CONNECTORS FOR ASSEMBLING SHIPPING CONTAINERS

Abstract

A series of connectors for connecting panels of a shipping crate or box together. The invention will allow the user to make a box from a kit. A set of uniquely shaped corner pieces that will accommodate the sides, top and bottom of the structure will be used and provide the framework for the finished product. Because of these corner pieces the finished crate or box will be as strong as a box that is made by a skilled carpenter. Intermediate reinforcement pieces are also disclosed.

Description

BACKGROUND OF THE INVENTION

A. Field of the Invention

This invention relates to the field of packaging and, more particularly, relates to apparatus for attaching panels of a package, box or container together to form an article shipping enclosure. The invention permits the easy formation of an extremely strong box in any size or shape in which to ship an item without undue cost or difficulty.

B. Prior Art

Articles that need to be shipped come in various shapes and sizes, and it is not uncommon to have odd-shaped items that need to be shipped. These types of odd-shaped items are difficult to ship because of their unique geometric structure. Currently a specific box or crate must be custom made to house the uniquely shaped item if the item does not fit into a pre-existing sized box. Custom manufacture of shipping boxes, whether of cardboard, wood or of any other material, is costly and time-consuming, both in terms of material and labor. Ordinarily a carpenter would need to make the box from wood, which may take hours, even with a skilled carpenter doing the work.

Conventional shipping crate building methods and apparatus result in exposed staples, screws and the like extending from either the inside or outside of the crate, which may damage the contents or injure a handler. As a result, many shipping outfits refuse to accept freight which is improperly crated, or which has been crated by methods, and using apparatus, which do not meet the strength and safety criteria of the shipper. Many individuals seeking to ship freight do not have the wherewithal to properly construct a crate which will meet the specifications of the shipper.

Even if the crate is insured prior to transit, it still must be inspected when it reaches its destination if it has been damaged during shipping to determine if it was indeed crated properly. If not, insurance coverage may be denied.

There are many prior art references directed to crate or box making kits, including collapsible plastic crates. A representative example of this type of device can be found at Sunus, U.S. Pat. No. 4,789,075.

Another example of a metal shipping crate can be found at Dunn, U.S. Pat. No. 6,726,041, and a returnable crate is found at Grigsby Sr., U.S. Pat. No. 6,585,126.

None of the prior art references use unitary box panel connectors to secure the various pieces that form the sides, top and bottom of the crate. The connectors permit the user the unique ability to form the structure in any shape or size to custom make a box or crate to fit specific shipping needs.

Therefore, a need exists to provide a simple apparatus for assembling shipping crates/packages/boxes and the like, which can be combined with crate/package/box side, top and bottom panels of any dimensions to construct shipping crates of any sizes and proportions.

It is, therefore, an object of this invention to provide a simplified shipping box and crate assembly kit, apparatus and method.

It is also an object of this invention to provide a simple apparatus for creating shipping boxes and crates of any sizes but which can withstand the rigors of typical freight handlers.

It is also an object of this invention to provide a cost efficient apparatus, system and method for constructing shipping boxes and crates.

These and other objects, features and advantages of the present invention will become apparent upon reading the following detailed description of the disclosed embodiments of the invention, in conjunction with appended drawings and claims.

BRIEF SUMMARY OF THE INVENTION

This invention is directed to a device to make a crate or box specific to an individual's shipping needs. A set of connector pieces will be used to join the side, bottom and top panels of a box in order that the assembled box can support the weight of the cargo inside the box and also allow the box to retain its shape.

A box or crate will have a defined top, defined bottom, and defined sidewalls. With this invention, a set of corner pieces, or edge pieces, or any combination of the two, will be used to connect the panels so that an individual can custom make his or her box or crate to fit a specific need. The exact size of the box that will be made will depend on the dimensions of the sides, top and bottom of the box, and the size of the box that will be made using the connectors of this invention has essentially no limit. In fact, in certain circumstances it may be desirable to use any of the known banding techniques, wherein a metal or other high tensile strength strap is placed around four sides of the crate or box being assembled and pulled taut there around.

