Collapsible shipping container

[0001] The present invention relates generally to a shipping container that can be converted into a collapsed condition upon shipment of the desired product in order to save space when returning the container. More particularly, the present application involves a collapsible shipping container that has a plurality of legs that can nest with an upper surface of a subsequent shipping container to save space during stacking of shipping containers for their return.

[0002] Shipping containers are used in order to transport goods, such as automotive parts, between locations. Such containers act to protect the goods during transport and are shaped in such a way to facilitate loading, unloading, and handling at their final destination. The shipping container can be disposed of once the goods are removed. Alternatively, shipping containers can be reused in order to save costs associated with purchasing a new shipping container every time a part or set of parts are transported. For reuse, the shipping container must be transported back to the manufacturer or distributor of the purchased part. There are costs associated with both transporting the shipping container back to the manufacturer or distributor and with storing empty shipping containers before they are ultimately transported back.

[0003] It is known to make shipping containers collapsible in order to save costs associated with their return for reuse. In this regard, the empty shipping container can be collapsed to a size smaller than that when transporting product so that a return shipment of empty, collapsed containers can include four or five times as many containers as a shipment of containers with product. The side walls of the shipping container can be hinged in order to render the container collapsible and effect the aforementioned space and cost savings.

[0004] Collapsed shipping containers are often stacked on top of one another during their return trip and at the site of the purchaser when waiting to be returned. It is also the case that collapsible shipping containers that have product therein are stacked on top of one another during transport to the purchaser. Stacking of shipping containers saves space during their transport and consequently reduces overall cost. One drawback to stacking of the containers is that the stack can become unstable hence resulting in damage or injury should the stack or a portion thereof tip. Containers can shift through forces experienced during transport by truck, boat, airplane or train. Collapsed containers may have more of a tendency to tip as there are a greater number of containers in a stack and the containers do not have the weight of the product therein to help stabilize their arrangement. Upon arrival at the manufacturer or distributor, the transported collapsed containers may be tipped over or otherwise shifted out of place hence necessitating clean-up time and cost.

[0005] Shipping containers are sometimes provided with legs that extend from a bottom wall in order to elevate the shipping container some distance off of the ground. In this manner, a fork truck may be used to lift and transport the shipping container to a desired location. Unfortunately, leg arrangements on the bottoms of shipping containers may increase the overall height of a stack of containers thus impacting the amount of containers that can be transported and thus causing an increase in overall cost. As such, there remains room for variation and improvement within the art.

[0006] Various features and advantages of the invention will be set forth in part in the following description, or may be obvious from the description, or may be learned from practice of the invention.

[0007] One aspect of the present invention provides for a stack of collapsible shipping containers that includes a first collapsible shipping container with a bottom and top and a frame therebetween. The top of the first collapsible shipping container has an upper surface with at least one locking projection extending therefrom. A second collapsible shipping container is included and has a bottom and a top with a frame therebetween. The bottom of the second collapsible shipping container has a lower surface with at least one leg extending therefrom. The leg of the second collapsible shipping container has a lower surface. The second collapsible shipping container rests on top of the first collapsible shipping container so that the lower surface of the leg of the second collapsible shipping container engages the upper surface of the top of the first collapsible shipping container. The locking projection of the first collapsible shipping container and the leg of the second collapsible shipping container can engage one another so as to at least partially prevent relative motion between the first and second shipping containers.

[0008] Another aspect of the present invention resides in a stack as immediately discussed in which the leg of the second collapsible shipping container defines a depression. The top of the first collapsible shipping container has at least one projection extending from the upper surface of the top. The projection of the first collapsible shipping container is disposed in the depression of the second collapsible shipping container.

[0009] An additional aspect of the present invention exists in a stack as described above in which the locking projection of the top of the first collapsible shipping container has an upper surface. The upper surface of the locking projection of the first collapsible shipping container is located above the lower surface of the leg of the second collapsible shipping container. Such an orientation is established when the second collapsible shipping container rests on top of the first collapsible shipping container such that the lower surface of the leg of the second collapsible shipping container engages the upper surface of the top of the first collapsible shipping container.

