POULTRY CRATE

Abstract

A collapsible poultry crate comprising a base defining a peripheral edge; a plurality of side walls, each side wall being mounted on the base along a respective portion of the peripheral edge for pivoting movement relative to the base each side wall pivoting between a closed position and an open position; each side wall having a respective top surface, two or more tabs extending from a respective top surface of the side walls; and a plurality of end walls, each end wall being mounted on the base along a respective portion of the peripheral edge for pivoting movement relative to the base; the base having a width and a length such that M poultry crates arranged in a predetermined pattern exhibit a footprint substantially the same as the footprint of N meat crates disposed in a predetermined pattern.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims priority to Provisional Patent Application No. 61/493,544, filed Jun. 6, 2011, and is incorporated herein as set forth in its entirety.

BACKGROUND OF THE INVENTION

This invention is directed to a poultry crate, and more particularly, to a poultry crate capable of reuse and recycling and which is capable of being stacked in a stable manner with crates adapted for other types of products.

When prepared for shipping, poultry is placed in a crate, flash frozen and then palletized directly at the processing plant and shipped to a distribution center for distribution to end user retail outlets.

The prior art poultry crates are made from cardboard and chicken wire with a styrofoam or plastic tray within the crate to act as a liner and to catch any drippings to prevent passage of salmonella. These crates are satisfactory, however, they suffer from the disadvantage that because they are made of cardboard they are subject to wear and tear. Furthermore, they do not have sufficient structural integrity to allow stacking of heavier crates thereupon such as a meat crate or several layers of poultry crates. Furthermore, they are not collapsible nor easily sterilized to be sent back to the distribution center for reuse. For these reasons, they are a single use crate.

It is also known in the art to utilize “bread crates”. These crates are formed of plastic and therefore, may be sterilized and recycled, however, they are not collapsible and therefore, shipping the crates back to a point of origin, results in the shipping of significant amount of dead air as stacks of crates are shipped around increasing the costs. As a result, these poultry crates are only used internally prior to repackaging in the cardboard crates.

Furthermore, at the distribution center, pallets of crates are created for shipping. The pallets are of standard dimensions to enable shipping. Because of the configuration and the inability for the prior art poultry crates to support other types of pallet crates such as meat crates thereupon, when creating pallets at the distribution center, they are formed entirely of poultry crates, or entirely of meat crates. However, this inflexibility may result in two short pallets being sent to the same end user increasing cost, increasing the carbon footprint for shipping because the footprint of two pallets are required where one may do. To get around this, it is known to build a first layer of meat crates, build a planar floor on the meat crate layer, and then stack the corrugated crates thereon. However, this is an unstable construction and does not solve the problems associated with using corrugated crates. Also, because of salmonella, they don't stack plastic meat crates on corrugated poultry crates.

Accordingly, a poultry crate which overcomes the shortcomings of the prior art is provided.

SUMMARY OF THE INVENTION

A poultry crate has a base, a first side wall pivotally connected to the base, a second side wall pivotally connected to the base, a first end wall pivotally connected to the base, and a fourth end wall pivotally connected to the base, each of the first end wall, second end wall, first side wall and second side wall are moveable between a first open position and a second collapsed position. Each side wall has a center, a first edge and a second edge. A rib structure extends along a height of the side wall at a position between the center and the first edge. A second rib structure extends along a height of the side wall between the center and the second edge. Each side wall has a top surface, a first tab is disposed on a top surface of the wall between the rib structure and the first edge and a second tab is disposed on a top surface of each side wall between a second rib structure and the second edge.

In a preferred embodiment, the wall has a width, the width of the detent is less than the width of the wall. The base is formed with a bottom surface, the bottom surface being formed with a catch along an edge of the base adapted to receive the first and second detent.

