Accordion Dunnage and Collapsible Dunnage Box With Accordion Dunnage

Abstract

A collapsible dunnage adapted for being positioned in a box for transporting parts that includes a plurality of top-opening pockets for receiving the parts to be transported and formed of a flexible web positioned in side-by-side registration with each other and movable between an expanded use position and a collapsed storage position while being maintained in the same side-by-side registration position. Fastener elements are attached to the dunnage and adapted for fastening the dunnage to complementary fastener elements carried by a box in which the dunnage is adapted to be positioned for use and storage. The box is collapsible and includes features that permit convenient storage of the collapsed accordion dunnage in the collapsed box.

Description

PRIORITY CLAIM

This application claims priority from and incorporates by reference U.S. Provisional Patent Application Ser. No. 62/833,089, filed Apr. 12, 2019 and U.S. Provisional Patent Application Ser. No. 62/852,464, filed May 24, 2019.

TECHNICAL FIELD AND BACKGROUND OF THE INVENTION

This invention relates to a new type of dunnage as described and claimed below, and a collapsible dunnage box in combination with the new dunnage. The dunnage as described and claimed below is referred to as “accordion” dunnage due to its unique construction that bears a superficial similarity to the appearance of the bellows of an accordion. The box disclosed in this application in combination with the accordion dunnage is a unique design having a collapse feature and is used to transport parts to, for example, assembly lines or to other commercial and industrial locations, where the box is emptied. The term “parts” as used in this application broadly means any item or object of a size and type suitable for being transported in dunnage in a box.

The ability of the box to be collapsed permits a large number of empty boxes to be returned to a remote location for cleaning and/or refilling in a much smaller volume than if the boxes remained in the erect condition. In many instances these boxes contain “dunnage.” Dunnage is generally defined as packing material such as boards, blocks, planks, metal or plastic bracing or other internal structures used in supporting and securing parts positioned in the box during shipment and storage. The increasing use of “just in time” parts deliveries has also increased the use of boxes with many varied types of internal dunnage structures which not only protect the parts while in the box but position the parts in a predetermined orientation for ease of removal.

This application relates to dunnage constructed of a fabric or other sheet material with an “accordion” fold conformation with pockets that are positioned in an open condition in the box during use that cradle and separate the parts in the box from each other. This position is referred to as the “use” position. Since this dunnage is also reusable along with the box itself, it is most efficient and cost-effective to be able to ship the box and the dunnage together back to their place of origin.

Prior art collapsible boxes include boxes with dunnage storage in the bottom of the box. Instead of a normal shallow bottom box component, the collapsing walls of the box are attached to a box component as the bottom. Normally, the collapsible box collapses down to a predetermined height. All of the volume is filled with the folded and pivoting sidewalls. There is no empty volume for the dunnage to utilize. The open usable volume that the dunnage bottom provides is a lower area volume that remains empty when the sidewalls are folded down. Removable dunnage can be removed from the erect box, folded up and placed in this bottom cavity, keeping the dunnage with the collapsed box.

The present invention provides a more space-efficient and time-saving manner of collapsing the box and its associated dunnage.

SUMMARY OF THE INVENTION

In one aspect of the invention, the storage volume of the collapsing box is positioned in the top of the box instead of in the bottom, as with the prior art. This is a particular benefit with the accordion-type dunnage that holds parts vertically. As described above, this dunnage may be made of fabric or other foldable web material so when empty it is collapsible onto itself, folding flat in an accordion-like manner with little effort. This dunnage is mounted proximate the top of the box.

In another aspect of the invention, as the endwalls of the box are folded upwards, the endwalls push the bottom of the accordion dunnage upwards into the storage volume in the top of the box.