[0010] Another aspect of the present invention resides in a stack as described above in which the locking projection of the first collapsible shipping container has a rectangular perimeter. The locking projection surrounds the perimeter of the lower surface of the leg when the second collapsible shipping container rests on top of the first collapsible shipping container. In this position, the lower surface of the leg of the second collapsible shipping container engages the upper surface of the top of the first collapsible shipping container.

[0011] The present invention provides for, in an additional aspect, a stack as mentioned above in which the top of the first collapsible shipping container and the bottom of the second collapsible shipping container are made of molded plastic.

[0012] Another aspect of the present invention is found in a collapsible shipping container that has a bottom with an upper surface and a lower surface. The bottom has at least one leg extending from the lower surface. The leg defines a depression, and the leg has a lower surface. A frame is present and is supported by the bottom. The frame is convertible from a shipping position to a collapsed position. A top is included that has an upper surface and a lower surface. The top has at least one projection extending from the upper surface of the top. The projection is configured for being disposed in a depression of a leg of a subsequent collapsible shipping container. The top has at least one locking projection extending from the upper surface of the top. The locking projection is configured for engaging a lower surface of a bottom of a subsequent collapsible shipping container to minimize relative motion therebetween.

[0013] An additional aspect of the present invention includes a collapsible shipping container as immediately discussed in which each one of the projections is surrounded by one of the locking projections. The locking projections are configured so as to surround the perimeter of the lower surface of the leg of a subsequent collapsible shipping container.

[0014] The present invention provides for in an additional aspect a shipping container as discussed above in which a plurality of projections and locking projections are present. The top has a plurality of intermediate projections located between and contiguous with adjacent locking projections.

[0015] An additional aspect of the present invention resides in a collapsible shipping container as previously discussed in which the frame has an upper supporting structure that engages the lower surface of the top and supports the top. The frame has a plurality of cross members attached to the upper supporting structure. The lower surface of the top defines a plurality of receiving channels for receipt of the cross members.

[0016] Another aspect of the present invention resides in a collapsible shipping container as described above in which the top and bottom are made of molded plastic.

[0017] An additional aspect of the present invention resides in a stack of collapsible shipping containers with a first collapsible shipping container that has a bottom and a top with a frame therebetween. The top of the first collapsible shipping container has an upper surface with at least one projection with an upper surface and at least one locking projection extending therefrom. The frame of the first collapsible shipping container has open sides when arranged in a shipping position. The bottom and top of the first collapsible shipping container are made of molded plastic. A second collapsible shipping container is included and has a bottom and a top with a frame therebetween. The bottom of the second collapsible shipping container has a lower surface with at least one leg extending therefrom. The leg defines a depression that is a channel, and the leg has a lower surface. The frame of the second collapsible shipping container has open sides when arranged in a shipping position. The bottom and top of the second collapsible shipping container are made of molded plastic. The upper surface of the projection of the top of the first collapsible shipping container is located above the lower surface of the leg of the second collapsible shipping container. The projection of the first collapsible shipping container is disposed in the depression of the leg of the second collapsible shipping container so as to limit relative motion between the first and second shipping containers. The locking projection of the first collapsible shipping container and the leg of the second collapsible shipping container engage one another to limit relative motion between the first and second shipping containers.

[0018] These and other features, aspects and advantages of the present invention will become better understood with reference to the following description and appended claims. The accompanying drawings, which are incorporated in and constitute part of this specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention.

[0028] Repeat use of reference characters in the present specification and drawings is intended to represent the same or analogous features or elements of the invention.

[0029] Reference will now be made in detail to embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the invention, and not meant as a limitation of the invention. For example, features illustrated or described as part of one embodiment can be used with another embodiment to yield still a third embodiment. It is intended that the present invention include these and other modifications and variations.