In a preferred embodiment, the length and width of the poultry crate are such that when positioned so that a first poultry crate has a first side wall adjacent a first side wall of a second crate and a second side wall adjacent a first side wall of a third crate, each side wall of each crate is coterminous. A fourth crate is disposed adjacent the end walls of the first crate and the second crate, the end wall of the fourth crate being coterminous with the second side wall of the second crate and a fifth crate having an end wall adjacent and coterminous with a second end wall of the fourth crate. A layer formed by the first, second, third and fourth crates has a footprint substantially equal to the footprint of a layer formed by first meat crate having a first side wall and a first end wall and second meat crate having a first side wall and a first end wall, the first end wall of the first meat crate being adjacent the first end wall of the second meat crate and coterminous therewith. The second layer also includes a third meat crate disposed adjacent the first meat crate; the third meat crate having a first side wall and a first end wall, the first end wall of the first meat crate being adjacent the first end wall of the third meat crate and coterminous therewith. A fourth meat crate has an end wall and a first side wall. The end wall of the fourth meat crate is adjacent to and coterminous with the end wall of the third meat crate, and the side wall of the fourth meat crate is adjacent and coterminous with the side wall of the second meat crate.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will now be described, by way of example, with reference to the accompanying drawings, where like numerals were used to note like elements and in which:

FIG. 1 is a perspective view of a poultry crate constructed in accordance with the invention;

FIG. 2 is a bottom perspective view of a poultry crate constructed in accordance with the invention;

FIG. 3 is a cut away view of a cross stacked pallet of poultry crates erected in accordance with the invention;

FIG. 4 is a sectional view of a first stacked poultry crate on a second poultry crate in accordance with the invention;

FIG. 5 is a schematic view of a pallet of a first row of crates each crate having a first dimension and a second row of crates, each crate in the second row of crates having a second dimension in accordance with the invention shown in phantom;

FIG. 6 is a schematic representation of the interaction between a lower row of poultry crates and an upper row of meat crates; and

FIG. 7 is an end view of the engagement of one side of the top row of a pallet constructed in accordance with FIG. 6.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The invention is directed to a poultry crate, generally indicated as 10 constructed in a way which enables the poultry crate to form a layer on a pallet capable of supporting a layer of a different number of a different type of crate, preferably a meat crate, thereon.

Reference is first made to FIGS. 1 and 2 wherein a poultry crate, generally indicated as 10 and constructed in accordance with the invention is provided. Poultry crate 10 is a collapsible crate as known in the art and is used to store or transport frozen poultry. Crate 10 includes a base 14, side walls 34, 36 and end walls 44, 46. Each of these walls has a handle opening 45 so that the container can be easily carried. The base 14 includes a bottom panel 15 that forms a lower support surface for carrying and supporting the goods positioned within container 10. Like the overall shape of the container 10, bottom panel 15 is generally rectangular in shape and as shown in FIG. 2, base 14 has two opposed side edges 16, 18 and two opposed end edges 20, 22. Edges 16 and 18 are formed with elongated pockets 19 formed along edges 16, 18. Similarly, pockets 21 are formed along respective edges 20, 22.

As known in the art, end walls 44, 46 are pivotally affixed to base 14 at a respective edge 20, 22 so as to be moveable between a closed position and open position. Similarly, side walls 34, 36 are rotatably affixed to a respective edge 16, 18 and are moveable between an open and closed position. Closed position means a position in which the walls collapse towards base 14 and open position is when the wall is upright to create the crate. Each wall may be affixed to base 14 by a hinge system as known in the art.

As best seen in FIG. 1 each side wall 34, 36 has a U-shaped horizontal cross section that is formed by a main end wall portion 50 and two shorter flange portions 52 extending from end wall portion 50 to form a corner as seen in FIG. 1. In a preferred embodiment, these wall portions are formed together as a single unit. Flange portions 52 extend from either side of main end wall portion 50. Additionally, the flange portions 52 are oriented orthogonally to main end wall portion 50 and when crate 10 is assembled (all walls in the open position) they extend in the direction of end walls 44, 46 respectively.

As known in the art, each corner of container 10 is provided with a cammed latch 242 to releasably maintain the crate in an upright position. Each latch 242 is operatively mounted proximate the ends of 34, 36 near flanges 52 as seen in FIG. 1.

As shown in the various figures, the top surfaces 43 of end walls 44, 46 are provided with a plurality of stacking tabs 61 that extend upwardly in a direction away from base 14. Each top surface 43 of respective end walls 44, 46 has a width. The respective width of each tab 61 is less than the width of respective side walls 44, 46. Similarly, each end wall 34, 36 includes upright tabs 58 extending from a top surface 53. Top surface 53 has a first width and each of tabs 58 has a respective width less than the width of top surface 53.

