BACKGROUND 1. Technical Field
The present invention is generally directed to container systems, and, in particular, is directed to a container system with an interlocking mechanism to secure the containers relative to each other during transport and storage. The present invention further relates to a self-palletizing container system.
2. Description of Related Art
Current package or container shipping systems require 1) containers or boxes for storing goods; 2) a palette upon which the containers are stacked; and 3) wrapping to maintain the containers together and on the palette during shipping. However, these known systems are deficient in a number of ways. For example, known container systems require separate paletting, incorporate excess wrapping material and are labor intensive with respect to storage and processing at job sites or warehouses.
SUMMARY Accordingly, the present invention overcomes the deficiencies of known shipping systems by providing an interlocking-palletized-container system which eliminates much of the waste inherent in current systems.
A container system for use with a forklift includes a plurality of containers. Each container includes a container body having corner interlocking structure cooperatively arranged whereby adjacent containers are connectable to each other, a base secured relative to the container body, and dimensioned to support the container body and being adapted to couple with the blade of the forklift to permit placement and transport of the containers in an interlocked relation thereof and a cover mountable to the container body. Each container may include a single pedestal, whereby the distance between the pedestals of adjacent coupled containers is at least equal to the width of the blade of the forklift. Each container body may include male and female connector members. The male and female connectors of adjacent containers cooperate to connect the adjacent containers. The male and female connectors each may extend for less than half the height of the container body. Each container may include two male connectors disposed in diametrical corners of the container body, and two female connectors disposed in diametrical corners of the container body.
In embodiments, the cover may include a contoured surface and the base may include a corresponding contoured surface. The contoured surfaces interlock to couple vertically stacked containers.
The interlocking structure is dimensioned and arranged to directly couple three or four containers.
The container system is self-palletized in that its use is independent of any need for a separate or individual pallet.
BRIEF DESCRIPTION OF THE DRAWINGS Embodiments of the present disclosure will be readily appreciated by reference to the drawings wherein:
FIG. 1 is a perspective view of a single container of the container system in accordance with the principles of the present disclosure;
FIG. 2 is an exploded perspective view of the single container illustrating the base, the container body and the cover;
FIGS. 3-4 are first and second side plans of the single container;
FIG. 5 is an enlarged cross-sectional view taken along the lines 5-5 of FIG. 4;
FIGS. 6A-6D are top plan, first side plan, second side plan and bottom plan views of the base of the single container;
FIGS. 7A-7C are top plan, first side plan and second side plan views respectively of the container body of the single container;
FIG. 8 is a top plan view of the container body of the single container illustrating the interlock mechanism;
FIGS. 9A-9B are top plan and bottom plan views of the cover of the single container;
FIG. 10 is a view illustrating assembly of two adjacent containers;
FIG. 11 is a view of four containers in interlocked relation;
FIG. 12 is a cross-sectional view illustrating two containers in stacked relation; and
FIGS. 13-14 are first and second side elevation views illustrating two containers in interlocked relation with a fork lift “f” blade depicted within the gaps defined between the containers.
DETAILED DESCRIPTION Referring now to FIGS. 1-5, the container system in accordance with the principles of the present disclosure is illustrated. The container system 1 includes a plurality of containers, which are adapted to interlock horizontally in side-by-side relation and also interlock vertically in stacked relation. The container system may be adapted for use with or without a forklift, and in one embodiment, is dimensioned such that the legs of the forklift can engage interconnected containers for transport and storage. FIGS. 1-5 illustrate a single container 10 of the system 1. Each container 10 includes a base 12, a container body 14 mountable to the base 12 and a cover 16 which is mountable to the container body 14.
With reference to FIGS. 6A-6D, in conjunction with FIGS. 1-5, the base 12 is dimensioned to support the container body 14 and is adapted to couple with the blade of the forklift to permit placement and transport of the containers 10 in an interlocked relation thereof. In one embodiment, the base 12 includes lower and upper members 18, 20 interconnected by a pedestal 22. The lower member 18 includes a general racetrack shaped recess 24 defining a general oval outer contour or inner protrusion 25 on the underside of the lower member 18. (See also FIG. 5) The upper member 20 includes a generally elongated X-shaped protrusion 26 on its upper surface. A pair of spaced openings 28 receives respective bolts or screws 30 extending along the length of the pedestal 22 for coupling the base 12 to the container body 14 (see also FIGS. 2 and 5). As best depicted in FIGS. 3 and 4, the pedestal 22 defines gaps 32a, 32b on each side of the pedestal 22. The respective lengths “11”, “12” of each gap are substantially equal. When coupled with an adjacent container 10 the cumulative distance between the pedestals 22 of adjacent interlocked containers 10 is at least equal to the width of the blade of the forklift such that a gap is defined therebetween for reception of the blade. Thus, the forklift blade may engage the interlocked containers 10 from any side of the container bodies 12.