This is a device, that is a kit for making a uniquely shaped crate with which an individual can custom make a box or crate to fit and address those particular needs in a matter of minutes without the necessity of hiring a skilled craftsman. The finished crate or box will be as strong as the box or crate that is made by the skilled carpenter and will accommodate the item to be shipped. Additionally, the crate or box may be reusable depending on the condition of the box material after the box has been shipped. The box may also be made without tape.

A unique set of corner pieces are disclosed. Corner sections of each of the sides, top and bottom of the crate or box will fit into corresponding channels defined by the corner pieces. Fasteners to secure the sides, top and bottom of the structure to the corner and side connectors will also be provided. This may be accomplished with staples, screws, bolts or adhesive, to name a few examples.

Additionally, a set of reinforcing members or strips may also be used in the interior of the box (i.e. between corners along adjacent edges of the side and the top and bottom) to secure the sides to the top or bottom and provide additional support and strength for the box or crate. These reinforcing members may be custom made to fit a particular need by simply snipping or cutting off a desired length of reinforcing member and placing it/them in desired locations on the box or crate either alone (i.e. without the use of corner connectors) to supplement the corner connectors

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1A-1C are left side elevational views of various designs for a first embodiment of a side connector of the invention.

FIGS. 2A-2C are left side elevational views of various designs for a second embodiment of a side connector of the invention.

FIGS. 3A-3C are left side elevational views of various designs for a third embodiment of a side connector of the invention.

FIGS. 4A-4C are left side elevational views of various designs for a fourth embodiment of a corner piece of the invention.

FIG. 4D is a front elevational view of the side connector shown in FIGS. 4A-4C.

FIGS. 5A-5C are left side elevational views of various designs for a fifth embodiment of a side connector of the invention.

FIGS. 6A-6C are left side perspective views of the various designs depicted in FIGS. 1A-1C.

FIGS. 7A-7C are left side perspective views of the various designs of the second embodiment depicted in FIGS. 2A-2C

FIG. 7D is a perspective view of a corner connector in accordance with the second embodiment of the invention.

FIGS. 8A-8C are left side perspective views of the various designs of the third embodiment depicted in FIGS. 3A-3C

FIG. 8D is a perspective view of a corner connector in accordance with the third embodiment of this invention.

FIGS. 9A-9C are left side perspective views of the various designs of the fifth embodiment depicted in FIGS. 3A-3C and 8A-8C.

FIG. 9D is a perspective view of a corner connector in accordance with the fifth embodiment of this invention.

FIGS. 10A-10C are a slightly modified version of the various designs of the fourth embodiment depicted in FIGS. 4A-4C.

FIG. 10D is a perspective view of a corner connector in accordance with the fourth embodiment of this invention.

FIG. 10E is a top plan view of a flat blank out of which the corner connector of FIG. 10D may be formed.

FIGS. 11A-11D depict various configurations of a connector in accordance with the first embodiment of this invention.

FIGS. 11E-11G are left side elevational views of the corner connectors shown in FIGS. 11A and 11C, respectively.

FIGS. 11F and 11H are left side elevational views of the corner connectors shown in FIGS. 11B and 11D, respectively.

FIG. 11I is a partial cutaway perspective view of corner connector 10′ having box panels associated therewith.

FIG. 12A is a perspective view of an assembled shipping container using corner connectors and side connectors of any of the embodiments of this invention.

FIG. 12B is a left side perspective view of a partially assembled shipping container using the corner connectors and side connectors of any of the embodiments of this invention.

FIGS. 13A and 13B are a perspective view of an assembled shipping container using the corner connectors shown in FIGS. 12A-12B and shorter side connectors.

FIGS. 14A and 14B are perspective views of a partially assembled shipping container employing the corner connectors shown in FIGS. 12A-12B and longer side connectors.

