Knock-Down Plastic Container for Produce and the Like

This invention relates to a new and improved molded plastic knock-down container of the type used for transporting produce from the field to food processing and packing locations and for similar purposes. Heretofore, such containers or bins have been fabricated entirely of wood or plywood in permanent form and have not been capable of disassembly.

Accordingly, it is a principal feature of the present invention that the container, hereinafter described in detail, may be disassembled in that it consists of four identical sides and a bottom; and when thus disassembled, the sides may be nested for transportation from the processing plant back to the fields and for storage. The size of the knocked-down containers is approximately one-sixth the size of the assembled containers, and hence space is saved in transportation and storage.

Another feature of the invention is the fact that the container may be easily set up by one man very rapidly. Two sides are joined together by three simple fasteners at each corner which may be engaged using a screwdriver or similar tool. The bottom and the bottoms of the sides have interfitting parts whereby the bottom is supported by the sides and the legs of the sides support the bottom above ground. Conversely the container may be easily disassembled using the same tools and the reverse procedures; and once disassembled, pairs of sides may be nested in compact fashion so that an entire container consisting of bottom and four sides nests together.

Another feature of the invention is the fact that because of the high strength of the walls of the sides the containers may be stacked nine high when filled, each container being approximately 45 inches high. Prior containers have not been capable of stacking so high.

Another feature of the device is the fact that being molded of plastic it is lighter in weight than conventional containers for this purpose. Thus the total empty weight of the container is about 70 lbs., whereas a wooden container of the same capacity is 145 lbs. as a minium. Each side weighs approximately 10 lbs., and the bottom weighs 30 lbs.

Another feature of the invention is economy in transportation. An extra tier of containers may be piled on a truck and still enable the truck to stay within highway load limits.

The present invention is preferably molded of a plastic material such as Profax, a trademark of Hercules Corporation. Such material is impervious to acids and resists heat and cold. It is more resilient and less fragile than wooden containers. When suitably dimensioned and with the choice of proper plastics, the strength of the container is approximately 21/2 times the required capability. In addition, the plastic may be formed with an aperture for drainage of liquids such as processing chemicals and juices.

The material from which the device is constructed is capable of a very long life, and since the device is not readily damaged during handling it may be re-used over a number of seasons.

Another feature of the invention is the fact that because of the nature of the material of construction the plastic may be color coded. It will be understood that most containers of this type are owned by canneries and are furnished to growers for filling. By color coding the containers of different owners may be readily distinguished. Further, in the molding of the sides, slugs may be inserted in the molds for imprinting of the name of the owner.

Along each side of the container a replaceable wooden skid is fastened to the bottom of each leg. The skids permit stacking on damp ground. Also, they take the wear when the containers slide over abrasive surfaces and can be replaced when worn.

Still another feature of the invention is the manner in which the bottom is supported above the ground by legs depending from the four sides. There are two legs at each corner of the box and one leg in the middle of each side edge of the box. Hence a fork lift may approach the container from four sides instead of only two sides as when wooden boxes are used.

Another important advantage of the invention is that the outside dimensions of the container may be exactly the same as wooden boxes. Hence the very expensive handling equipment presently used for lifting containers and emptying the same need not be modified or replaced.

Other objects of the present invention will become apparent upon reading the following specification and referring to the accompanying drawings in which similar characters of reference represent corresponding parts in each of the several views.

In the drawings:

FIG. 1 is a perspective view from above showing the assembled container.

FIG. 2 is a perspective view from below of the assembled container.

FIG. 3 is an enlarged fragmentary sectional view of a corner taken substantially along the line 3--3 of FIG. 2.

FIG. 4 is a fragmentary sectional view taken substantially along the line 4--4 of FIG. 3.

FIG. 5 is a perspective view of a side disassembled.

FIG. 6 is a fragmentary sectional view through a side and bottom taken substantially along the line 6--6 of FIG. 5.

FIG. 7 is an exploded side elevational view showing four sides and a bottom disassembled.

