form. This difference in angles between each end wall and its hingedly connected interlocking flap especially prevents excessive lateral twisting of the substrate at each elongate end of the elongate partially assembled container; and while upon a waters surface.

Summarily, each hingedly attached interlocking flap has multiple strengthening advantages; and even as the container is almost planar and unassembled. The container will still remain leak proof to contain a human user without a full upward erection of the side walls or end walls, and especially without an absolute requirement of any means of interlocking, or any direct interlocking between the interlocking flaps and the notches located within each side wall.

It is an eighth object of this invention to optionally have elastic cords secured at each elongate end of the container. This embodiment may also have a closed cell floatation foam material adhered to its surface, or may have closed or filled flute channel apertures, and including only channels at one end being plugged to compensate for any water absorbing or non-floating properties of the elastic cords.

Advantages of a corrugated plastic embodiment or most any other material substrate utilizing the elastic cords include a container which is instantly and partially pre-assembled in seconds. When the substrate is other than a plastic material having memory retention properties in any bends, and when the container is not upon a waters surface, a final interlocking of the hingedly connected end wall interlocking flaps will most likely be required by the user. But when the substrate is of a corrugated plastic or any plastic with at least some memory retention within any hinge bend line areas, and when used as a container upon a waters surface, an interlocking of the interlocking flaps is not required, and as previously described concerning the partially assembled rectangular saucer like form. With the elastic cords embodiment, all walls will be more fully erected upwardly and nearly to a fully assembled containers position.

It is a ninth object of this invention to have at least one or more hinge bend lines extending the shortest length of the container.

Advantages of the ninth object include the ability of the container to be folded for storage and transport. This embodiment is disclosed within U.S. application for patent Ser. No. 12/069,625, and filed Feb. 12, 2008 by Wagenknecht, et al.

Combined advantages of the eighth and ninth objects include an emergency container being compactable to a small size with an almost instant deployment. A container with a cavity area of approximately 2 foot by 10 foot with 11 inch high side walls will compact to a size of 40 inches by 48 inches by 3 inches for stowing into a trunk compartment of a small car. In a drowning or rescue situation, the compacted and folded container may be easily accessed and instantly assembled within 3 to 4 seconds. As previously described, the containers design does not require a full assembly or a final interlocking of the hingedly connected interlocking flaps to support a person on the water. Further combined advantages of the eighth and ninth objects included one prototype testing with a person being in a first floating container while on the water and deploying 4 other units from the same first container, and with each unit having its own attached means of propulsion, or side wall strengthening flaps. The total time required to deploy the +4 units was exactly 55 seconds. Other tests included the side wall strengthening flaps being pre-folded and pre-threaded through the apertures of the sixth object.

It is a tenth object of this invention to alternatively have either one or both end wall(s), or portions of the walls angled outwardly from the floor of the container.

An advantage of the tenth object is a container having less resistance while on water, and when the container is being propelled in its elongate direction.

It is an eleventh object of this invention to enable a replacement of a damaged hingedly connected interlocking flap via rods connecting a corrugated materials open flute channel apertures, and by forming a corrugated plastic container so that open flute channels are positioned at an upper portion of each distal end wall.

An advantage of the eleventh object is an easy replacement of a damaged hingedly connected interlocking flap via splicing rods which extend through flute channels of the interlocking flap, and into the open flute channels of the end wall. Corrugated plastic is described by a manufacturer as a living hinge; as it will bend repeatedly for tens of thousands of times without fracturing, but still is not totally indestructible, and so, in positioning the flute channel openings at the upper edges of each end wall, a replacement hingedly connected interlocking flap is attached more easily and more securely by placing interconnecting rods within the flutes.

It is a twelfth object or goal of this invention; wherein if any parts at all should be added by the manufacturer, they shall add to either the structural stability of the container as in the fourth, fifth and seventh objects; or they shall add to the speed in assembly as in the eighth object; or they shall add to the containers floatation, and such as a closed cell floatation foam, or a flute channel plug(s) or rod(s) which shall at least plug one end of an open flute channel to at least slow a liquids entry; and where any added part may have secondary and alternate functions or results.

In summation; the overall size of this leak proof container is relative to the need or purpose. The same container design with side wall strengthening flaps may serve as a food or soup container with a serratingly attached spoon, or to function as an almost instantly assembled water craft with the serratingly attached side walls serving as a means of propulsion; and with all requiring no assembly tools.

REFERENCE NUMERALS IN DRAWINGS

  • 1. a first portion of bend lines parallel the substrate's longest length, and being spaced inwardly to determine a side walls height.
  • 2. a second portion of bend lines parallel the substrate's shortest length to define the hingedly connected interlocking flap being attached to the end walls.
  • 3. a third portion of bend lines being parallel with and located further inwardly than the second portions to perpendicularly abut or nearly abut the first portions to determine an end wall(s) height.
  • 4. a fourth portion of bend lines extend inwardly and angularly from the substrate's corner areas to a location near or at a location where the first and second portions abut or nearly abut to define exteriorly located hingedly mated triangular shape projections.
  • 5. a fifth portion of bend lines located between the third portions, and being perpendicular to the substrates elongate length to enable a more compact folding of the substrate.
  • 6. a sixth portion of bend lines parallel the side walls to define side wall flaps.
  • 7. a curved portion of bend lines replacing item (3) portions of bend lines, and remaining in a still generally parallel direction with the substrates shortest length.
  • 10. a side wall.
  • 12. a generally V-shape notch within a side wall or a substrate's perimeter edge.
  • 13. an angled shape notch within a side wall or a substrate's perimeter edge.
  • 14. a hingedly connected side wall strengthening flap, or (SWSF).
  • 15. a semi-circular shape notch within a side wall or a substrate's perimeter edge.
  • 16. an (SWSF) in a shape of a paddle.
  • 17. a line of apertures depicting perforations or cut through slits within the sixth bend line portions of a hingedly connected side wall strengthening flap.
  • 18. an end wall.
  • 19. a portion of an end walls planar surface which is angled outwardly from, and or other than 90 degrees to the floors planar surface.
  • 20. an end wall's hingedly connected interlocking flap.
  • 21. an extension of an end wall being part of a replacement interlocking flap.
  • 22. a narrow slot type notch within the end wall's interlocking flap.
  • 24. an exteriorly located hingedly mated triangular shape corner projection.
  • 26. an aperture location.
  • 28. a corrugated material's flute channel opening.
  • 30. a dashed line with arrows show a flute channel's elongate direction.
  • 32. a notched area within a flat substrate's corner to shorten an end wall flap.
  • 33. a chamfered or rounded corner.
  • 34. a floor.
  • 36. an elastic cord.
  • 37. a hand hold aperture centeredly located within the interlocking flap.
  • 38. a knotted end or tie-off location of an elastic cord.
  • 39. a connecting rod for a replacement interlocking flap.
  • 40. a closed cell floatational foam.
  • 42. a hinge bend line of a replacement interlocking flap.
  • 44. a rod like flute channel plug.
  • 46. an alphabetical letter H-shape flute channel plug.
  • 48. an approximate alphabetical letter W-shape flute channel plug.
  • 50. a waters surface.
  • 52. a slit formed hinge bend line.
  • 53. a slit forming tool example.
  • 54. a notch or slot formed hinge bend line.
  • 55. a notch or slot forming tool example.
  • 56. an aperture formed hinge bend line.
  • 57. a notch shape aperture within an aperture formed hinge bend line.
  • 58. a planar membrane wall within a corrugated material.
  • 60. a conjoining rib within a corrugated material.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings, closely related figures may have the same number, but different alphabetic suffixes.