FIGS. 15A-15D are left side elevational views showing either corner connector members or side connector members depicted in any one of FIGS. 1A, 1B, 1C, 6A, 6B or 6C attached to panels of a shipping container using various fastener structures.

FIGS. 16A-16D are left side elevational views of the corner connectors or side connectors shown in FIGS. 2A, 2B, 2C, 7A, 7B, or 7C connected to panels of a shipping container using various attachments structure.

FIGS. 17A-17D are left side elevational views of corner or side connectors shown in FIGS. 3A, 3B, 3C, 8A, 8B and 8C (and, as slightly modified, in FIGS. 9A, 9B and 9C).

FIGS. 18A-18D depict the side connectors shown in FIGS. 4A, 4B, 4C, 10A, 10B, and 10C connecting panels of a shipping container showing the use of various fastener structures.

FIGS. 19A-19C are left side elevational views of the side connectors shown in FIGS. 5A, 5B, 5C, 9A, 9B and 9C connecting shipping container panels using various fastener structures.

FIGS. 20A and 20B depict a further modified embodiment of the invention.

FIGS. 20C and 20D depict yet a further embodiment of the invention.

FIGS. 20E and 20F show a further embodiment of the invention.

FIGS. 21A and 21B show another embodiment of the invention.

FIG. 21C depicts a corner connector in substantially the form of the side connector shown in FIGS. 21A and 21B.

FIGS. 22A and 22B depict a further embodiment of the invention.

FIG. 22C depicts a corner connector substantially in accordance with the embodiment shown in FIGS. 22A and 22B.

FIG. 23 is a respective view of a still further embodiment of a corner connector in accordance with this invention.

DETAILED DESCRIPTION OF THE EMBODIMENTS

This device is a kit to make shipping cartons or boxes specifically designed to ship any uniquely shaped items. Boxes to ship devices are common in the prior art. However, there are standard-sized boxes that are used to ship letters, posters, and the like. The difficulty arises when a uniquely shaped object must be shipped that does not fit one of the standard boxes that currently exist.

A carpenter or other skilled craftsman must be employed to make a specifically designed box in order to ship the item. This is, of course, costly in terms of labor and material. It would be helpful to have a kit from which individual boxes of virtually any size or proportions can be made using a plurality of standard corner and side connectors.

Additionally, because of security concerns, the interior contents of the box or crate may be visually examined by the shipper or government authority. It is important to easily gain access to the internal contents of the box or crate and then be allowed to reseal the box or crate. This kit will allow an individual to perform that particular function.

A typical shipping container or box suitable for use with the teachings of this invention is shown in FIGS. 12A-14B and comprises a top 2, bottom 3, and sides 4, 5, 6 and 7. They may be joined at the eight corners by eight corresponding corner connectors, which may be any one of the various embodiments of corner connectors disclosed herein, or modifications thereof which will occur to those of skill in the art. Additionally, or alternatively, intermediate panel edge connectors such as any of the side connectors disclosed herein may be employed anywhere along the edges E of the shipping container to provide primary (if used without corner connectors) or additional intermediate (if used together with one or more corner connectors) support and strength. In this manner, standard wood or cardboard pieces can be used to form a box to fit the specific need of the consumer.

As depicted in FIG. 1A, a first embodiment of this invention is comprised of a side connector piece 10. The side connector piece 10 has a pair of channels 12, 22 which define an outside edge and an inside edge. The side connector pieces may be made in any of several different designs such as those depicted in FIGS. 1-5, and may be of any length.

The top, bottom and side panels that will be used to form the box or crate will be inserted into these channels such as depicted in FIGS. 12A-14B. It is to be understood that boxes of any configuration, such as pentagons, octagons, triangles, etc., may be assembled using the teachings of this invention. Modifications will have to be made to the connector members of this invention as will occur to those of skill in the art to accommodate angles between top, bottom and side panels which are other then 90°/right angles.