In another aspect of the invention a collapsible box with an accordion dunnage includes a bottom, first and second opposing endwalls and first and second opposed sidewalls connecting the bottom on opposing sides of the box. The box may also optionally include a top cover. Each of the sidewalls includes a top sidewall panel and a bottom sidewall panel attached by a bottom hinge to the bottom. The top and bottom sidewall panels are attached together along adjacent edges by a center hinge, whereby the top and bottom sidewalls are pivotally-moveable relative to each other and the bottom between an erect position and a collapsed position. The dunnage set including a plurality of foldable dunnage elements positioned in the box and moveable between a use position suspended from near the top of the box, hanging down into the volume of the box when in the box is in an erect position, being progressively folded into a flattened position as the box is collapsed.

In accordance with another aspect of the invention, a collapsible box is provided that includes a bottom, a top, and first and second opposing endwalls and first and second opposed sidewalls connecting the bottom and top of the box on opposing sides of the box. Each of the sidewalls includes a top sidewall panel attached by a top hinge to the top, a bottom sidewall panel attached by a bottom hinge to the bottom. The top and bottom sidewall panels are attached together along adjacent edges by a center hinge, whereby the top and bottom sidewalls are pivotally-moveable relative to each other and the top and bottom between an erect position and a collapsed position. A collar is positioned atop the first and second opposing sidewalls and the first and second opposing endwalls to provide a raised wall that remains erect with perpendicular walls that form a storage volume when the first and second opposing sidewalls and the first and second opposing endwalls are collapsed in a horizontal position.

In accordance with another aspect of the invention, a collapsible dunnage adapted for being positioned in a box for transporting parts is provided, and includes a plurality of top-opening pockets for receiving the parts to be transported and formed of a flexible web positioned in side-by-side registration with each other and movable between an expanded use position and a collapsed storage position while being maintained in the same side-by-side registration position. Fastener elements are attached to the dunnage and adapted for fastening the dunnage to complementary fastener elements carried by a box in which the dunnage is adapted to be positioned for use and storage.

In accordance with another aspect of the invention, the flexible web is a fabric.

In accordance with another aspect of the invention, the flexible web is selected from the group of webs consisting of fabric, film, plastic and netting.

In accordance with another aspect of the invention, the fastener elements are touch fastener elements adapted to fasten to complementary touch fastener elements carried by the box.

In accordance with another aspect of the invention, the fastener elements of the dunnage are one or the other of hooks and loops and the fastener elements of the box are complementary to the one or the other of the hooks and loops of the dunnage.

In accordance with another aspect of the invention, the pockets include flexible first and second sidewalls and flexible first and second endwalls positioned between and joined to the first and second sidewalls, the first and second sidewalls and first and second end walls configured to provide one or more generally rectangularly-shaped pockets with a volume in the use position that are adapted to collapse when empty in an accordion-like manner.

In accordance with another aspect of the invention, a collapsible box with dunnage is provided that includes a bottom and first and second opposing endwalls mounted for pivotal movement relative to the bottom. First and second opposed sidewalls connect the bottom of the box on opposing sides of the box, each of the sidewalls including a top sidewall panel and a bottom sidewall panel attached by a bottom hinge to the bottom. The top and bottom sidewall panels are attached together along adjacent edges by a center hinge, whereby the top and bottom sidewalls are pivotally-moveable relative to each other and the bottom between an erect use position and a collapsed storage position. A collar is positioned atop the first and second opposing sidewalls and the first and second opposing endwalls to provide a raised wall that remains erect with perpendicular walls that form a storage volume when the first and second opposing sidewalls and the first and second opposing endwalls are collapsed in a horizontal position. A collapsible dunnage is adapted for being positioned in the box for transporting parts, and includes a plurality of top-opening pockets for receiving the parts to be transported and formed of a flexible web positioned in side-by-side registration with each other and movable between an expanded use position and a collapsed storage position while being maintained in the same side-by-side registration position. Fastener elements are attached to the dunnage and adapted for fastening the dunnage to complementary fastener elements carried by a box in which the dunnage is adapted to be positioned for use and storage.

In accordance with another aspect of the invention, the endwalls are pivotally-mounted to opposing ends of a top of the box and are adapted to move between a position perpendicular to the top of the box in the erect use position and a position parallel to the top of the box in the collapsed storage position.