A reader may refer to the drawings for a fairly accurate representation, as almost all drawings derive from superimposed line art renditions of electronic photos taken of actual full size prototypes, or from reduced computer aided drawings (CAD) files of plot lines used to cut out the original full size prototypes. FIG. 20 is especially noted as a copyable photo converted to dotted line tint screen.

FIG. 1,a; An overhead plan view of the unassembled preferred embodiment showing cutaway portions and hinge bend lines.

FIG. 1,b; A perspective view of the assembled preferred embodiment showing the assembled containers components.

FIG. 2,a; A side view of the preferred embodiment showing the assembled containers components.

FIG. 2,b; An overhead view of the preferred embodiment showing the assembled containers components.

FIG. 3,a; A perspective view of an alternative embodiment of corrugated plastic showing the assembled containers components.

FIG. 3,b; An overhead view of an alternative embodiment of corrugated plastic showing the assembled containers components.

FIG. 3,c; A side view of an alternative embodiment of corrugated plastic showing a partially assembled containers components before a final interlocking of the end walls interlocking flaps.

FIG. 4; An overhead plan view of an unassembled alternative embodiment showing chamfered corner areas and cutaway portions and hinge bend lines.

FIG. 5,a; An overhead view of an alternative embodiment of corrugated plastic with chamfered corner areas and showing the assembled containers components.

FIG. 5,b; A side view of an alternative embodiment of corrugated plastic with chamfered corner areas and showing the assembled containers components.

FIG. 6,a; An overhead plan view of an unassembled alternative embodiment of a thin paperboard with alternative fold lines and notches.

FIG. 6,b; A side view showing the unassembled paperboard alternative embodiment compacted in half.

FIG. 6,c; An overhead plan view of an unassembled alternative embodiment being similar to FIG. 6,a, but with additional fold lines.

FIG. 6,d; A side view of FIG. 6,c partially folded.

FIG. 6,e; A side view of FIG. 6,c completely folded.

FIG. 7,a; An overhead plan view of an unassembled alternative embodiment showing side wall strengthening flaps.

FIG. 7,b; A perspective view of an assembled alternative embodiment with side wall strengthening flaps secured by the end wall interlocking flaps.

FIG. 8; An overhead plan view of an unassembled alternative embodiment showing side wall reinforcing flaps in a shape of a folding paddle blade.

FIG. 9; An overhead plan view of an unassembled alternative embodiment showing only 1 side wall strengthening flap in a shape of a paddle blade.

FIG. 10,a; An overhead plan view of an unassembled alternative embodiment showing only 1 side wall strengthening flap with 2 bend lines and an end wall defining bend line being located further inward than its opposing end wall defining bend line.

FIG. 10,b; A side view from one elongate end showing the assembled strengthening flap and side wall of FIG. 10,a.

FIG. 10,c; A perspective view of FIG. 10,a in an assembled position and showing the double bend formed sidewall strengthening flap and an angled end wall.

FIG. 11; A perspective view of the preferred embodiment with optional elastic cords.

FIG. 12,a; An end view of corrugated plastic with 1 surface covered in a closed cell foam.

FIG. 12,b; An end view of corrugated plastic with 2 surfaces covered in a closed cell foam.

FIG. 13,a; An overhead plan view similar to the unassembled alternative embodiment of FIG. 4, but with curved bend lines to form an angled end wall.

FIG. 13,b is a perspective view from one elongate end of the assembled container of FIG. 13,a.

FIG. 14,a; A perspective side view of one end wall and not showing the damaged interlocking flap which has been cut away at the previous hinge bend line.

FIG. 14,b; An overhead plan view of a replacement interlocking flap.

FIG. 14,c; A perspective side view of one end wall and a replacement interlocking flap.

FIG. 14,d; The perspective side view of FIG. 14,c, but with added connecting rods.

FIG. 15,a; A plan view of a doubling up of corrugated material surrounding a notch of an interlocking flap before the material has been folded over onto itself.

FIG. 15,b; A plan view of a doubling up of corrugated material surrounding a notch of an interlocking flap after the material has been folded over onto itself.

FIG. 15,c; A side view of a doubling up of corrugated material surrounding a notch of an interlocking flap after the material has been folded over onto itself.

FIG. 16; An overhead view of a corrugated plastic substrate container being similar to FIG. 3,b, but including rod like flute channel plugs, and with no interlocking flap notches.

FIG. 17; A perspective end view of an interlocking flap and zoom views of means for attachment to a side walls notch, including H-shape and W-shape flute channel plugs.

FIG. 18; A perspective side view of an unassembled preferred embodiment as if it were on a waters surface, and after having all bend lines being bent at least once.

FIG. 19; A perspective view of slit, slot, and notch formed hinge bend lines within a corrugated plastic embodiment.

FIG. 20; A perspective view of a photo converted into copyable line art shows 2 passengers rowing within in one alternative embodiment while on the water, and with 2 side wall strengthening flaps having been removed and having their length cut in half, and folded to fit in the apertures near edges of the side walls.

DETAILED DESCRIPTION OF THE DRAWINGS

FIG. 1,a; An overhead plan view of the unassembled preferred embodiment showing cutaway portions and hinge bend lines. Shown are several portions of bend lines including a first portion of bend lines (1) which parallel the substrate's longest length, and are spaced inwardly to determine a side walls height. Shown also are a second portion of bend lines (2) which parallel the substrates shortest length, and are distanced inwardly to define the hingedly connected interlocking flap (20). Shown also are a third portion (3) of bend lines being parallel with and located further inwardly than the second portions (2) to perpendicularly and nearly abut, or perpendicularly abut and conjoin the first portions (1). Shown also are a fourth portion of bend lines (4) which extend inwardly and angularly from the substrates corner areas to a location where the first (1) and second portions (2) abut or nearly abut. Shown also are locations of generally V-shape notches (12) within the edges of the planned side wall(s) (10). Shown also are locations of narrow notches (22) within the interlocking flap(s) (20) of the end wall(s) (18). Shown also are notched areas (32) within the flat substrate's corner areas to shorten a length of the interlocking flaps (20), and the floor (34).

FIG. 1,b; A perspective view of the preferred embodiment of FIG. 1,a, and showing the container's assembled components. Shown are the two side walls (10), the two end walls (18), the two end wall interlocking flaps (20), the four exteriorly located hingedly mated triangular shape corner projections (24), and a floor (34).

FIG. 2,a; A side view of the preferred embodiment showing the container's assembled components. Shown are a side wall (10), two of the generally V-shape notches (12) within a side wall, two of the end wall's interlocking flaps (20), and two of the four exteriorly located hingedly mated triangular shape corner projections (24).

FIG. 2,b; An overhead view of the preferred embodiment showing the assembled container's components. Shown are the two side walls (10), the two end walls (18), two of the end wall's interlocking flaps (20), the four exteriorly located hingedly mated triangular shape corner projections (24), and the floor (34).