Channels 12, 22 are defined by respective sidewalls 14, 16, and 24, 26. The channels of any particular configuration of edge or corner connector may be of different length. Also, outer sidewalls 14, 24 may be hinged or articulated to permit the use of adhesive strips or toher adhesive material 15 that is secured to the interior surface of the sidewalls 14, 24. Adhesive material 15, if in the form of an adhesive strip, is configured so that a non-adhesive backing strip is peeled back at the corner and then secured to the side, tops or bottom panel that forms the box.

The panels that form the box will be placed within the channels 12, 22. The material which the panels are formed of may be plastic, wood, steel, aluminum, cardboard, etc, and will be dictated by the item that is to be shipped as well as the cost of the panels and cost to ship the item. Additionally, the connector members may preferably be constructed of plastic, graphite, metal or any other suitable material. It must be strong enough to support and form the box while at the same time supporting any weight that is to be applied to the box. Although the corner pieces (and, optionally, the side pieces) are used to make the box or crate, the box or crate may be made without the use of tape.

The sides 4-7, top 2 and bottom 3 of the box or crate can be varied by cutting the sides, top and bottom to the length and width that is required by the user. Depending on the condition of the box material the box may be reusable.

Additionally, there may be other alternative embodiments of the side and corner connectors which will occur to those of skill in the art, and while the box or crate will have the general appearance of a crate or box the side and corner connectors vary such as depicted in the drawings.

The box is formed by placing any one of the corner connectors depicted in FIGS. 7D, 8D, 9D, 10D or 11A-11D, as an example, on the corners where the side panels 4, 5, 6 and 7 will be. Each box or crate will have a defined top and/or a defined bottom as well as three, four or more sides. The sides do not necessarily need to be of equal width or length.

The corner connectors are placed on the corner of side, top and bottom panels 2-7 such that corresponding corners of the sides, top, and bottom of the box will be placed in the channels 12, 22 and 32. Additionally, there may be one or more adhesive reinforcing strips 15, 45, 115 & 135 placed on the inside surface of the sidewalls 14/24, 44/54, 74/84, 102 and 134 (or on the corresponding flexible members 25, 55, 85, 125 and 145) to secure the top to the sides and the bottom to the sides of the box. The reinforcing strips may be made by simply cutting the strip to a specific length and inserting the strip into the sidewall.

Additionally, the panels 2-7 may be secured within the respective channels by fasteners F such as staples, nails, screws or the like as depicted in FIGS. 15-19. The fastener body may extend through sidewalls 16, 26, 46, 56, 76, 86 and/or 104 to the hollow section 8, 48, 78, 112, 168, 258, 298 This will protect the goods inside the box from being damaged because there will be no possibility that the end of the fastener would strike the contents of the box or crate because protective walls 28, 58, 88 and 118, 178, 228, 248 will prevent the fastener from coming in to contact with the article being shipped.

Additionally, the sides may be secured with adhesive for additional support.

FIGS. 4A-4D represent another side connector embodiment 100 showing a single channel 106 and having an open space or shoulder 110. Box top or bottom panel 2 or 3 will be placed directly on shoulder 110 and then secured to the shoulder by using a fastener F such as a screw, bolt, nail, staple, rivet, adhesive, or the like. The other portion of the box or crate will be inserted into the channel 106 as discussed above, and may be held in place therein with a fastener.

FIG. 10D shows a corner connector in accordance with this fourth embodiment of the invention, as discussed in further detail below.

Referring now more specifically to the drawings, FIGS. 1A-1C and 6A-6C show a first embodiment of an intermediate side connector 10 comprised of first sidewalls 14, 16 which define a first channel 12, second sidewalls 24, 26 which define a second channel 22, and a barrier wall 28 connected to first and second sidewalls 16, 26 to form an interior space 18. First channel 12 is adapted to receive an edge portion E of a top panel 2 or side panel 4, 5, 6 or 7 of a shipping box as shown in FIGS. 12A-14B.