Each side wall 34, 36 is provided with a pair of reinforcing rib structures 30, 32 disposed on either side of a center line 55 and handle opening 45. Each corner of side wall 35 is provided with respective rib structures 37, 38. Rib structures 30, 32, 37 and 38 extend along the height of the respective side walls 34, 36 substantially from base 14 to top surface 53. Rib structures 37, 38 are, in one nonlimiting embodiment, formed as spaced parallel longitudinal rib pairs 37a, 37b and 38a, 38b respectively. A plurality of horizontal ribs 39 extend between ribs 37a, 37b and horizontal ribs 41 extend between respective spaced ribs 38a, 38b making up rib structure 38. Tabs 58 are disposed along upper surface 53 at a position between rib structures 32 and 38 in the one instance and between rib structures 30 and 37 in the other instance and closer to a respective projection 52 than center line 53 in a preferred nonlimiting embodiment.

A support structure 62 extends from rib 37a to rib 38b substantially adjacent top surface 53 of each side wall 34, 36. Furthermore, each tab 58, 61 is tapered. Support structure 62 may be a lattice as shown in FIG. 1, or a horizontal rib, vertical rib or a combination thereof near the top of each side wall.

There are certain industry dictated requirements for the size of a poultry crate, among other things, the dimensions of a foam drainage tray used within container 10 to trap drippings and prevent the spread of salmonella. However, the prior art has not solved the problems discussed above a result of the standards. As will be discussed below, one aspect of the invention is the ability of a layer of poultry crates constructed in accordance with the invention, including industry standards to support a layer of meat crates.

In accordance with the invention, the exterior dimensions of the crate are such that when arranged, as N crates as will be described below, they support N−1 crates of another standard size, namely meat crates: The thickness of each end wall 44, 46 is about 0.525 inches and the thickness of each side wall is about 0.500 inches (width). However, the interior dimensions remain about 22.825 inches ±0.25 inches by 14.878 inches ±0.25 inches for the base and a height of 5.906 inches ±0.25 inches as required by industry standard. The footprint of each poultry crate is different than the footprint of each meat crate.

In the invention, the tabs have been removed from the corners to transfer the load of stacked crates to a position between rib structures 30, 37 and 32, 38. The tabs are also away from the ribs although closer to the corner than the center line 53 discussed above. The rib structures 30, 32 are disposed at or about ⅓ of the length of a side wall 34, 36 from the respective corners.

Reference is now made to FIGS. 3 and 4 in which features of the poultry crate 10 are demonstrated in connection with the formation of a pallet (stacked crates) of same type. It is known in the art to stack or “palletize” a number of items for shipping. It is known in the art to palletize collapsible plastic crates to ship produce, meat or the like. However, in the first instance during transit, stacked items are prone to slippage, shifting and even toppling and it is not known to mix crates of different dimensions in a single pallet.

In accordance with the invention, a pallet 100 includes a first layer 102 of two or more poultry crates 10 arranged in a pattern. A second layer 104 of two or more poultry crates 10 are disposed upon layer 102 and supported thereby. Poultry crates 10 of layer 104 may be arranged in a pattern which is either identical to or different from the poultry crates 10 in layer 102 of pallet 100.

Like numerals are utilized to indicate like structures. In the pattern of layer 102, a five container pattern is provided in which a first poultry crate 10a is provided. First poultry crate 10a, as discussed above has opposed end walls 44, 46 at opposite edges of floor 15 and a side wall 36 extending from wall 15. Second poultry crate 10b has identical structure and the two are positioned end wall to end wall such that end wall 44 of poultry crate 10b is in substantially coterminous facing relationship with end wall 46 of first poultry crate 10a.

A third poultry crate 10c is disposed in layer 102 and in orientation such that side wall 36 is substantially coplanar with end wall 44 of first poultry container 10a and end wall 44 (not shown) of crate 10c abuts against side wall 36 of first crate 10a. Once given this initial pattern of row 102, and as can be readily discerned from rows 104 or 106, a fourth and fifth poultry crate are disposed in end row 102 such that the side wall of the fourth crate is adjacent and coterminous with side wall 34 of crate 10c of that row and an end wall of the fourth crate abuts and is adjacent to side walls 36 of both crate 10a and 10b. A fifth crate is disposed in row 102 such that a side wall of the fifth crate is adjacent and coterminous with a second side wall of the fourth crate and an end wall of the fifth crate abuts side wall 36 of crate 10b.