[0030] It is to be understood that the ranges mentioned herein include all ranges located within the prescribed range. As such, all ranges mentioned herein include all sub-ranges included in the mentioned ranges. For instance, a range from 100-200 also includes ranges from 110-150, 170-190, and 153-162. Further, all limits mentioned herein include all other limits included in the mentioned limits. For instance, a limit of up to 7 also includes a limit of up to 5, up to 3, and up to 4.5.

[0031] The present invention provides for a collapsible shipping container 100 that can be used to hold product 12 during transport from one location to the next. After the product 12 has been transported to and used at the final destination, the collapsible shipping container 100 can be returned and subsequently reused in order to reduce overall costs. The collapsible shipping container 100 can be oriented into a collapsed position in which the top 102 and bottom 104 are moved towards one another to lower the overall vertical height of the collapsible shipping container 100. A second collapsible shipping container 200 can be placed on top of the first collapsible shipping container 100 to form a stack 10. Multiple collapsible shipping containers can likewise be incorporated into the stack 10 so that a large number of collapsible shipping containers can be returned in a single trip. The first collapsible shipping container 100 may include one or more projections 126 and/or locking projections 132 that work in conjunction with one or more legs 216 of the second collapsible shipping container 200 in order to prevent or minimize relative motion between these two containers 100 and 200. Further, the collapsible shipping containers 100 and 200 may be configured so that a lower surface 218 of a leg 216 of the second collapsible shipping container 200 is below the upper surface 134 of a locking projection 132 of the first collapsible shipping container 100 when the two containers 100 and 200 are engaged. Such an arrangement may save one inch of space per engagement between the first and second collapsible shipping containers 100 and 200. Such a space savings between engaged collapsible shipping containers can be realized at every engagement along the height of the stack 10 thus potentially resulting in a significant savings of overall space and cost.

[0032] FIG. 1 shows a stack 10 in accordance with one exemplary embodiment of the present invention. A first collapsible shipping container 100 is configured into a shipping position for holding product 12 therein. A second collapsible shipping container 200, also oriented into a shipping position, rests on top of the first collapsible shipping container 100 and likewise stores product 12. Although shown as employing dunnages 164 and 264 to hold product 12, it is to be understood that other arrangements are possible in which dunnages 164 and 264 are not present. The shipping containers 100 and 200 can be arranged in the stack 10 during transport to the site of a purchaser of the product 12. After product 12 has been removed, the containers 100 and 200 can each be oriented into a collapsed position as shown in FIG. 2. In this orientation, the collapsible shipping containers 100 and 200 take up less space when transported back to the manufacturer or distributor for reuse. The collapsible shipping containers 100 and 200 can be assembled into a stack 10 when either one of or all of the containers 100 and 200 are oriented into the shipping or collapsed positions.

[0033] As shown, a bottom 204 of the second collapsible shipping container 200 rests on a top 102 of the first collapsible shipping container 100. Top 102 and bottom 204 are shown in more detail in FIGS. 3 and 4. Top 102 has an upper surface 108 from which a series of projections 126 extend. It is to be understood that any number of projections 126 can be present in accordance with various exemplary embodiments. Projections 126 are shown has having a generally elongated rectangular shape although other shapes are possible in other embodiments. An upper surface 128 of the projection is flat, although it can be convex, concave, sinusoidal or variously shaped in other embodiments. A locking projection 132 likewise extends from the upper surface 108. Locking projection 132 has an upper surface 134 that can be provided in manners similar to those previously discussed with respect to surface 128. The locking projection 132 has an outer perimeter that surrounds the projection 126. Although shown as being rectangular in shape and essentially resembling a square, the locking projection 132 can be variously shaped in other exemplary embodiments of the present invention. Portions of the upper surface 108 are located between the locking projection 132 and projection 126. Other areas of the upper surface 108 are found outside of the perimeter of the locking projection 132.