FIG. 3,a; A perspective view of an alternative embodiment of corrugated plastic showing the assembled container's components. Shown are the two side walls (10), the two end walls (18), a slit, slot or notch formed bend line (2) defining one of the two of the end wall's interlocking flaps (20), the four exteriorly located hingedly mated triangular shape corner projections (24), the floor (34), and general locations of flute channel opening(s) (28).

FIG. 3,b; An overhead view of an alternative embodiment of corrugated plastic showing the assembled container's components. Shown are the two side walls (10), the two end walls (18), two interlocking flaps (20), the interlocking flaps notch (22) locations, the four exteriorly located hingedly mated triangular shape corner projections (24), the floor (34), various flute channel opening(s) (28), and the direction of the elongate flute channels (30).

FIG. 3,c; A side view of an alternative embodiment of corrugated plastic showing a partially assembled container's components before a final interlocking of the two interlocking flaps (20) is made, and also showing one side wall (10), two of a side wall's generally V-shape notches (12), and two of the exteriorly located hingedly mated triangular shape corner projections (24).

FIG. 4; An overhead plan view of an unassembled alternative embodiment showing chamfered corner areas and cutaway portions and hinge bend lines. Shown are the same bend lines and notched or cutaway portions (32) as described in FIG. 1,a; but with most corner areas being chamfered, except within the side wall notches (12). Shown are several bend lines including a first portion (1) of bend lines which parallel the substrate's longest length, and are spaced inwardly to determine a side walls height. Shown also are a second portion (2) of bend lines which parallel the substrate's shortest length, and being spaced inwardly to define the hingedly connected interlocking flap. Shown also are a third portion (3) of bend lines being parallel with and located further inwardly than the second portions to perpendicularly and nearly abut or to abut and conjoin the first portions (1). Shown also are a fourth portion (4) of bend lines which extend inwardly and angularly from the substrate's corner areas to a location where the first and second portions abut or nearly abut. Shown also are locations of a narrow notch (22) within the end wall's interlocking flap. Note that part of the cutaway portions (32) within the flat substrates corner areas is to shorten a length of the interlocking flap. Also shown are areas of chamfering (33). To retain the drawings clarity, not all rounded corners are numbered, but remain evident.

FIG. 5,a; An overhead view of an alternative embodiment of corrugated plastic with chamfered corner areas and showing the assembled container's components. Shown are the two side walls (10), the two end walls (18), two of the end walls hingedly connected interlocking flaps (20), the four exteriorly located hingedly mated triangular shape corner projections (24), the corrugated plastics open end flute channels (28), a direction of the elongate flute channels being represented by a dashed line with double end arrows (30), and the floor (34).

FIG. 5,b; A side view of an alternative embodiment of corrugated plastic with chamfered corner areas and showing the assembled containers components. Shown is one side wall (10), two of the side wall's generally V-shape notches (12), two of the end wall's interlocking flaps (20), and two of the exteriorly located hingedly mated triangular shape corner projections (24).

FIG. 6,a; An overhead plan view of an unassembled alternative embodiment showing a single fold line (5) within the center of the substrate, and being perpendicular to the substrates elongate length, and alternative shape notches in a shape of a narrow angled notch (13) within the substrate's perimeter edge or side wall area, and also showing hand hold aperture (37) locations.

FIG. 6,b; A side view showing the unassembled alternative embodiment compacted in half, and a location of the single fold line (5).

FIG. 6,c; An overhead plan view of an unassembled alternative embodiment showing multiple fold line (5) locations and alternative shape notches in a shape of a narrow angled notch (13) within the substrate's perimeter edge or vertically uppermost side wall area.

FIG. 6,d; A side view showing the unassembled alternative embodiment with each distal end folded inwardly, and locations of the multiple fold lines (5).

FIG. 6,e; A side view showing the unassembled alternative embodiment completely folded, and locations of the multiple fold lines (5).

FIG. 7,a; An overhead plan view of an unassembled alternative embodiment showing side wall strengthening flaps (14) and their bend line (6) locations.

FIG. 7,b; A perspective view of an assembled alternative embodiment with two side wall strengthening flaps secured by the end wall interlocking flaps. Shown are bend line (6) locations, the two side walls (10), two strengthening flaps (14), and the two end wall interlocking flaps (20). One strengthening flap is shown located within the cavity area and the oppositely located strengthening flap being exterior to the cavity area.

FIG. 8; An overhead plan view of an unassembled alternative embodiment showing two strengthening flaps in a shape of paddle blades (16), and bend line (6) locations, and serrated cut through portions (17) within the bend lines (6), and multiple apertures (26) near the substrates edges.

FIG. 9; An overhead plan view of an unassembled alternative embodiment showing a container with only one side wall strengthening flap in a shape of a paddle (16), and serration portions (17) within the strengthening flaps bend line (6).

FIG. 10,a; An overhead plan view of an unassembled alternative embodiment showing a container with only one side wall strengthening flap (14), and including 2 bend lines (6) which form an additional and opposing surface between the substrate and the strengthening flap. Shown also is an end wall (18) and its bend line (3), and an angled end wall (19) with its bend line (3) being located further inward from the substrates perimeter edge than the opposite end walls bend line (3), or further inward than the first portions of bend lines (1).

FIG. 10,b; A side view from one elongate end showing the assembled strengthening flap (14), and the two bend lines (6), and the side wall (10) of FIG. 10,a.

FIG. 10,c; A perspective view of FIG. 10,a in an assembled position and showing the double bend lines (6) which form the sidewall strengthening flap (14), a straight end wall (18) and an angled end wall (19), and the 2 interlocking flaps (20), and the side wall (10) which is hingedly connected to the strengthening flap.

FIG. 11; A perspective view of the preferred embodiment with optional elastic cords (36) and their knotted or secured or tied off ends (38) and the two interlocking flaps (20), and aperture locations (26), and a slit or slot formed hinge bend line (2) and flute channel openings (28), and with one flap shown removed to reveal an elastic cord.

FIG. 12,a; An end view of corrugated plastic showing the open ended flute channels (28) and showing 1 surface of the corrugated sheet covered in a closed cell foam (40) material.

FIG. 12,b; An end view of corrugated plastic showing the open ended flute channels (28) and showing 2 surfaces of the corrugated sheet covered in a closed cell foam (40) material.

FIG. 13,a is an overhead plan view of an alternative embodiment with bend portions (7) being slightly curved and still being generally parallel with the substrates shortest dimension. The drawing is similar to FIG. 4, and shows the first portions (1) of bend lines which parallel the substrate's longest length, and are spaced inwardly to determine a side walls height. Shown also are a second portion (2) of bend lines which parallel the substrate's shortest length, and being spaced inwardly to define the hingedly connected interlocking flaps (20). Notice the seventh portion (7) of bend lines which are generally parallel with and located further inwardly than the second portions (2), to perpendicularly and nearly abut or to abut and conjoin the first portions (1). Shown also are a fourth portion (4) of bend lines which extend inwardly and angularly from the substrate's corner areas to a location where the first and seventh portions (7) abut or nearly abut. Shown also are locations of a generally V-shape notch (12) within the side walls (10). Shown also are locations of a narrow notch (22) within the end walls (18) interlocking flaps (20). Also shown are two angled portions (19) of the end walls. Note that a part of the cutaway portions (32) within the flat substrates corner areas is to shorten a length of the interlocking flap. Shown also are several areas of chamfering (33). To retain the drawings clarity, not all rounded corners are numbered, but remain evident.