Row 104 of pallet 100 is “cross stacked” relative to row 102 meaning that in this non-limiting embodiment, the pattern has rotated 180° relative to row 102. Accordingly, crates 10c, 10d, 10e are disposed such that an end wall 34 of crate 10e of layer 104 is substantially coplanar with side wall 36 of crate 10c of row 102 and end wall 44 of crate 10a of layer 102. Adjacent end walls 34, 36 of crates 10c, 10d, and 10e abut each other and side wall 36 of crate 10c of layer 10 are substantially coplanar with end wall 46 of crate 10b.

Third layer 106 has the same orientation and stacking pattern as layer 104 so that like numbered crates are supported by like numbered crates, i.e. crate 10c lies of row 106 lies over crate 10c of row 104.

In this embodiment, an end wall of a poultry crate supports an end wall of a higher row. As seen in FIGS. 3 and 4, when stacked adjacent to each other and coterminous with each other, when end walls are placed adjacent to end walls, tabs 61 are adjacent each other as a result of symmetry of construction. This is true whether wall 44 abuts wall 46 or wall 44 abuts wall 44. Similarly, when side walls 34, 36 or side wall pairs 34, 34 or 36, 36 of adjacent crates are arranged adjacent each other and coterminous with each other, tabs 58 align with each other. When cross stacked, or even when not, respective tabs 58, 61, as a result of their having a width of less than the width of the respective wall from which they extend, are received within pockets 19 along the edge base 14 of an upper poultry crate. Tab 58, 61 is dimensioned to be received so there is little or no gap between the structure of tab 58 extending into pocket 19. In this way, there is little or no shifting of crates in one row with respect to crates in another row.

Reference is now made to FIGS. 5 and 6 in which a pallet constructed of layers in which a top layer is formed of a different dimension and crate than the bottom layer. As shown schematically in FIG. 5, one such example is a layer of four meat crates stacked upon a layer of five poultry crates. In other words, N crates of one layer support M crates of another layer in this preferred, non-limiting instance, M=N−1.

A layer 204 of meat containers 80a-80d, shown in phantom, each meat crate generally indicated as 80 in this particular nonlimiting example, like numerals are utilized to indicate like structure. Each meat crate 80 having a first end wall 82 and an opposed end wall 84, and opposed side walls 86, 88 extending from a base 90. The first meat crate 80 has one side wall adjacent a side wall 86 or 88 of a second meat crate 80b and its end wall 82 or 84 adjacent an end wall 82 or 84 of a third crate 80c. Similarly, a fourth meat crate 80d is disposed so as to have an end wall 82 or 84 adjacent end wall 84 of second meat crate 80b and a side wall 86 or 88 adjacent side wall 86 or 88 of third meat crate 80c. The footprint, or outer perimeter of row 104, substantially equals in size and shape the outer perimeter, or footprint, of row 106.

It should be noted that as known in the art, meat crates 80 have industry dictated dimensions and a distinct pattern extending from base 90. As a result, an accumulated pattern extends from a layer of crates 80 as exhibited by bases 90 of layer 24. It is a distinct pattern, generally indicated as 300. As a result of the size of each poultry crate 10, including the novel wall thickness as discussed above, five poultry crates 10 exhibit substantially the same footprint as four meat crates 80 when oriented as shown in FIG. 5. Furthermore, tabs 58, 61 are oriented in respective side walls and end walls such that they are received within openings 302 of pattern 300 to engage the structure forming pattern 300.

Each meat crate 80 is formed with a base 90, which is formed with an undercut rim 92 extending about an outer edge of base 90. As seen in FIGS. 6 and 7, tabs 61 of crates 10c, 10d, and 10e are received under rim under cut 92 as are tabs 58 of crates 10a, 10b which are on the side walls which form the outer walls of layer 202. In this way, the end walls of certain poultry crates and side walls of other poultry crates 10 act to secure the meat crates 80 as tabs 58, 61 engage undercut 92 or openings 302 as shown in FIGS. 6 and 7.