In accordance with another aspect of the invention, a collapsible box with dunnage is provided that includes a bottom, top and first and second opposing endwalls and first and second opposed sidewalls connecting the bottom and top of the box on opposing sides of the box. Each of the sidewalls include a top sidewall panel attached by a top hinge to the top and a bottom sidewall panel attached by a bottom hinge to the bottom. The top and bottom sidewall panels are attached together along adjacent edges by a center hinge whereby the top and bottom sidewalls are pivotally-moveable relative to each other and the top and bottom between an erect position and a collapsed position. A collar is positioned atop the first and second opposing sidewalls and the first and second opposing endwalls to provide a raised wall that remains erect with perpendicular walls that form a storage volume when the first and second opposing sidewalls and the first and second opposing endwalls are collapsed in a horizontal position. An accordion dunnage includes a plurality pockets supported in the collar for extending into the box in an erect use position adapted for holding parts for shipment and storage, and collapsible with the sidewalls and endwalls for storage in the volume defined by the collar when the box is in a collapsed position.

BRIEF DESCRIPTION OF THE DRAWINGS

Preferred and exemplary embodiments of the invention are further explained with reference to the drawings, in which:

FIGS. 1-6, inclusive, are views of a prior art collapsible box;

FIG. 7 is a perspective view of a collapsible box according to an embodiment of the invention that places the “storage volume” of the collapsed box at the top of the box instead of at the bottom;

FIGS. 8-12 are cross-sectional views of the box according to FIG. 7 in progressive states of collapse into its storage position;

FIG. 13 is a perspective view of the box of FIG. 7 without dunnage;

FIG. 14 is a perspective view of an accordion dunnage in an open use configuration;

FIG. 15 is a top plan view of the accordion dunnage of FIG. 14; and

FIG. 16 is a perspective view of the accordion dunnage of FIG. 14 in a flattened, closed storage position;

FIG. 17 is a perspective view of the box of FIG. 13 in a use position with a closed lid;

FIG. 18 is a perspective view of the box of FIG. 13 in a deployed position with the accordion dunnage in a use position;

FIG. 19 is a perspective view of the box of FIG. 13 in a deployed position with the accordion dunnage in a partial use position;

FIG. 20 is a perspective view of the box of FIG. 13 moving from the use position to the collapsed position and with accordion dunnage shown in a collapsed storage position.

FIG. 21 is a perspective view of the box of FIG. 13 in a collapsed position and with accordion dunnage shown in a collapsed storage position; and

FIG. 22 is a perspective view of the box of FIG. 13 as it is being transitioned from the storage position with the accordion dunnage shown in a partially collapsed storage position moving to a use position.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT AND BEST MODE

Prior Art

Referring now specifically to the drawings, a collapsible box “CB” according to a prior art collapsible box is shown in FIGS. 1-6. The collapsible box “CB” of FIG. 1 is shown in a fully erect, use position. The collapsing walls are attached at the bottom. The height “B” shows the open usable volume that the dunnage bottom provides. FIG. 2 shows an endwall being folded into the volume of the collapsible box CB″ as part of the collapse process. FIG. 3 shows the box “CB” fully collapsed, with the height “A” representing the volume that is filled with the folded and pivoting sidewalls, with no empty volume. In FIG. 4 the collapsed box “CB” is opened by first folding away the interlocking covers. The lower volume is shown remaining empty when the sidewalls are folded down. According to FIGS. 5 and 6, removable dunnage pockets can be removed from the erect box “CB”, folded up and placed in the bottom of the collapsed box “CB”, keeping the dunnage pockets with the collapsed box “CB”.

Dunnage Box

A collapsible dunnage box 10 with which the accordion dunnage of the invention is used is shown in FIGS. 7-13 and 17-22. As best shown in FIG. 7, the box 10 includes a base 12 to which are mounted opposed first and second base endwalls 14, 16 and first and second base sidewalls 18, 20. The base endwalls 14, 16 are mounted for pivoting movement on base endwall hinges 14A, 16A. The base sidewalls 18, 20 are formed by two base sidewall panels 18A, 18B and 20A, 20B, respectively that are joined along an adjoining common hinge line by respective base sidewall hinges 18C, 20C.