FIGS. 11A-11B show the first embodiment of the connector in the form of a corner connector 10′ which incorporates all of the elements of connector 10 shown in FIGS. 1A-1C and 6A-6C, and further includes third and fourth sidewalls 34, 36 which define a third channel 32. Inner sidewall 36 is attached to connector 10′ along distal edges 19, 27 and 29 of sidewalls 14, 24 and 28, respectively.

FIGS. 15A-15D show the edge connector 10 of this first embodiment having a top or bottom panel 2, 3 disposed in first channel 12 and a side panel 4, 5, 6 or 7 disposed in second channel 22 with fasteners F attaching the panels to the connector 10.

FIGS. 2A-2C and 7A-7C depict a slightly modified version of a side connector which can easily be modified to form a corner connector 4′ shown in FIG. 7D. In this embodiment, channel 42 does not extend below sidewall 56. As shown in FIGS. 7B and 7C, sidewalls 44 and 54 can be hinged, as by the use of a length of one-sided adhesive tape, or any other flexible material adhered to the outer surface of sidewalls 44, 54. Adhesive material 45 may then be applied to the box panel-facing side of sidewalls 44, 54, which will adhere to the particular box panels situated within channels 42, 52 to strengthen the connecting therebetween.

FIGS. 6A-6B and 7A-7C depict a slightly modified version of a side connector which can easily be modified to form a corner connector 40′ shown in FIG. 7D. In this embodiment, channel 42 does not extend below sidewall 56. As shown in FIGS. 7B and 7C, sidewalls 44 and 54 can be hinged, as by the use of a length of one-sided adhesive tape, or any other flexible material adhered to the outer surface of sidewalls 44, 54. Adhesive material 45 may then be applied to the box panel-facing side of sidewalls 44, 54, which will adhere to the particular box panels situated within channels 42, 52 to strengthen the connecting therebetween.

As can be seen in FIG. 7D, corner connector 40′ is essentially identical to side connector 40, with the exception that a third channel 62 is defined by third sidewall pair 64, 66. Sidewall 66 is connected to sidewalls 42, 52 and barrier wall 58 along peripheral edges thereof, similar to the configuration discussed with respect to FIG. 11A.

FIGS. 16A-16D show the embodiments of connector 40 shown in FIGS. 2A-2C and 7A-7C having top or bottom panel 2, 3 disposed within channel 42 and a side panel 4, 5, 6, or 7 disposed within channel 52 and the top or bottom panel, as well as the side panel, being connected to connector 40 suing a fastener F such as screws, nails, staples, double sided adhesive 15 or simple packing tape 55.

Turning now to FIGS. 3A-3C and 8A-8C, a still further modified embodiment of the invention is shown in the form of edge connector 70 and corner connector 70′. Both employ first and second sidewalls 74, 76 which define a first channel 72, and second set of sidewalls 84, 86 which define a second channel 82.

FIG. 8D shows a corner connector corresponding to this third embodiment in which a third set of sidewalls 94, 96 define a third channel 92. Inner sidewall 96 connects to connector 70′ along distal edges of sidewalls 74, 84 and barrier wall 88.

FIGS. 17A-17D show the embodiments of connector 40 shown in FIGS. 2A-2C and 7A-7C having top or bottom panel 2, 3 disposed within channel 72 and a side panel 4, 5, 6, or 7 disposed within channel 82 and the top or bottom panel, as well as the side panel, being connected to connector 40 suing a fastener F such as screws, nails, staples, double sided adhesive 75 or simple packing tape 85.

FIGS. 4A-4D and 10A-10C depict a fourth embodiment of a side connector in accordance with this invention. Side connector 100 includes inner and outer sidewalls 102, 104 which form a channel 106 ending at end wall 111. A shoulder 110 extends from inner sidewall 104 toward the interior of the shipping box, and is supported by barrier wall 118. Sidewall 104, shoulder 110 and barrier 118 define an interior space 112. Outer sidewall 102 may be hinged as shown in FIG. 4B, and adhesive material 115 may be applied to the inner surface of sidewall 102 to assist in the interconnection of connector 100 to a box side panel 4, 5, 6 or 7. As shown in FIG. 4C, a flexible extension member 125 may be attached to the exterior surface of outer sidewall 102. Flexible extension 125 may also utilize an adhesive material 115.