FIG. 13,b is a perspective view from one elongate end of the assembled container of FIG. 13,a. Shown are two end walls (18), and two portions of the end walls which are angled portions (19), and four locations of curved bend lines (7), and two side walls (10), and four hingedly-mated triangular shape projections (24), and the floor (34). The side wall notches and interlocking flaps are not included in this drawing for a better view of the angled portions.

FIG. 14,a; A perspective side view of one end wall (18), and not showing the damaged interlocking flap which has been cut away at the previous hinge bend line.

FIG. 14,b; An overhead plan view of a replacement interlocking flap (20), and an extension of an end wall being part of a replacement interlocking flap (21), and a slit formed hinge bend line (2) of a replacement interlocking flap.

FIG. 14,c; A perspective side view of one end wall (18), and a replacement interlocking flap (20), and an extension of an end wall being part of a replacement interlocking flap (21), and a corrugated materials open flute channel location (28).

FIG. 14,d; The perspective side view of FIG. 14,c, but with added connecting rods (39), and showing a replacement interlocking flap (20), and an extension of an end wall being part of a replacement interlocking flap (21), and a corrugated materials open flute channels (28), and the end wall (18).

FIG. 15,a; A plan view of a doubling up of corrugated material surrounding a notch (22) of an interlocking flap (20) before the material has been folded over onto itself, and also showing a circular shape notch (15) within the side wall (10).

FIG. 15,b; A plan view of a doubling up of corrugated material surrounding a notch (22) of an interlocking flap (20) after the material has been folded over onto itself, and also showing a circular shape notch (15) within the side wall (10).

FIG. 15,c; A side view of a doubling up of corrugated material surrounding a notch (22) of an interlocking flap (20) after the material has been folded over onto itself.

FIG. 16; An overhead view of a corrugated plastic substrate container being similar to FIG. 3,b, but including flute channel plugs (44), and with no interlocking flap notch locations. Also shown are end walls (18), locations of V-shape notches (12) within the upper edges of the side walls (10), the interlocking flaps (20), the floor (34), the flute channel opening(s) (28), the slit formed hinge bend line (2) locations, and the direction of the elongate flute channels (30).

FIG. 17; A perspective end view of an interlocking flap (20) having only one notch (22) location to receive a notched W-shape flute channel plug (48) and also showing an H-shape flute channel plug (46), and with a zoomed in view of the two types of plugs.

FIG. 18; A perspective side view of an unassembled embodiment after being pre-bent or assembled at least once, and as if it were on a waters surface (50), and showing all bend line locations (1),(2),(3),(4). Within this embodiment, the portion of bend lines (2) are formed by slitting one planar membrane wall of the two walled substrate, and where internal conjoining ribs self score up to the remaining planar wall which serves as the hinge or bend line (2) to define the hinged flap (20). Shown also are two side walls (10) and the two flaps (20) which are hingedly connected to the end walls (18), and the floor (34), and slit formed hinge bend line locations (2).

FIG. 19; A perspective view of various hinge bend lines within a corrugated plastic embodiment, and showing a slit formed bend line (52), and a slit forming tool (53) example; and a slot formed bend line (54) location, and a slot forming tool (55) example; and a notch formed bend line (56), and a zoomed in view of a notch shape (57). Also shown is a planar membrane wall (58) within the corrugated material, and a conjoining rib (60) within the corrugated material, and one of many flute channel openings (28).

FIG. 20; A perspective view of 2 passengers shown rowing within in one alternative embodiment while on the water, and with 2 side wall strengthening flaps (16) having been removed and having their length cut in half, and folded to fit in the apertures (26) adjacent edges of the side walls. This container and means of propulsion are formed completely and only from corrugated plastic; and with absolutely no other parts used to retain its structural stability, and as shown in FIG. 8.

PREFERRED EMBODIMENT

Shown in FIG. 1,a; is a plan view of the preferred embodiment in a flat and unassembled state, and comprising a plurality of bend lines with the substrates interior portion, and notched or cut away areas (32) within the perimeter edges of the body. A first portions of bend lines (1) parallel the substrate's longest length, and are spaced inwardly to determine a side walls height. A second portions of bend lines (2) parallel the substrate's shortest length and are distanced inwardly from the substrates perimeter edge to define two interlocking flaps (20) which are hingedly connected to the end walls (18). A third portions of bend lines (3) define the end walls (18) height and are parallel with and located further inwardly than the second portions (2) to perpendicularly nearly abut or abut to conjoin the first portions (1). A fourth portions of bend lines (4) extend inwardly and angularly from approximate corner areas to locations where the first (1) and third portions (3) nearly abut or abut. The notched areas (12) within the perimeter edges of the two side walls (10) include V-shape notches (12). Two narrow notches (22) are located within each interlocking flap (20). The corner area notches (32) shorten a length of each interlocking flap (20). Shown in FIG. 1,b; are the components of an assembled preferred embodiment, and comprising, two end walls (18), two hingedly connected interlocking flaps (20), four exteriorly located hingedly-mated triangular shape corner flap projections (24), and the floor (34).

Operation

In the forming of a leak proof self securing container which is purposed to contain a human user and or their objects; most any substrate material may be used, yet one which is repeatably bendable within any hinge bend line locations will permit a folding and unfolding of the container from and back to a generally flat substrate form for a compact stackability between uses.

The substrate may be of wood or metal which is conjoined with alternative flexible materials forming the hinge bend line portions. The alternative conjoining materials may comprise rubber or flexible plastic composites such as those with a plastic copolymer base that remain flexible in the hinge bend line areas.

Two of the most preferred materials which can be used for the entire substrate material including the hinge bend line locations; are paperboards comprising cardboards or corrugated cardboards in most any ply thickness, and copolymer based plastics. Plastics which are bendable, or those which are heat formed or vacuum formed or injection molded will all work fine within this container's design.

When the container is formed in a larger size, and other than when purposed as a food container etc., and when purposed to contain a human; and in example, an emergency floating container, it is best formed from a stiffer but still bendable substrate such as a polymer plastic. Unlimited variations and combinations of plastics prevent a complete listing, and so shall not be completely disclosed here; yet one most preferred type of plastic substrates is a corrugated plastic being formed from a copolymer plastic base, and which hereon may be referred to as CP.

To best describe how to construct the container, it shall be elongate within at least a few thousandths of an inch to best clarify and differentiate its side walls from the end walls, etc.; yet the container may also be generally square in shape.

FIG. 1,a shows an overhead plan view of the bend lines (1), (2), (3), (4) and cut through notches (12), (22), (32) within the exterior perimeter edges, and the resulting side walls (10), the end walls (18), and hingedly connected interlocking flaps (20) of the preferred embodiment, while FIG. 1,b shows components of the same, but assembled container.