Top endwalls 22, 24 are mounted to the top edge of the base endwalls 14, 16, respectively, and top sidewalls 26, 28 are pivotally mounted to the top edge of the base sidewall panels 18A, 20A, respectively. The top endwalls 22, 24 and top sidewalls 26, 28 collectively define a collar 30. The collar 30 includes a pair of opposed lifting recesses 31.

The box 10 is usable with various types of dunnage. Prior art dunnage includes individual pockets positioned in the box 10 and suspended from dunnage hangers by fastening members, for example, hooks, attached to the top of the dunnage pockets. This prior art dunnage is preferably constructed of a crushable, reusable web material, for example, cloth, plastic, film or similar material, capable of being crushed and compressed into a randomly-defined shape and then decompressed into their original shape for reuse by being suspended from the dunnage hangers by the hooks or other fastening members.

In contrast to the collapsible box “CB” of FIGS. 1-6, the storage volume for the dunnage is formed in the top of the box 10 in the collar 30. In effect, the storage volume is defined by the collar 30 that extends around the top of the box 10 as shown even when the box 10 is completely collapsed. This is particularly useful with dunnage of the type that is formed of hanging dunnage elements, for example, the dunnage pockets described above, or the novel accordion dunnage described below that hold parts vertically within their folds.

Referring now to FIGS. 8-12, the box 10 has been vertically cross-sectioned to more clearly reveal the interior of the box 10 and the interrelationship between the action of the base endwalls 14, 16 and the base sidewalls 18, 20.

FIG. 8 shows the base endwalls 14, 16 and the base sidewalls 18, 20 flat and fully erect, in the deployed “use” position capable of storing and shipping parts in the dunnage, not shown.

FIG. 9 shows the beginning of the box 10 collapsing process, with the base endwalls 14, 16 being pushed inwardly and upwardly into the volume of the box 10 and towards each other into a storage position.

In FIG. 10, the base endwalls 14, 16 are fully pushed inwardly and up into the storage position perpendicular to their use position, while the base sidewalls 18, 20 remain vertical and fully erect, as in FIGS. 8 and 9.

In FIG. 11, the base endwalls 14, 16 are fully pushed up into the storage position, with the base sidewalls 18, 20 beginning to hinge inwardly into the volume of the box 10 along their common hinges 18C, 20C.

In FIG. 12 the box 10 is fully collapsed into a storage position, with the base endwalls 14, 16 now forming the base of a dunnage pocket 32 storage volume. Note that the fully hinged, stowed base sidewalls 18, 20 reside in the box 10 directly beneath the stowed base endwalls 14, 16. The collar 30 has now descended onto the top of the base 12 and defines a volume sufficient for the dunnage to be folded and positioned in that volume for storage and shipment back to, for example, a parts supplier where the box 10 will be re-erected by reversing the process shown and described in FIGS. 8-12. FIG. 13 shows a fully erected box without dunnage pockets for clarity.

Accordion Dunnage

Referring now to FIGS. 14-16, a novel dunnage, referred to as “accordion” dunnage is shown. The accordion dunnage 50, two sets of which are shown, includes a plurality of top opening pockets, 52, 54, 56 into which parts can be placed for shipment and storage. The three pockets 52, 54, 56 are constructed of sidewalls 58, 60, 62, 64 and endwalls 66, 68, 70, 72, 74 and 76. The sidewalls 58, 60, 62, 64 are constructed in registration with each other, as shown. A bottom panel 78, which may be a single or separate panels for each pocket 52, 54, 56, encloses the bottom of the pockets 52, 54, 56. Other embodiments of the accordion dunnage may include any suitable number of pockets including a single pocket.