As can be seen, by providing a collapsible poultry crate having internal dimensions consistent with industry poultry crate standards, and an exterior dimension enabling the crates to be palletized to exhibit a footprint capable of supporting a layer of meat crates thereon, it becomes possible to mix and match crates at a distribution center within a single pallet. Furthermore, by providing tabs on an upper surface of each wall, the tabs having a width less than the width of the wall, it becomes possible to distribute the tabs in a manner that engages a row of crates supported by a lower row of poultry crates. Lastly, by providing ribs along the height of the at least the side walls, a load supporting structure provides the integrity for the poultry crate for a layer of poultry crates to form a layer within a pallet supporting either like poultry crates or a different sized crate such as a meat crate.

While there have been shown, described and pointed out, novel features of the present invention as applied to the preferred embodiments thereof, it will be understood that various omissions and substitutions and changes in the form of details of the disclosed invention may be made by those skilled in the art without departing from the spirit and scope of the invention. It is the intention, therefore, to be limited only as indicated by the scope of the claims appended hereto. There also is to be understood that the following claims are intended to cover all the generic and specific features of the invention herein described and all statements of the scope of the invention, which as a matter of language might be said to fall therebetween. In particular, this invention should not be construed as being limited to the use of the specific structures, materials, or methods as disclosed herein.

Claims

1. A collapsible poultry crate comprising:

a base defining a peripheral edge;

a plurality of side walls, each side wall being mounted on the base along a respective portion of the peripheral edge for pivoting movement relative to the base each side wall pivoting between a closed position and an open position; each side wall having a respective top surface, two or more tabs extending from a respective top surface of the side walls; and

a plurality of end walls, each end wall being mounted on the base along a respective portion of the peripheral edge for pivoting movement relative to the base;

the base having a width and a length such that N poultry crates arranged in a predetermined pattern exhibit a footprint substantially the same as the footprint of M meat crates disposed in a predetermined pattern, each meat crate having a different footprint than each poultry crate.

2. The collapsible poultry crate of claim 1, wherein M=N−1.

3. The collapsible poultry crate of claim 1, having a base, wherein the base has a first edge and a second edge opposed from the first edge and further comprising at least a first pocket formed along the first edge and a second pocket formed in the second edge.

4. The collapsible poultry crate of claim 1, each sidewall having a respective corner, and a first rib structure extending along a height of the respective sidewall substantially at the corner.

5. The collapsible poultry crate of claim 3, wherein each sidewall has a length, and a respective second rib structure extending along a height of the respective sidewalls, the second rib structure disposed at a position spaced about one third of the length of the sidewall from the corner of the sidewall.

6. The collapsible poultry crate of claim 5, wherein at least one of the two or more tabs extends from the top surface of the sidewall at a position disposed along the length of the sidewall between the first rib and the second rib structure.

7. The collapsible poultry crate of claim 2, wherein the first rib structure includes a first longitudinal rib and a second longitudinal rib spaced from the first longitudinal rib, each of the first longitudinal rib and second longitudinal rib extending along the height of the sidewall, and a plurality of horizontal ribs extending between the first longitudinal rib and the second longitudinal rib.

8. The collapsible poultry crate of claim 1, wherein each tab is tapered.

9. The collapsible poultry crate of claim 4, wherein each sidewall has a second corner, a third rib structure extending along a height of the respective sidewall substantially at the second corner.

10. The collapsible poultry crate of claim 9, further comprising a support structure extending along the sidewall adjacent the top surface, and at least between the first rib structure and the third rib structure.

11. The support structure of claim 10, wherein the support structure is one of a lattice, horizontal rib, vertical rib and combination thereof.

12. A collapsible poultry crate comprising:

a base defining a peripheral edge;

a plurality of side walls, each side wall being mounted on the base along a respective portion of the peripheral edge for pivoting movement relative to the base each side wall pivoting between a closed position and an open position; each side wall having a respective top surface, two or more tabs extending from a respective top surface of the side walls;

a plurality of end walls, each end wall being mounted on the base along a respective portion of the peripheral edge for pivoting movement relative to the base, the plurality of side walls and plurality of end walls defining an interior space having a length of about 22.85 inches ±0.25 inches and a width of about 14.878 inches ±0.25 inches; and

wherein each end wall has a thickness, the thickness of each end wall being about 0.525 inches ±0.25 inches, and each side wall has a thickness, the thickness of each side wall being about 0.500 inches ±0.25 inches.