The substrate in FIG. 1,a is shown in a flat and planar position, wherein a first portion of bend lines (1) parallel the substrate's longest length, and are spaced inwardly to determine a side walls (10) height. A second portion of bend lines (2) parallel the substrate's shortest length and are distanced inwardly from the substrates perimeter edge to define two interlocking flaps (20) which are hingedly connected to the end walls (18). A third portion of bend lines (3) are parallel with and located further inwardly than the second portions (2) to perpendicularly and nearly abut or abut and conjoin the first portions (1), and to determine the end wall(s) (18) height. A fourth portion of bend lines (4) extend inwardly and angularly from approximate corner areas to locations where the first portions (1) and third portions (3) nearly abut or abut. The stated second portions (2) define the interlocking flaps (20) which include the notches (22) which interlock with the V-shape notches (12) located in the perimeter edges of the substrate, or within the uppermost edge of the side walls (10) of the assembled container in FIG. 1,b to secure each end wall (18) and each corner's resulting exteriorly located triangular shape hingedly-mated flap projection (24); wherein each end wall (18) is wedge-locked between the side walls (10) in its assembled position.

After all bend lines and perimeter edge notches are formed as shown in FIG. 1,a, and as an end wall (18) is forced upward and inward to form the exteriorly located hingedly-mated triangular shape flap projections (24) as shown in FIG. 1,b., the hingedly attached side walls (10) will also pull inwardly and upward. The projections (24) are located exteriorly to the container's cavity area. The user then pushes the end wall's slotted and hingedly connected interlocking flap (20) in a downward direction until the notches (22) interlock with the side wall's V-shape notches (12). The same process is then repeated at the substrate's opposite elongate end. The container is at this point fully assembled as shown in FIG. 1,b with all four walls being hingedly connected to the floor (34), and with each end wall (18) being wedge-locked between the two side walls (10) and the exteriorly located hingedly-mated triangular shape projections (24).

Material surrounding the notches (22) within the interlocking flap (20) additionally prevents the side walls (10) from bending laterally outward from the location of interlocking and also portions of the side walls being near that location.

If the manufacturer insists on adding a part to the part-less container, it might be at this location surrounding the notches (22) of the interlocking flap (20) with a reinforcement of thin metal or plastic bonding, etc. After numerous interlockings, the substrate may begin to show signs of wear at this location first, and pending the user's care in assembly, and the material type.

Another method of reinforcing the interlocking flap may include an extra bend extending the longest length of the flap, with portions of the flap folding back onto itself, and with the notch (22) formed through the extra bending location. Not all possible variations of flap reinforcements are claimed or shown in the drawings, yet are disclosed here as being obvious by the writer.

Note within FIG. 1,b, the difference in angle between the vertical end wall (18) and the hingedly attached interlocking flap (20). This difference is also seen within FIG. 2,a. Much strength is added to the entire end wall area and side wall areas which are near the end walls with this flap being hingedly attached to the end wall in this angled form within the assembled container. The difference in angle further prevents a lateral twisting of the assembled container, and to at least some degree within a partially assembled container.

With a container having a cavity area of 26 inches wide, and 10 feet long, and with 11 inch high side walls, the entire assembly at a casual pace takes about 15 seconds for 1 person and so with 2 assembly persons, the time taken to walk the feet is eliminated, and the assembly process is reduced from 15 seconds to about 6 seconds.

FIG. 3,a is a perspective view and FIG. 3,b is an overhead view of an alternative embodiment of corrugated plastic material, and showing locations of the substrate's open flute channels (28).

The views within FIGS. 3,a, 3,b, and 3,c are to introduce the alternative embodiment of corrugated plastic. FIG. 3,c is a side view showing the interlocking flaps (20) just before they are pushed downward into and interlocked with the V-shape notches (12) located within the uppermost edges of the side walls (10).

FIG. 4 is an alternative embodiment representing most any substrate material with almost all corner areas or sharp edged locations within the perimeters edges being chamfered areas (33). Any chamfering in the V-shape notch (12) should be minimal to not defeat its locking grip with the narrow notches (22) of the interlocking flaps. To retain the drawings clarity, not all rounded corners are numbered, but remain evident. Also note the nearly abutting bend lines in FIG. 4, (3).

FIG. 5,a is an overhead view of an assembled CP embodiment with all the same bend line locations of FIG. 4 and chamfered areas (33) surrounding the interlocking flaps (20). Other components shown are the two side walls (10), and the two end walls (18), and two hingedly connected interlocking flaps (20), and the four exteriorly located hingedly mated triangular shape corner projections (24), and one of the open end flute channel (28) locations, and a direction of the elongate flute channels being represented by a dashed line with double end arrows (30), and the floor (34).

FIG. 5, b is a side view showing some of the chamfered locations (33) of FIG. 5,a, and other components including two of the generally V-shape notches (12) located within the upper edges of a side wall (10), and the two interlocking flaps (20), and two exteriorly located hingedly mated triangular shape corner projections (24).

An alternative shape narrow notch (13) is shown in FIG. 6,a. Notice the slight angle of the notch (13) which is similar in angle to one side of the previous V-shape notch (12). The angle of the notch (13), or the V-shape notch (12) within other drawings, depends on the type of material used, and so may vary according to the manufacturers choice of ease or difficulty in executing the interlocking of the notched flap (20) within the notched portion (13) of the side wall, or for the material's strength to retain the interlocking and assembled containers shape.

When an embodiment is extremely elongate as in FIG. 6,a; the manufacturing user may want to incorporate a fifth portion of bend lines (5) which extend the substrate's complete shortest width; and wherein the container may be folded in half for a more compact storage or easier transporting, and as shown when folded in half in FIG. 6,b. FIG. 6,a also shows hand hold aperture locations (37).

When a containers size is 10 to 12 feet long, several bend lines (5) may be formed as in FIG. 6,c; and with FIGS. 6,d and 6,e showing the stages of bending and folding the substrate.

As previously described within the objects and advantages section, the weakest point within an extremely long assembled container of 10 to 12 foot long will be intermediate its side walls elongate length; and with the center portions of the walls upper edges not wavering in a direction of their length, but in a slight lateral direction when under pressure.

The alternative embodiment within the overhead plan view of FIG. 7,a shows how a sixth portion of bend lines (6) form side wall strengthening flaps (14) which are hingedly connected to the side walls. FIG. 7,b is a perspective view of the assembled version of FIG. 7,a; and showing the side wall strengthening flaps (14) being retained within the cavity area of the container by the interlocking flaps (20). The flaps (20) are held tightly adjacent the side wall in areas near the notches (22) of the interlocking flaps (20); yet may bow slightly away from the side walls in areas where additional support is needed the most; which is in the center areas of the elongate side walls, or intermediate their elongate length.

Any slight bowing does not hinder a side wall's lateral strength, but serves to increase it, as was previously described with added strength being added by the interlocking flap's difference in angle with the end wall's vertical orientation. The described bowing is not shown in drawings, as a type and size of substrate determines if any bowing occurs at all. Irregardless of whether the strengthening flap (14) in FIG. 7,b completely abuts the attached side wall (10) or not; at least some degree of increased side wall lateral stability is still achieved.

FIG. 8 is an overhead plan view of an alternative embodiment utilizing a sixth portion (6) of bend lines which define a side wall strengthening flap, and which is in a shape of a folding paddle (16); and with a line of apertures (17) which denote a perforated area along the bend line. The apertures (17) only represent intermittent areas within the hinge bend line for clarity of the drawing, and may be through cut slits within the actual container. A user may choose to remove the paddle shape side wall strengtheners for several other uses, and including a folding of the strengthener to thread through one or more apertures (26) located adjacent an upper edge of the side walls. Aperture (26) uses may include connecting two containers together, or carrying one container via folded side wall strengtheners, or as a type of oar locks for an emergency paddling situation.