The accordion dunnage 50 is preferably fabricated of a flexible web, for example, webs of fabric, film, plastic or netting or a combination of these webs. The specific web selected will depend on a number of factors that will widely vary, including the weight, size and shape of the parts to be placed in the pockets 52, 54, 56, requirements for flame retardancy, wear, chemical resistence and the like.

Due to its flexibility and construction, the accordion dunnage 50 is movable between an expanded use position shown in FIGS. 14 and 15, and a collapsed storage position shown in FIG. 16, while being maintained in the same side-by-side registration configuration. The construction of the accordion dunnage 50 not only resembles an accordion bellows with its pleats, but functions in a similar manner, expanding and flattening between the use and storage positions.

The components of the accordion dunnage 50 may be joined by any suitable means, including stitching, seaming, such as overedge seaming, gluing, stapling, sonic welding or any other suitable means depending on the material from which the sidewalls 58, 60, 62, 64 and endwalls 66, 68, 70, 72, 74 and 76 are constructed.

The accordion dunnage 50 can be suspended in the box 10 in any suitable manner. One suitable manner is the use of touch fasteners, for example hook and loop elements 80 that cooperate with complementary hook and loop elements attached to the interior of the box 10 near the top. Touch fasteners or other attachment elements may be placed strategically on the accordion dunnage 50 itself so that when a plurality of accordion dunnage 50 sets are in the use position in the box 10, adjacent attachment elements provide mutual support to the accordion dunnage 50.

Referring now to FIGS. 17-23, FIG. 17 shows a dunnage box 10 in its deployed use position as it would appear with the accordion dunnage 50 sets positioned in the box 10 and loaded with parts, with the lid 40,42 closed for shipment and storage.

As shown in FIGS. 18 and 19, with the lid 40, 42 removed for clarity, the accordion dunnage 50 is shown in position in the box 10. In FIG. 18, two sets of the accordion dunnage 50 are shown fully expanded and in the use position. FIG. 19 shows one set of the accordion dunnage 50 collapsed in preparation for the box 10 being collapsed, with the other set of accordion dunnage 50 still in its expanded use position.

In FIG. 20 the accordion dunnage 50 has been collapsed into storage position resting on the inwardly folded endwalls 14, 16 and the box 10 is beginning its movement into its collapsed storage position, shown in FIG. 21.

FIG. 22 shows the box 10 having been expanded into its use position with the endwalls 14, 16 in the process of being folded outwardly and downwardly into the use position. As this occurs, the accordion dunnage 50 is allowed to fold back down into the expanded box 10 and into its use position, as shown in FIG. 18.

The accordion dunnage 50 is therefore conveniently stored in the top portion of the box 10 in its collapsed position and thus can remain with the box 10 when being shipped in its collapsed position back to a facility where it is expanded into its use position, the accordion dunnage deployed into its use position and refilled with parts for shipment to, for example, an assembly line for again being emptied.

An accordion dunnage and collapsible dunnage box with accordion dunnage according to the invention has been described with reference to specific embodiments and examples. Various details of the invention maybe changed without departing from the scope of the invention.

Furthermore, the foregoing description of the preferred embodiments of the invention and best mode for practicing the invention are provided for the purpose of illustration only and not for the purpose of limitation, the invention being defined by the claims.

Claims

1. A collapsible dunnage adapted for being positioned in a box for transporting parts, comprising:

(a) one or more top-opening pockets for receiving the parts to be transported and formed of a flexible webs positioned in side-by-side registration with each other and movable between an expanded use position and a collapsed storage position while being maintained in the same side-by-side registration position;

(b) fastener elements attached to the dunnage and adapted for fastening the dunnage to complementary fastener elements carried by the box in which the dunnage is adapted to be positioned for use and storage.

2. A collapsible dunnage according to claim 1, wherein the flexible web is a fabric.

3. A collapsible dunnage according to claim 1, wherein the flexible web is selected from the group of webs consisting of fabric, film, plastic and netting.

4. A collapsible dunnage according to claim 1, wherein the fastener elements are touch fastener elements adapted to fasten to complementary touch fastener elements carried by the box.