13. The collapsible poultry crate of claim 12, wherein each tab has a thickness, the thickness of the tab being less than the thickness of the side wall.

14. The collapsible poultry crate of claim 12, wherein the base has a first edge and a second edge opposed from the first edge and further comprising at least a first pocket formed along the first edge and a second pocket formed along the second edge.

15. The collapsible poultry crate of claim 12, wherein each sidewall has a respective corner, and a first rib structure extending along a height of the respective sidewall substantially at the corner.

16. The collapsible poultry crate of claim 12, wherein each sidewall has a length, and a second rib structure extending along a height of the respective sidewalls, the second rib structure disposed at a position spaced about one third of the length of the sidewall from each corner.

17. The collapsible poultry crate of claim 16, wherein at least one of the two or more tabs extends from the top surface of the sidewall at a position disposed along the length of the sidewall between the first rib structure and the second rib structure.

18. The collapsible poultry crate of claim 15, wherein the first rib structure includes a first longitudinal rib and a second longitudinal rib spaced from the first longitudinal rib, each of the first longitudinal rib and the second longitudinal rib extending along the height of the sidewall, and a plurality of horizontal ribs extending between the first longitudinal rib and the second.

19. The collapsible poultry crate of claim 12, wherein each tab is tapered.

20. The collapsible poultry crate of claim 12, wherein each sidewall has a respective corner, and a third rib structure extending along a height of the respective sidewall substantially at the second corner.

21. The collapsible poultry crate of claim 20, further comprising a support structure extending along the sidewall adjacent the top surface, and at least between the first rib structure and the third rib structure.

22. The support structure of claim 21, wherein the support structure is one of a lattice, horizontal rib, vertical rib or combination thereof.

23. A pallet of crates having a first layer and a second layer, the first layer comprising: M poultry crates, each poultry crate having a base defining a peripheral edge, a plurality of side walls, each side wall being mounted on the base, along a respective portion of the peripheral edge for pivoting movement relative to the base each side panel pivoting between a closed position and an open position; a plurality of side walls, each side wall being pivotally mounted on the bottom panel, each side wall having a respective top surface, two or more tabs extending from a respective top surface of the end walls;

the second layer being formed of N meat crates where N is less than M; and

the base of the poultry crate having a width and a length such that M poultry crates arranged in a predetermined pattern exhibit a footprint substantially the same as the footprint of N meat crates disposed in a predetermined pattern.

24. The pallet of claim 23, wherein the base of the poultry crate has a first edge and a second edge opposed from the first edge and further comprising at least a first pocket formed along the first edge and a second pocket formed in the second edge.

25. The pallet of claim 23, wherein each sidewalk of the poultry crate has a respective corner, and a first rib structure extending along a height of the respective sidewall substantially at the corner.

26. The pallet of claim 25, wherein each sidewall of the poultry crate has a length, and a respective second rib structure extending along a height of the respective sidewalls, the second rib structure disposed at a position spaced about one third of the length of the sidewall from the corner of the sidewall.

27. The pallet of claim 26, wherein at least one of the two or more tabs of the poultry crate extends from the top surface of the sidewall at a position disposed along the length of the sidewall between the first rib and the second rib structure.

28. The pallet of claim 24, wherein the first rib structure of the poultry crate includes a first longitudinal rib, and a second longitudinal rib spaced from the first longitudinal rib, each of the first longitudinal rib and second longitudinal rib extending along the height of the sidewall, and a plurality of horizontal ribs extending between the first longitudinal rib and the second longitudinal rib.

29. The pallet of claim 23, wherein each tab is tapered.

30. The pallet of claim 25, wherein each sidewall of the poultry crate has a second corner, a third rib structure extending along a height of the respective sidewall substantially at the second corner.

31. The pallet of claim 30, further comprising a support structure extending along the sidewall of the poultry crate adjacent the top surface, and at least between the first rib structure and the third rib structure.

32. The pallet of claim 31, wherein the support structure is one of a lattice, horizontal rib, vertical rib and combination thereof.