Corrugated plastic is limited in its available width when purchasing in small quantities, and so FIG. 9 depicts a container with only 1 side wall strengthening flap to provide for a wider container. FIG. 9 shows a sixth portion (6) of bend lines which define a side wall strengthening flap, and which is in a general shape of a folding paddle (16); and with a line of apertures which denote a perforated or intermittent cut through area (17) within the bend line.

Not all possible variations or shapes of side wall strengthening flaps are shown in the drawings, yet are disclosed here as being obvious by the manufacturer to retain at least some degree of side wall strengthening, and irregardless of most any shape the flap is manufactured in.

FIG. 10,a shows only 1 side wall strengthening flap, but with 2 bend lines (6) to define the strengthening flap (14), while also showing a straight end wall (18), and an angled end wall (19). The angle is achieved by moving one of the 3rd portion of bend lines (3) further inward than the other 3rd portion (3) from the perimeter edge of the substrate.

FIG. 10,b is a side view showing the double bend which provides more strength through the two bends (6) which define the plural hinge of the side wall's (10) strengthening flap (14).

FIG. 10,c depicts the assembled embodiment of FIG. 10,a. Shown is the straight end wall (18), the angled end wall (19), two interlocking flaps (20), the locations of the two bend lines (6) which define the strengthening flap (14) which is hingedly connected to the side wall (10).

FIG. 11 shows a slit formed bend line (2) which opens up two rows of flute channel apertures (28) after the conjoining ribs self score until reaching the opposite planar wall of the CP material, and will be further explained in FIG. 19.

FIG. 11 also shows two different methods of threading elastic cords (36) through any apertures (26) or flute channel openings (28). This embodiment will self assemble within seconds, and with any final interlocking of the flaps remaining as an option to the user, and according to the purpose of the container at the time. When the entire container is folded to the configuration of FIG. 6,b, or FIG. 6,e, the container will snap open and assemble itself in about 2 seconds. Any final interlocking of the flaps will require about 3 or 4 seconds per flap.

The elastic cord embodiment in FIG. 11 of an emergency floating container for a human user and or their objects may be 10 feet long for use as a water craft, or 18 inches long for use as a toy boat. Within the invention's design, size is relative according to the manufacturer's end use purpose. The same 18 inch size container may have uses including a foot bath, an oil change pan, a tool parts tray, etc.

FIG. 12,a shows an end view of the flute channel openings (28) within a new type of corrugated plastic having a closed cell foam lamination (40), and with FIG. 12,b having a two sided lamination of foam (40). When a container is purposed to be an emergency floating container, the foam will compensate for any water absorbing non-floating parts such as the previous elastic cords. The foam material has a secondary function as a surface protection against dings, etc.

FIG. 13,a and FIG. 13,b are to show the reader how portions of an angled end wall (19) may be accomplished in multiple ways, and that the entire end wall does not have to be angled, but only a portion to reduce any drag within water, and with the assembled version of FIG. 13,a being shown in FIG. 13,b.

FIG. 13,a is an overhead plan view of an alternative embodiment with bend portions (7) being slightly curved and still being generally parallel with the substrates shortest dimension. The drawing is similar to FIG. 4, and shows the first portions (1) of bend lines which parallel the substrate's longest length, and are spaced inwardly to determine a side walls height. Shown also are a second portion (2) of bend lines which parallel the substrate's shortest length, and being spaced inwardly to define the hingedly connected interlocking flaps (20). Notice the seventh portion (7) of bend lines which are curved, yet still generally parallel with and located further inwardly than the second portions (2), to perpendicularly and nearly abut or to abut and conjoin the first portions (1). Shown also are a fourth portion (4) of bend lines which extend inwardly and angularly from the substrate's corner areas to a location where the first and seventh portions (7) abut or nearly abut. Shown also are locations of a generally V-shape notch (12) within the side walls (10). Shown also are locations of a narrow notch (22) within the end walls (18) interlocking flaps (20). Also shown are two angled portions (19) of the end walls. Note that a part of the cutaway portions (32) within the flat substrates corner areas is to shorten a length of the interlocking flap. Shown also are several areas of chamfering (33). To retain the drawings clarity, not all rounded corners are numbered, but remain evident.

FIG. 13,b is a perspective view from one elongate end of the assembled container of FIG. 13,a. Shown are two end walls (18), and two portions of the end walls which are angled portions (19), and four locations of curved bend lines (7), and two side walls (10), and four hingedly-mated triangular shape projections (24), and the floor (34). The side wall notches and interlocking flaps are not included in this drawing for a better view of the angled portions.

The slit formed hinged interlocking flap is the second foremost source of strength after the wedge-locked end walls and the exteriorly located hingedly mated corner projections, and either if the interlocking flap is originally and hingedly attached to the end wall, or whether it is offered by the manufacturer as a separate unit to be installed by the end user as shown in FIG. 14,d.

FIG. 14,a shows one end wall (18) with a damaged interlocking flap removed or completely cut off at the hinge line, and with a replacement interlocking flap (20) being shown in FIG. 14,b, and with a slit formed hinge bend line (2) and an extended portion (21) and its positioning shown in FIG. 14,c, and with any connecting rods (39) shown in FIG. 14,c. Connecting rods may be of any shape other than those shown, and may be injection molded to more precisely match the shape of a flute channel. A replacement connecting flap only applies to a CP container with open flute channels at each elongate end, and may include the connecting rods being pre-attached within the extended portions (21).

One method of reinforcing the material surrounding the notch (22) within an interlocking flap (20) is shown in FIG. 15,a and b; where plan views show a doubling up of corrugated material surrounding a notch (22) of an interlocking flap (20) before and after the material has been folded over onto itself. FIG. 15,c shows a side view of FIG. 15,b where the notch is cut through two layers of substrate. Also note the generally circular shape notch (15) within the side walls (10) of FIG. 15,a and FIG. 15,b.

Just as the corrugated plastic embodiment has multiple and additional functional properties within its existing form; and comparatively as the closed cell laminated foam embodiment comprises further properties beyond floatation, and such as a surface protective material; a flute channel plug (44) in FIG. 16 also has a secondary function as a means to attach a flap (20) within a side wall notch (12).

When any shape of flute channel plug (44), (46), (48) is inserted within both opposite ends of an open flute channel of a corrugated plastic container, a closed and buoyant floatation cell is formed. When a plug is inserted into only one end of any flute channel, a certain amount of air may be trapped within the channel as the substrate is either floating on a waters surface, or swept under the surface; and so at least aids or at least has the potential to aid in a containers floatation. All plugs are preferably formed of a material such as wood or air impregnated plastic to not reduce the containers floatation properties, yet may be of most any material substrate and may be inserted anywhere in the container, and may also have the previously described secondary function as a means of attachment between an interlocking flap and a side walls notch.

FIG. 16 shows an overhead view of a corrugated plastic substrate container being similar to FIG. 3,b, but including rod like flute channel plugs (44), and with no interlocking flap notch locations. Also shown are end walls (18), the side walls (10), the interlocking flaps (20), the floor (34), various locations of flute channel openings (28), and with flute channels that have been opened via bend lines formed via a hinge forming slit (2), and also showing the direction of the elongate flute channels (30). The air trapping rod-like plugs (44) shown may be partially inserted into any flute channels of the interlocking flaps (20) to surround and laterally retain the side walls (10) within the notched area, and so eliminates a need for a notch within the interlocking flap. Most plugs may also be used to reinforce the material surrounding a notch within a corrugated interlocking flap; yet are not all shown.