[0034] The top 102 can be provided with any number or none of the locking projections 132 and projections 126. In the exemplary embodiment shown, nine locking projections 132 and nine projections 126 are present. Other embodiments exist in which from zero to fifteen locking projections 132 and projections 126 are present. In FIG. 3, the locking projections 132 and projections 126 are arranged in three sets of three 140, 142 and 144. A first set of three 140 locking projections 132 and projections 126 are arranged proximate to an end of the top 102 while a third set of three 144 locking projections 132 and projections 126 are proximate to an opposite end of top 102. A second set of three 142 locking projections 132 and projections 126 are located between the first and third set of three 140 and 144 locking projections 132 and projections 126. A plurality of intermediate projections 146 extend from the upper surface 108 of top 102 and are contiguous with and located between adjacent locking projections 132 in the sets 140, 142 and 144 of locking projections 132 and projections 126. The projections 126, locking projections 132 and intermediate projections 126 can be arranged in such a way that they form a continuous projection from, or substantially from, one end to an opposite end of the upper surface 108.

[0035] FIG. 4 shows the bottom 204 of the second collapsible shipping container 200. The bottom 204 has a lower surface 214 from which a plurality of legs 216 extend. It is to be understood that in accordance with other exemplary embodiments of the present invention that any number of legs 216 can be present in the bottom 204. For example from zero to fifteen legs 216 may be present in other variations. The exemplary embodiment in FIG. 4 shows nine legs 216 extending from lower surface 214. Legs 216 terminate in a lower surface 218 that is flat. However, in other embodiments lower surface 218 can be convex, concave, sinusoidal, or curved in shape. Leg 216 defines a depression 230 that extends from one end 236 to an opposite end 238 of the lower surface 218 of the leg 216. In the configuration in FIG. 4, depression 230 is in the shape of a channel. The depression 230 can have any desired depth and may have a depth from ¼^th th to ¾^th that of the height of leg 216. Other embodiments exist in which depression 230 is circular, triangular or sinusoidal in shape. As shown, depression 230 extends across the lower surface 218 so as to essentially split the lower surface 218 into two portions. Other exemplary embodiments exist in which the depression 230 does not extend completely from one end 236 to the other 238. The depression 230 can be located in the middle of the lower surface 218 so that the lower surface 218 is split into two equal parts. Other exemplary embodiments exist in which the depression 230 does not extend completely from one end 236 to the other 238.

[0036] The legs 216 are arranged on bottom 204 into three sets of three 220, 222 and 224. The first set 220 of legs 216 are located proximate to an end of bottom 204 and are arranged in a linear fashion. The third set 224 of legs 216 are proximate to an opposite end of bottom 204 and likewise are oriented in a linear manner. The second set 222 of legs 216 are linearly oriented and are positioned between the first and third sets 220 and 224 of legs 216. The legs 216 are arranged so that the depressions 230 extend in the same direction as other depressions 230 and are parallel in orientation to other depressions 230.

[0037] When oriented into the stack 10 as shown in FIGS. 1 and 2, the bottom 204 engages the top 102 so that the lower surfaces 214 of legs 216 contact the portions of the upper surface 108 that are between the projections 126 and locking projections 132. The projections 126 are disposed in the depressions 230 of legs 216 when configured as shown in FIGS. 1 and 2. The legs 216 are thus nested and locked into the projections 126 and locking projections 132 so that relative movement between the bottom 214 and top 102 is hindered thus helping to minimize movement between the first collapsible shipping container 100 and second collapsible shipping container 200 in stack 10. Spacing between the locking projections 132 and legs 216 can be sized so to achieve various amounts of or no movement between these components. Shipping containers in the stack 10 may be prevented from sliding off of the stack 10 or otherwise causing the stack 10 to tip. The locking projections 132 may have an outer perimeter that completely surrounds the outer perimeter of the lower surface 218 of leg 216 to prevent the legs 216 to moving beyond the locking projections 132. The upper surface 128 of projection 126 may or may not contact a portion of the leg 216 that helps define the depression 230. Although shown as having complimentary shapes for purposes of nesting, the projections 126, locking projections 132, legs 216 and depressions 230 need not have complimentary shapes in accordance with other embodiments of the present invention.