With reference now to FIGS. 7A-7C, in conjunction with FIGS. 1-5, each container body 10 includes an outer wall 34 defining an inner volume 36 for storage of goods. The corners 38 of the outer wall 34 are planar wall segments. Each corner 38 interlocks with a respective corner 38 of an adjacent container 10. In one embodiment, each container body 14 includes at least one or two male connectors 40 and at least one or two correspondingly dimensioned female connectors 42. The male connectors 40 are received within the female connectors 42 of an adjacent container 10 to releasably couple the containers 10 to each other during transport or storage. In one embodiment, each container body 14 includes a male connector 40 on diametrically opposed corners 38 and a female connector 42 on the remaining diametrically opposed corners 38. The male and female connectors 40, 42 extend for only a portion of the vertical height of the container body 14. In some embodiments, the lengths of the male and female connectors 40, 42 extend for less than 50% of the height of the container 14, or less than 33% or less than 25%. This facilitates maneuvering and interlocking of the male and female connectors 40, 42 as will be discussed hereinbelow.
With particular reference to FIG. 8, further details of the interlock mechanism will be discussed. The male connectors 40 are generally T-shaped having a leg segment 44 depending from the corner 38 and a cross-bar segment 48 connected to the leg segment 44. The cross bar 48 includes a planar outer surface 50 which leads to curved outer corner surfaces 52. At the junctures of the leg segment 44 and the cross bar 48 are internal inwardly curved or concave surfaces 54 which are coterminous with the outer corner surfaces 52 and arranged about a radius of curvature “k”. The female connectors 42 each include spaced legs 56 defining an internal chamber or volume 58 for receiving two male connectors 40 of adjacent containers 10. The legs 56 define inner generally concave surfaces 60 adjacent the corner 38, arranged about a radius of curvature “m”, which extend to outer outwardly curved or convex surfaces 62. As will be appreciated from the discussion hereinbelow, the curved surfaces 52, 54, 60, 62 of the male and female connectors 40, 42, in conjunction with the cooperative structure of the connectors 40, 42 facilitate mounting and interlocking of the containers relative to each other.
Referring again to FIGS. 7C and 8, in conjunction with FIG. 5, the bottom wall 64 of the container body 12 includes a generally x-shaped protrusion 66 defining a general x-shaped recess 67 on the underside of the bottom wall 64, which extends through the corners 34. The protrusion 66 and accompanying recess 67 generally correspond in dimension to the x-shaped protrusion 26 of the base 12. The protrusions 26, 66 interlock during assembly of the base 12 to the container body 14. The bottom wall 64 also includes two openings 68 (FIG. 7A and FIG. 8) which may be threaded to receive the screws 30 extending through the base 12 to couple the components. In the alternative lock nuts (not shown) may be used in lieu of threaded openings.
With reference to FIGS. 9A-9B, in conjunction with FIGS. 1-5, the cover 16 includes an outer general racetrack shaped protrusion 70 defining a general oval outer contour or inner recess 72. The protrusion 70 and the recess 72 of the cover 16 are corresponding in dimension to the respective racetrack shaped recess 24 and the oval protrusion 26 of the base 12 to interlock and stabilize vertically stacked containers 10. In particular, the protrusion 70 and recess 24 of the cover 16 and the base 12 respectively are sufficient in depth to interlock the vertically stacked containers 10 in a manner which will eliminate lateral movement under normal storage and transport conditions. The cover 16 fits over the edge of the outer wall 34 of the container body 12 in snap relation, friction fit, etc. therewith.
Referring now to FIG. 10, a process for interlocking containers 10 of the system will now be discussed. Two assembled containers 10 are positioned in side-by-side relation. One segment 48a of the cross bar 48 of a male connector 40 is positioned within the inner volume 58 of the female connector 42. The curved outer surface 52 of the segment 48a engages the convex and concave surfaces 62, 60 (see also FIG. 8) and may be rotated along the surfaces 62, 60 in the direction of directional arrow “t” to place the containers in side-by-side relation. It is envisioned that the male connectors 40 may also be resilient to partially flex during positioning of the segments 48a within a female connector 42 of an adjacent container 10. In the alternative, a male connector 40 of one container 10 may be interlocked with a female connector 42 of an adjacent container 10 by vertical positioning, via from above or below, the male connector 40 within the female connector 42. 42. The respective lengths of the male and female connectors 40, 42 may facilitate bottom loading and interlocking of the containers 10 in that the connectors 40, 42 do not extend beyond the midpoint of the container body 14. FIG. 11 illustrates four containers 10 interlocked with each other. As shown, the four containers 10 are interlocked by positioning two bar segments 48a of cross bars 48 of male connectors 40 of diametrically opposed first and second containers 10a, 10b within a single female connector 42 of a third container 10c, and the remaining bar segments 48a of the cross bars 48 of the diametrically opposed containers 10a, 10b in a female connector 42 of a fourth container 10d. Additional containers 10 may be coupled in the same manner.
FIG. 12 illustrates containers 10 in stacked relation. As shown, the general racetrack and oval protrusions and recesses of the base 12 and cover 16 interlock to stabilize the vertically stacked containers 10 in the manner discussed hereinabove.
FIGS. 13-14 illustrate two containers in interlocked relation with a fork lift “f” blade depicted within the gaps 20 of the pedestals 22.
Related subject matter is disclosed in commonly owned U.S. Patent Publication No. 2013/0015183 to Fredette appended hereto, the entire contents of which are incorporated herein by reference.
Although the illustrative embodiments of the present disclosure have been described herein with reference to the accompanying drawings, the above description, disclosure, and figures should not be construed as limiting, but merely as exemplifications of particular embodiments. It is to be understood, therefore, that the disclosure is not limited to those precise embodiments, and that various other changes and modifications may be effected therein by one skilled in the art without departing from the scope or spirit of the disclosure.