FIG. 17; A perspective end view of an interlocking flap (20) having only one notch (22) location to receive a generally W-shape flute channel plug (48). The outer portions of the W-shape are inserted into flute channels surrounding the notch (22), and the centered apex portion of the W-shape is located within the notch. The drawing also shows an H-shape flute channel plug (46) which eliminates the need for forming any notch (22) within the interlocking flap (20).

Notice all the retained angles between the multiple planar surfaces of the substrate within FIG. 18. A perspective side view is shown of an unassembled embodiment after it was pre-bent or assembled at least once, and as if it were on a waters surface (50) with a human user in the cavity area, but with the human not shown, and showing all bend line locations (1),(2),(3),(4). Shown also are the two flaps (20) which are hingedly connected to the end walls (18). The difference in planar angles of all surfaces prevent a lateral twisting of the substrate when on a waters surface. In this embodiment, the hingedly connected slit formed flaps (20) will especially aid to prevent lateral twisting of the container near each distal end.

This retained form of a rectangular saucer-like shape is especially due to the method in which the interlocking flap defining slit formed bend lines (2) were formed in the corrugated plastic substrate.

If these bends were crimped bends, the membrane wall being exterior to the bend line would need to stretch a much further distance than the interior wall surface of the bend line, and so would result in a lesser degree of any angles, or a more floppy and less stable form near each distal end of the container.

Shown also in FIG. 18 are two side walls (10) which are hingedly connected to the floor (34) via slit formed bends (1), and the floor (34) being hingedly connected to the end walls (18) via slit formed bends (3).

The unassembled container of FIG. 18 which retains its partially assembled form upon a waters surface enables a swimming user or a container retained user to guide only the two side walls inwardly and upwardly for the containers assembly.

Many prototype tests made in a small but fast flowing river have included persons jumping from the shoreline and onto the unassembled container, and remaining afloat to pull only the two side walls upward, and wherein the persons weight load combined with the waters upward pressure caused all walls to be shifted inward and upward, and with the four triangular shape projections shifting outwardly for the containers assembly. This embodiment was manufactured by forming all hinge bend lines with slits made on only one side of the CP material.

As previously described, a corrugated plastic substrate has two planar walls which are conjoined by elongate paralleling ribs. When one planar wall is slit with a hand held cutting tool, a controlled depth saw blade, or a CNC cutting machine, the internal ribs between the two walls upon bending the substrate, will self score until the slit reaches the opposite planar wall, which will then function as a hinge bend line. It is this method of forming a hinge bend line which best enables the substrate to more so retain a partial shape of any previous bends, and combined with the memory retension of the plastic substrate. Bend lines which parallel any flute channels can be either crimped or slit formed, but material surrounding slit or slot or notch formed bend lines which are perpendicular to the elongate flute channels are more easily bent, and will retain a straighter and more accurate bend line location.

Material within a slot formed bend line will self score upon bending a substrate similarly to a slit formed bend line. Material surrounding an aligned plurality of notched apertures or a notch formed bend line will stretch in a direction toward the bend line, and is not as easily bent, but will retain an accurate location.

Within the three methods described for forming any bend lines, one additional advantage is in the manufacturing of any larger size container, and such as one using an initial 4 foot by 12 foot by ½ inch thick corrugated plastic material. Large bending equipment is not needed to form any bends within the semi rigid material.

The elimination of large, and so, very expensive bending equipment may far outweigh any previously described goals of the invention within the previous objects and advantages portion of this disclosure. If selected slit or slot formed hinge bend lines are somewhat intermittent in their continuity, and or do not extend completely to an edge of the CP material, the substrate will retain a more rigid and planar form until the end user makes any initial bends. Shipping and handling will be easier when transporting a more rigid and planar substrate, and so dollar costs of transport and handling should also be reduced.

FIG. 19 shows a perspective view of various hinge bend lines within a corrugated plastic embodiment; and showing a slit formed bend line (52), and a slit forming tool (53) example; and a slot formed bend line (54) location, and a slot forming tool (55) example; and a notch formed bend line (56), and a zoomed in view of a notch shape (57). Also shown is a planar membrane wall (58) within the corrugated material, and a conjoining rib (60) within the corrugated material, and one of many flute channel openings (28). A final size or end use purpose of the container will determine the manufacturers choice of which type of hinge bend line forming tool is best.

CONCLUSION, RAMIFICATIONS, AND SCOPE

In summation, a means of attachment of the hingedly attached interlocking flap to the notches within the side walls may not require a narrow notch within the interlocking flap, as some means disclosed in the drawings eliminate a need for the narrow slot like notch within the interlocking flap. The notches within the side walls are a necessary element for a good lateral securement of the side walls for a container which requires no parts; yet it shall be deemed as an obviousness that an almost unlimited number of means to attach the hinged interlocking flap to the side walls does exist, and where this disclosure does not attempt to disclose all.

The foremost asset of the assembled container is its lateral wall strength, and especially in an extremely elongate form, and while remaining substantially leak proof, it retains opposingly stressed elements which produce a secure wedge-locked strength near and at each end wall location. The side wall strengthening flaps complete its strength nearly to the equivalent of a six sided box; and yet with all being formed from a single planar substrate which requires no parts, or glues, or tapes, or staples, or tabs, or tab receiving apertures, or assembly tools.

It should be understood by the reader that this new concept of a leak proof self securing container for a human user and or their objects entails many diverse uses; and wherein the end uses cannot all be disclosed, yet should be addressed to inform or remind the reader that as previously stated, size is relative to the final intended purpose; and wherein any purposes to be absolutely leak proof or the degree to which the container is to be leak proof is also according to a type of material substrate a manufacturer chooses to form the container from.

Any paperboard embodiments of the leak proof container may include various coatings of oils, waxes, or plasticizers or other water proofing sprays, or immersions to further a container's leak proof properties. And similarly, any plastic embodiment may include buoyant coatings of closed cell foam or in combination with air impregnated plastic portions in locations of the entire substrate or portions of the substrate. All plastic types are not claimed, as it shall be understood that most any combination of plastic polymers from the hundreds which exist; will function fine.

And just as a manufacturer's chosen size of the leak proof container will determine whether a 200 lb. or a 400 lb. person may use the container as a water craft; a smaller size leak proof container may alternately serve as a toy boat or floating tackle box.

The side wall strengthening flaps are of great value when in specific shapes such as a folding paddle blade. When combined with the bend lines (5) a store display may exhibit dozens of container type emergency water crafts with an attached means of propulsion being stacked on a single pallet.

It is understood that various end uses of any invention can not always be claimable; and yet when a disclosure such as this has so many multiple and purposed uses in an emergency flood situation, and as previously described in application Ser. No. 11/288,463, the overall value of the invention changes via the greater synergistic effect of the combined end uses.

Although previous descriptions contain many specifics, these should not be construed as limiting the scope of the invention but as merely providing illustrations of some of the several presently preferred embodiments of this invention of a leak proof self securing container from a single sheet; and wherein a similar container may be of an aluminum or wood or plastic substrate having flexible hinge bend lines of a different material which are adhered or vulcanized or heat melted to the substrate in locations adjacent or surrounding the bend lines.