[0038] FIG. 5 is a partial cross-sectional view of the stack 10 of FIG. 1. The nesting arrangement of top 102 and bottom 204 is illustrated. As can bee seen, the lower surface 218 of leg 216 is located below the upper surface 134 of locking projection 132 when the top 102 and bottom 204 are in engagement. The upper surface 128 of projection 126 is likewise located above the lower surface 218 of leg 216 during engagement. The nested arrangement of top 102 and bottom 204 may be beneficial in saving space during stacking of various shipping containers into stack 10. In accordance with one exemplary embodiment of the present invention, a space savings of one inch is realized per engagement between successive shipping containers. This space savings may add up across the vertical height of the entire stack 10 as many more shipping containers can be included thus resulting in a significant savings of space across the overall height thereof.

[0039] FIG. 6 is a perspective view of the first collapsible shipping container 100 in a shipping position without the top 102. A frame 106 is supported by an upper surface 112 of a bottom 104. The upper surface 112 of the bottom 104 can be planar and may have depressions corresponding to the positions of various legs 116 on the bottom 104. Alternatively, the upper surface 12 can be planar and generally smooth across its entire area in accordance with other exemplary embodiments. A series of legs 116 are present to elevate other portions of the bottom 104 and hence the shipping container 100 off of the ground. As a general rule, the legs 116 may be arranged so as to provide two inches of clearance for allowing a fork truck to lift the bottom 104. The bottom 104 could also be made so that three inches of clearance from the ground are present in order to allow a floor jack to be used to lift the container 100. The frame 106 has an upper supporting structure 148 onto which the top 102 rests. The upper supporting structure 148 includes four members that extend around essentially the side perimeter of the first collapsible shipping container 100. A series of three cross members 150 are connected to and extend between opposite sides of the upper supporting structure 148. The cross members 150 also act to support the top 102.

[0040] Referring back to the cross-sectional view in FIG. 5, the lower surface 110 of top 102 defines a plurality of receiving channels 152 into which the cross members 150 and upper supporting structure 148 may be disposed. The cross members 150 may rest underneath or within the projections 126, locking projections 132 and intermediate projections 146 of the top 102. During engagement of the first collapsible shipping containers 100 and 200, the cross members 150 may be located above the lower surfaces 218 of legs 216. Dunnage 164 can be suspended from the upper supporting structure 148, cross members 150, intermediate supporting structure 156 and/or top 102 in accordance with various exemplary embodiments.

[0041] The frame 106 includes a lower supporting structure 154 that extends around substantially the entire perimeter of the bottom 104 of the first collapsible shipping container 100 as shown with reference to FIG. 6. The lower supporting structure 154 can be a series of bars that rest on or are otherwise nested into or attached to the bottom 104. An intermediate supporting structure 156 is present between the lower supporting structure 154 and upper supporting structure 148. The intermediate supporting structure 154 can be a plurality of vertically oriented bars 160 that extend between the upper and lower supporting structures 148, 154 to help define a holding space 158 of the first collapsible shipping container 100 into which products 12 may be retained. The intermediate supporting structure 156 is configured so that the sides 166 of the frame 106 of the first collapsible shipping container 100 are open. However, it is to be understood that other exemplary embodiments of the present invention are possible in which one or more sides 166 of the frame 106 are closed.