FIG. 10D, is a perspective view of a fourth embodiment of the corner connector of this invention, which corresponds to side connector 100′. Corner connector 100′ is substantially the same as side connector 100 with the addition of third set of sidewalls 124, 126 which define third channel 122. Inner sidewall 126 connects to sidewall 104, shoulder 110 and barrier wall 118 along distal edges thereof.

FIGS. 5A-5C and 9A-9D show a fifth embodiment of the invention, wherein a side connector 130 is disclosed. Side connector 130 includes first set of sidewalls 134, 136 which define a first channel 132, and second set of sidewalls 144, 146 which define second channel 142. As in the other embodiments, sidewalls 134, 144 may be hinged or articulated, either as a live hinge integral to said sidewalls, or by the use of a flexible section 145. Adhesive material 135 may be employed to adhere to shipping box side panels 3, 4, 5 or 6 and top or bottom 2, 3.

FIGS. 19A-19C show the connector 130 of FIGS. 5A-5C and 9A-9B. Top or bottom panels 2, 3 are disposed within channel 132, while a side panel 4, 5, 6, or 7 is disposed in channel 142. Fasteners such as staples shown in FIG. 19A, nails or screws shown in 19B, and packing tape 145 shown in FIG. 19C may be used to enhance the connection between box panels 2-7 and connector 130.

FIG. 9D is a perspective view of a corner connector in accordance with this invention. In this embodiment, a second connector section 100 is integrally attached to the connector segment 100 shown in FIGS. 4A-4C and 10A-10C. Preferably, but not by way of limitation, corner connector, 100′ is formed out of a flat piece of stock material in the shape shown in FIG. 10E. Corner connector 100′ is, thus, upon being formed into the shape shown in FIG. 10D, a mirror image of connector 100 shown in FIGS. 4A-4C and 10A-10C. When used, a first panel side is placed within first channel 106, a second side panel is inserted within second channel 106′, and a top or bottom box panel 2 or 3 is placed upon shoulder 110 in substantial registry with the upper end 113 of sidewall 104.

One or more fasteners may be placed through top or bottom panels 2, 3 and through shoulder 110 into space 112, where they are protected by barrier wall 118 from contacting the item within the shipping box, as shown in FIGS. 18A and 18B. As shown, additional fasteners F may be placed through side panels 4, 5, 6 or 7, the ends of which should also rest within space 112.

FIGS. 18C and 18D show the embodiments corresponding to FIGS. 4C and 4B, respectively, having box side panels 4, 5, 6 or 7 inserted within channel 106 and top or bottom panel 2, 3 resting against shoulder 110. Top or bottom panel 2, 3 may be retained against shoulder 110 by any suitable means such as fasteners F, adhesive, or the like.

FIGS. 20A and 20B depict a modified form of the side connector of this invention, which includes a first channel 162 defined by outer end and inner sidewalls 164, 166 respectively, a second channel 172 defined by outer an dinner walls 174, 176, respectively, and an end wall 169 at the base of channel 172 (although end wall 169 may be positioned at the end of channel 162 in the alternative), and a barrier wall 178 defining a fastener and protection space 168. As can be seen from these figures, the side connector is manufactured from a single piece of (originally flat) material such as metal, and bent into the form shown. As discussed above and in connection with essentially all embodiments of the invention, the connectors disclosed herein may be formed by injection molding, extrusion, or any other manufacturing technique which will occur to those of skill in the art.

FIGS. 20C and 20D depict a still further modified embodiment of the side connector 180 of this invention, comprised of a first channel defined by outer end and inner sidewalls 184, 186, a second channel 192 defined by, outer and inner sidewalls 194, 196, and an end wall 199. Again, it can be seen that the embodiment of FIGS. 20C and 20D can be formed by bending/stamping a single flat piece of material, or may be extruded, injection molded, etc.