And in conclusion, the photograph converted to copyable line art in FIG. 20 depicts 2 passengers within the 10 mil or ½ inch thick walled open container type emergency water craft, and while on the waters surface, and while using the side wall strengthening flaps as a means of propulsion, and with no other parts being used as shown in the plan view drawing of FIG. 8 which shows only 1 substrate sheet. The photo was captured as one frame from a low resolution video device; and so is a rough line art rendition, yet is self evident in describing the preceding disclosures and merits of a leak proof self securing container from a single sheet, and which requires no additional parts.

Claims

1. A container for a human user and or their objects comprising;

a single rectangular corrugated substrate having a plurality of generally planar walls (58) conjoined by a plurality of paralleling ribs (60) and further comprising;
a plurality of bend lines (1) (2) (3) (4),
wherein a portion of said bend lines (1) (3) define a floor (34) being hingedly connected with two side walls (10) and two end walls (18),
wherein said side walls have notches (12) (13) (15),
wherein a portion of said bend lines (2) hingedly connect said end walls (18) with interlocking flaps (20),
wherein said flaps (20) have a means of attachment to said notches (12) (13) (15),
wherein a portion of said bend lines (4) hingedly connect two halves of a hingedly-mated triangular shape exteriorly located corner projection(s) (24),
wherein said projection(s) (24) hingedly connect said side wall(s) (10) to said end wall(s) (18),
whereas said comprisements cooperate to laterally secure said walls (10) (18) to define a leak-proof water craft.

2. A water craft as recited in claim 1, and further comprising;

said substrate being a corrugated plastic material.

3. A water craft as recited in claim 1, and further comprising;

said substrate being a corrugated paperboard material.

4. A water craft as recited in claim 1, and further comprising;

a fifth portion(s) of bend line(s) (5) extending a complete shortest dimension of said substrate to enable a compact folding of said substrate.

5. A water craft as recited in claim 1, and further comprising;

a sixth portion(s) of bend line(s) (6) paralleling a longest length of said substrate to define a strengthening flap(s) (14) (16) being hingedly connected to said side wall(s) (10).

6. A water craft as recited in claim 5, and further comprising;

said bend line(s) (6) having intermittent through cut perforations (17).

7. A water craft as recited in claim 1, and further comprising;

wherein said planar walls conjoined by a plurality of elongate paralleling ribs define flute channels (28), and wherein said means of attachment includes rod shape flute channel plugs (44) being inserted partially into said channels (28).

8. A water craft as recited in claim 1, and further comprising;

wherein said planar walls conjoined by a plurality of elongate paralleling ribs define flute channels (28), and wherein said means of attachment includes alphabetical letter H-shape plugs (46) being inserted into said channels (28).

9. A water craft as recited in claim 1, and further comprising;

said means of attachment includes narrow notches (22) within said interlocking flap(s) (20) to interlock within said notches (12) (13) (15) of said side wall(s) (10).

10. A water craft as recited in claim 1, and further comprising;

said means of attachment includes narrow notches (22) within said interlocking flap(s) (20) which interlock within said notches (12) (13) (15) of said side wall(s) (10), wherein said planar walls conjoined by a plurality of elongate paralleling ribs define flute channels (28), and wherein said means of attachment additionally includes alphabetical letter W-shape plugs (48) being inserted into said channels (28), and wherein a centered apex portion of said W-shape plug (48) is located within said notch (22).

11. A water craft as recited in claim 1, and further comprising;

wherein said interlocking flap (20) is replaced with a separate assembly comprising said interlocking flap (20) having an extension (21) portion and interconnecting rods (39) and said hinge bend line (2) and said means for attachment,
wherein said means for attachment comprises notches (22),
or notches (22) and alphabetical letter W-shape plugs (48),
or rod shape flute channel plugs (44), or alphabetical letter H-shape plugs (46),
or combinations thereof.

12. A water craft as recited in claim 1, and further comprising;

a plurality of apertures (26) (37) located adjacent edge(s) of said substrate.

13. A water craft as recited in claim 1, and further comprising;

elastic cords (36) to quicken an assembly of said water craft.

14. A water craft as recited in claim 1, and further comprising;

at least one or more said end walls (18) having at least portions or all being angled (19) outwardly.

15. A method for forming a container for a human user and or their objects comprising;

a single rectangular generally planar substrate,
wherein said substrate is a corrugated plastic substrate comprising a plurality of generally planar walls (58) conjoined by a plurality of paralleling ribs (60),
a plurality of bend lines (1) (2) (3) (4),
wherein a portion of said bend lines (1) (3) define a floor (34) being hingedly connected with two side walls (10) and two end walls (18),
wherein said side walls have notches (12) (13) (15),
wherein a portion of said bend lines (2) hingedly connect said end walls (18) with interlocking flaps (20),
wherein said flaps (20) have notches (22),
wherein said notches (22) interlock with said notches (12) (13) (15) of said side walls (10),
wherein a portion of said bend lines (4) hingedly connect two halves of a hingedly-mated triangular shape exteriorly located corner projection(s) (24),
wherein said projection(s) (24) hingedly connect said side wall(s) (10) to said end wall(s) (18),
wherein said comprisements cooperate to laterally secure said walls (10) (18) to define a leak-proof said container,
wherein all said bend lines (1) (2) (3) (4) locations are slit formed (52) or slot formed (54) or aperture formed (56) within a first said planar wall (58),
wherein a second said planar wall (58) serves as said bend lines (1) (2) (3) (4), and whereas bending equipment is eliminated in said method.

16. A container for a human user and or their objects comprising;

a generally planar rectangular substrate,
a plurality of bend lines (1) (2) (3) (4),
wherein said bend lines (1) and said bend lines (3) define a floor (34) being hingedly connected with two side walls (10) and two end walls (18),
wherein said side walls have notches (12) (13) (15),
wherein said bend lines (2) hingedly connect said end walls (18) with interlocking flaps (20) having notches (22),
wherein said notches (22) interlock with said notches (12) (13) (15) within said side walls (10),
wherein said bend lines (4) hingedly connect two halves of a hingedly-mated triangular shape exteriorly located corner projection(s) (24),
wherein said projection(s) (24) hingedly connect said side wall(s) (10) to said end wall(s) (18),
wherein said comprisements cooperate to laterally secure said walls (10) (18) to define a single part leak-proof said container.

17. A leak-proof container as recited in claim 17, and further comprising;

said substrate being a paperboard material.

18. A leak-proof container as recited in claim 17, and further comprising;

said substrate being a corrugated paperboard material.

19. A leak-proof container as recited in claim 17, and further comprising;

said substrate being a plastic material.

20. A leak-proof container as recited in claim 17, and further comprising;

said substrate being a corrugated plastic material.
Patent History
Publication number: 20090044743
Type: Application
Filed: Oct 16, 2008
Publication Date: Feb 19, 2009
Inventors: Charles Maxwell Wagenknecht (Rockford, IL), Terry Lee Wagenknecht (Rockford, IL), Samuel James Wagenknecht (Rockford, IL)
Application Number: 12/288,089
Classifications
Current U.S. Class: Collapsible (114/354); Miscellaneous Joint Construction (229/198.2)
International Classification: B63B 7/02 (20060101); B65D 5/42 (20060101);