[0042] The frame 106 is reoriented in order to convert the first collapsible shipping container 100 from the shipping position to the collapsed position. In this regard, the intermediate supporting structure 156 is removed or otherwise changed so that the upper and lower supporting structures 148 and 154 are moved closer to one another. In accordance with one embodiment, the intermediate supporting structure 156 is removed from engagement with the upper and lower supporting structures 148 and 154 so that they may contact and nest with one another to achieve the collapsed position. In accordance with another alternative exemplary embodiment, a pivot 162 is present on one end of the bars 160. Here, the bars 160 of the intermediate supporting structure 156 are disconnected from the upper supporting structure 148 and the bars 160 are pivoted downward to allow the first collapsible shipping container 100 to assume the collapsed position. Other arrangements of effecting a collapsing of the shipping container 100 are possible in accordance with other exemplary embodiments of the present invention.

[0043] A front view of the bottom 104 of the first collapsible shipping container 100 is shown in FIG. 7. The bottom 104 can be constructed in an identical manner to bottom 204 of the second collapsible shipping container 200. In this regard, components previously included and described in relation to bottom 204 may be present in bottom 104 and may be provided and function in an identical manner as previously described. For example, legs 116 can extend from a lower surface 114 of the bottom 104. Legs 116 may define depressions 130 that are channels and that extend from one end 136 to an opposite end 138 of the lower surface 118 of the legs 116. Nine legs 116 can be present in three sets 120, 122 and 124 of legs 116. These components can be arranged or provided as discussed above with respect to their counterparts on the second collapsible shipping container 200.

[0044] FIG. 8 shows a partially exploded perspective view of the second collapsible shipping container 200 in the shipping position. Container 200 includes components that may be arranged and function in a manner identical to those previously discussed found in the first collapsible shipping container 100. For example, the second collapsible shipping container 200 can include a top 202 with an upper and lower surface 208 and 210. Projections 226 that have upper surfaces 228 along with locking projections 232 that have upper surface 234 in addition to intermediate projections 246 may extend from the upper surface 208. Three sets 240, 242 and 244 of the locking projections 232 and projections 226 can be provided. Further, a frame 206 can include upper, lower and intermediate supporting structures 248, 254 and 256 in addition to cross members 250 that can be disposed within receiving channels 252. A holding space 258 can be at least partially defined by bars 260 of the intermediate supporting structure 256 that can pivot on one end through the use of pivots 262 to allow the container 200 to assume a collapsed position. The sides 266 of the frame 206 can be open, and the upper surface 212 of the bottom 204 can be planar or may have depressions defined across its area. The aforementioned components of the second collapsible shipping container 200 can be provided and function in manners similar to their first collapsible shipping container 100 counterparts and thus need not be repeated here.

[0045] The first and second collapsible shipping containers 160 and 200 can thus be made so as to be completely identical to one another. Alternatively, these two containers 100 and 200 can be different. For example, the top 202 of the second collapsible shipping container 200 need not have projections 226 or locking projections 232, and the bottom 104 of the first collapsible shipping container 100 need not have legs 116 in accordance with certain exemplary embodiments of the present invention. This arrangement can be made because the interaction between the first and second containers 100 and 200 exists between the bottom 204 and top 102 and not between top 202 and bottom 104. However, it may be beneficial to include the components shown in the figures and likewise described as it may be the case that a third or fourth container is to be added to the first and second collapsible shipping containers 100 and 200 into stack 10. The inclusion of such additional components allows the containers 100 and 200 to be interchangeably placed on top of one another and to be interchangeably used in conjunction with additionally configured collapsible shipping containers.

[0046] The collapsible shipping containers 100 and 200 can be made from a variety of materials and through various processes in accordance with different embodiments. For example, frames 106 and 206 can be made of metal in accordance with certain exemplary embodiments. Tops 102, 202 and bottoms 104, 204 can be made of molded plastic in accordance with certain exemplary embodiments of the present invention.

[0047] While the present invention has been described in connection with certain preferred embodiments, it is to be understood that the subject matter encompassed by way of the present invention is not to be limited to those specific embodiments. On the contrary, it is intended for the subject matter of the invention to include all alternatives, modifications and equivalents as can be included within the spirit and scope of the following claims.