5. A collapsible dunnage according to claim 1, wherein the fastener elements of the dunnage are one or the other of hooks and loops and the fastener elements of the box are complementary of the one or the other of the hooks and loops of the dunnage.

6. A collapsible dunnage according to claim 1, and including a plurality of pockets having flexible first and second sidewalls and flexible first and second endwalls positioned between and joined to the first and second sidewalls, the first and second sidewalls and first and second endwall configured to provide a generally rectangularly-shaped pocket volume in the use position that are adapted to collapse when empty in an accordion-like manner.

7. A collapsible box with dunnage, comprising:

(a) a bottom;

(b) and first and second opposing endwalls mounted for pivotal movement relative to the bottom;

(c) first and second opposed sidewalls connecting the bottom of the box on opposing sides of the box, each of the sidewalls comprising; (I) a top sidewall panel; (ii) a bottom sidewall panel attached by a bottom hinge to the bottom; (iii) the top and bottom sidewall panels attached together along adjacent edges by a center hinge, whereby the top and bottom sidewalls are pivotally-moveable relative to each other and the bottom between an erect position and a collapsed storage position; (iv) a collar positioned atop the first and second opposing sidewalls and the first and second opposing endwalls to provide a raised wall that remains erect with perpendicular walls that form a storage volume when the first and second opposing sidewalls and the first and second opposing endwalls are collapsed in a horizontal position; and (v) a collapsible dunnage adapted for being positioned in the box for transporting parts, comprising: (a) a plurality of top-opening pockets for receiving the parts to be transported and formed of flexible webs positioned in side-by-side registration with each other and movable between an expanded use position and a collapsed storage position while being maintained in the same side-by-side registration position; and (b) fastener elements attached to the dunnage and adapted for fastening the dunnage to complementary fastener elements carried by a box in which the dunnage is adapted to be positioned for use and storage.

8. A collapsible box according to claim 7, wherein the endwalls are pivotally-mounted to opposing ends of a top of the box and are adapted to move between a position perpendicular to the top in the erect position and a position parallel to the top in the collapsed storage position.

9. A collapsible box with dunnage, comprising:

(a) a bottom, top and first and second opposing endwalls;

(b) first and second opposed sidewalls connecting the bottom and top of the box on opposing sides of the box, each of the sidewalls comprising; (I) a top sidewall panel attached by a top hinge to the top; (ii) a bottom sidewall panel attached by a bottom hinge to the bottom; (iii) the top and bottom sidewall panels attached together along adjacent edges by a center hinge, whereby the top and bottom sidewalls are pivotally-moveable relative to each other and the top and bottom between an erect position and a collapsed position; (iv) a collar positioned atop the first and second opposing sidewalls and the first and second opposing endwalls to provide a raised wall that remains erect with perpendicular walls that form a storage volume when the first and second opposing sidewalls and the first and second opposing endwalls are collapsed in a horizontal position; and (v) a dunnage set comprising a plurality of dunnage elements having pockets supported in the collar for extending into the box in an erect use position and adapted for holding parts for shipment and storage, and collapsible with the sidewalls and endwalls for storage in the volume defined by the collar when the box is in a collapsed storage position.

10. A collapsible dunnage according to claim 9, wherein the flexible web is a fabric.

11. A collapsible dunnage according to claim 9, wherein the flexible web is selected from the group of webs consisting of fabric, film and netting.

12. A collapsible dunnage according to claim 9, wherein the fastener elements are touch fastener elements adapted to fasten to complementary touch fastener elements carried by the box.

13. A collapsible dunnage according to claim 9, wherein the fastener elements of the dunnage are one or the other of hooks and loops and the fastener elements of the box are complementary to the one or the other of the hooks and loops of the dunnage.

14. A collapsible dunnage according to claim 9, wherein the pockets include flexible first and second sidewalls and flexible first and second endwalls positioned between and joined to the first and second sidewalls, the first and second sidewalls and first and second endwall configured to provide a generally rectangularly-shaped pocket volume in the use position that are adapted to collapse when empty in an accordion-like manner.