FIGS. 20E and 20F disclose a still further modified form of the side connector 200 of this invention, comprising a first channel 202 defined by outer and inner sidewalls 204, 206, a second channel 212 defined by outer and inner sidewalls 214, 216. This embodiment likewise may be formed by a single piece of bent material or may be injection molded, extruded, or the like.

FIGS. 21A-21C depict a still further modified embodiment of the invention.

FIGS. 21A and 21B depict a side connector and FIG. 21C depicts a corner connector similar in construction to a pair of side connectors connected to each other. The angle between the two is 90° shown in FIG. 21C, although that angle may be more or less than 90° depending upon the angle of the corner of the crate being made.

The connector of this embodiment includes a channel 222 defined by outer and inner sidewalls 224, 226, a top sidewall 230 adapted to receive a crate panel in coplanar fashion thereon, and a barrier wall 228. In use, a first panel will be inserted into channel 222, a second panel will be placed coplanar with top sidewall 230, and fasteners placed there through and through sidewalls 224, 226 and 230 and 232. Sidewalls 226 and 232, along with barrier wall 228, define a space 238 in which the sharp ends of fasteners (not shown) can reside, so that they are protected by barrier wall 228 from contacting the contents of the crate.

FIG. 21C shows the corner connector corresponding to the embodiment shown in FIGS. 21A and 21B, the second section thereof defining a second channel 242 defined by outer and inner sidewalls 244, 246, a top sidewall 250, a barrier wall 248, and an inner sidewall 252. It will readily occur to those skilled in the art that a second panel section can be inserted into channel 242, and the same panel section of the crate that will mate with top sidewall 230 will also mate with top sidewall 250 of the other side of the connector 240, and fasteners placed through both panels to secure them to connector 240.

FIGS. 22A-22C depict a further modified embodiment in this invention.

FIGS. 22A and 22B show a side connector 260 which defines a first channel 262, which is defined by outer and inner sidewalls 264, 266, a top sidewall 270 and a panel end wall 272. A barrier wall 268 and barrier space 278 are also employed. In use, a first crate panel is inserted into channel 262 and a fastener placed through sidewalls 264 and 266, and a second crate panel is placed in coplanar orientation on top sidewall 270. The side edge of the panel (not shown) may be placed in abutting relationship with sidewall 272 for added stability. A fastener (not shown) is then placed through the second panel and through top sidewall 270.

FIG. 22C shows a corner connector in accordance with the embodiment shown in FIGS. 22A and 22B. Corner connector 280 incorporates a connector 260 according to FIGS. 22A and 22B, and a mirror image connector thereof comprised of first channel 282 defined by outer and inner sidewalls 284, 286, a top sidewall 290 and a secondary sidewall 292. A barrier wall 288, along with top sidewall 290 and inner sidewall 286, defines a barrier space 298.

FIG. 23 depicts yet a further embodiment of the invention in the form of a corner connector 300 which includes a first channel defined by outer and inner sidewalls 304, 306 connected to a second outer sidewall 324. Second outer sidewall 324 and second inner sidewall 326 define a second channel 322. Top sidewalls 310 and 320 are adapted to receive a first crate panel in coplanar arrangement thereon, so that a fastener can be placed there through. Channels 302 and 322 are adapted to receive third and fourth crate panels therein, such that fasteners can be passed through sidewalls 304, 306 and 324, 326 to secure the second and third crate panels in position relative thereto.

In this way, boxes and crates can be erected having a greater strength combined with simplicity of assembly than ever before achieved. Boxes or crates assembled using the side and corner connectors disclosed herein may be further held together by traditional banding, packing tape, etc, or may be held together solely by the side connectors employed alone, the corner connectors employed alone, or any combination of side and corner connectors disclosed herein.

The principles, preferred embodiment and modes of operation of the present invention have been described in the foregoing specification. The invention is not to be construed as limited to the particular forms disclosed because these are regarded as merely illustrative, rather than restrictive. Moreover, variations and changes may be made by those skilled in the art without departing from the spirit of the invention as described by the following claims.

While the embodiments of the invention have been disclosed, certain modifications may be made by those skilled in the art to modify the invention without departing from the spirit of the invention.

Claims

1. A shipping container for transporting cargo, the shipping container comprising:

a plurality of side panels;

at least one of a top panel and a bottom panel;

at least one corner connector assembly interconnecting two side panels of the plurality of side panels and the at least one of the top panel and the bottom panel, the at least one corner connector assembly including a pair of coupling members oriented in a predetermined relation to each other, each coupling member including: a first sidewall oriented so as to be parallel to a corresponding one of the two side panels being interconnected, a top sidewall oriented so as to be parallel to and support a corner section of the at least one of the top panel and bottom panel, a barrier wall connected to the top sidewall extending away from the top sidewall, and interior sidewall positioned between the first sidewall and the barrier wall, the interior sidewall being oriented so as to be parallel to the first sidewall, the first sidewall and the interior sidewall defining a channel that receives a corner section of the corresponding side panel; and

a plurality of fasteners securing the at least one corner connector to the two side panels and the at least one of the top panel and the bottom panel so as to retain the two side panels and the at least one of the top panel and the bottom panel in a predetermined relation relative to each other, at least a first fastener of the plurality of fasteners being positioned such that a portion of the first fastener passing through the at least one corner connector extends into a space defined at least by the second sidewall and the interior sidewall,

wherein at least the barrier wall is operable to shield the cargo from contact with the first fastener.

2. A shipping container for transporting cargo, the shipping container comprising:

a plurality of side panels;

at least one of a top panel and a bottom panel;

at least one edge connector interconnecting a side panel of the plurality of side panels and the at least one of the top panel and the bottom panel, the at least one edge connector including: a first sidewall constructed so as to be parallel to the side panel, a second sidewall constructed so as to be parallel to and support an edge section of the at least one of the top panel and the bottom panel, a barrier wall connected to the second sidewall and extending away from the at least one of the top panel and the bottom panel, and a first interior sidewall positioned between the first sidewall and the barrier wall, the interior sidewall being constructed so as to be parallel to the first sidewall, the first sidewall and the interior sidewall defining a channel that receives an edge section of the side panel;

at least one fastener securing the at least one edge connector to the side panel and the at least one of the top panel and the bottom panel so as to retain the side panel and the at least one of the top panel and the bottom panel in a predetermined relation, at least a first fastener of the at least one fastener being positioned such that a portion of the first fastener passing through the at least one edge connector extends into a space defined at least by the barrier wall and the interior sidewall,

wherein at least the barrier wall is operable to shield the cargo from contact with the first fastener.

3. An edge connector for use in constructing a shipping container that includes a plurality of side panels, at least one of a top panel and a bottom panel, and a plurality of fasteners, the edge connector being operable to interconnect a side panel of the plurality of side panels and the at least one of the top panel and the bottom panel, the edge connector comprising:

a first exterior side member;

a second exterior side member oriented non-parallel to the first exterior side member and constructed so as to support an edge section of the at least one of the top panel and the bottom panel, the second exterior side member defining a first surface and a second surface, the first surface of the second exterior side member being operable to contact the edge section of the at least one of the top panel and the bottom panel when the edge section of the at least one of the top panel and the bottom panel is placed upon the second exterior side member;

a third exterior side member connected to the second exterior side member and extending in a direction generally opposite the first surface of the second exterior side member; and

an interior side member positioned between the first exterior side member and the third exterior side member, the interior side member being substantially parallel to the first exterior side member, the first exterior side member and the interior side member defining a channel that is operable to receive an edge section of the side panel;

wherein at least the third exterior side member and the interior side member define a space operable to receive and contain an end portion of a fastener passing through at least one of the interior side member and the second exterior side member such that the end portion of the fastener does not pass through the third exterior side member.