The container, which is the subject of this invention, comprises a bottom 11 and four identical sides 12 which interfit and are fastened together to form a unit which may be conveniently assembled and disassembled. The bottom 11 and sides 12 are molded of a plastic material of a type commercially available and known as Profax, a product of Hercules Corporation, it being understood that other plastic materials are also suitable. Other than the five parts mentioned, there are male and female fastener elements holding the sides assembled. A preferred fastener is one commercially available and known as Dzus, a product of Dzus Fastener Co., Inc., illustrated in U.S. Pat. No. 1,955,740, each comprising a stud and a receptacle and characterized by the fact that a mere one-quarter turn of the male fastener element by a screwdriver or other appropriate tool draws the two elements together and locks same and a similar one-quarter turn disengages the two elements, substantially as shown in U.S. Pat. No. 1,955,740.

Bottom 11 is preferably of rectangular shape and sufficiently strong to support the weight of the contents of the container. Accordingly, it comprises a bottom panel 16 which is approximately smooth on the upper surface and is reinforced against deflection on its bottom surface by longitudinal and transverse reinforcing ribs 17, 18, respectively, the ribs being disposed in an approximately square pattern. Panel 16 is formed with a hole 19 for drainage of chemicals and juices. Each edge of panel 16 is formed with projecting lip 21.

Each side 12 comprises a substantially rectangular side panel 26 which is also smooth on its inside surface and is reinforced on its external surface by vertical and horizontal reinforcing ribs 27, 28, respectively, the pattern of ribs preferably being approximately square. The top edge 29 of each side is smooth so that a tier of containers may be stacked.

At one end of each side 12 is a first vertical post 47 which, as best shown in FIG. 3, is formed with an outward offset 48 and then an extension 49 which is parallel to, but spaced outwardly of, panel 26. Hence there is a rabbet 51 formed at the first post end of side 12, the end 52 of extension 49 being slightly inwardly disposed relative to the end of the container. A counterbored hole 53 is formed near the outer end of extension 49 to receive male fastener element 54 of the type commercially available and heretofore described.

At one end of side 12 opposite first post 47 is second vertical post 56 which is generally complementary to the rabbet 51. Thus, there is an inward angularly-extending slanted reinforcement wall 57 extending from panel 26 to outward directed inner wall 58 which is flush against offset 58 in the assembled condition of the container as best shown in FIG. 3. Extending outwardly at right angles to wall 58 is side 59 which is flush against the inside of extension 49 and which terminates in an outward offset 61 which fits over end 52. Hollow cylindrical cover 62 is formed on the inside of side 59 opposite hole 53 and secured (as by ultrasonic welding) within cover 62 is the female fastener element 64 which mates with male element 54. Counterbored hole 65 in sidewall 59 provides entry for element 54.

Each side 12 is supported above the ground or an underlying container by three feet, the shape of each of the three feet differing somewhat as next explained. First foot 66 comprises a top 73 which projects inward from panel 26 with a groove 81 between the bottom of panel 26 and top 73, a vertical inner face 69 below top 73, a bottom 74 and inner end 71. A rectangular cross-section boss 34 is located on top of top 73 but there is a gap 82 above boss to receive lip 21. Second foot 67 underlies second post 56 and is similar to foor 66 and the same reference numerals followed by subscript a designates corresponding parts. Second foot 67 also has a vertical outer face 68 which is an extension of surface 49 of post 56 and lies against the inside of first foot 66. Foot 66 is set in from end 52 for such purpose.

Third or middle foot 76 resembles foot 66 in shape and function, and the same reference numerals followed by subscript b are used to designate corresponding elements.

Between feet 66, 76 and 67 are projections 84 which are longer than projections 34, 34b but have the same elevation with the same gap 82 between the top of the projection and the underside of panel 26.

To accommodate wear, a skid 86 underlies each side 12, preferably of wood. A screw 87 attaches to a nut 88 fixed in the bottom 74 of each foot. Thus the skid 86 may be replaced when worn.

To assemble a container, a pair of sides 12 is selected and the second post 56 of one side 12 is fitted into the rabbet 51 of the first post 47 of the other side 12, as best shown in FIG. 3. Each male fastener 54 is turned one-quarter turn by a screwdriver or other implement and this causes the male fastener 54 to lock in the female fastener 64, and in so doing, to draw the parts tightly together in the condition shown in FIGS. 3 and 4. Thereupon, a bottom 11 is selected and placed on top of the projections 34 and top surfaces 73, 73a, 73b of the feet 66, 67, 76 so that the lip 21 fits into the gap 82 and fills same, as best shown in FIG. 6. The third and fourth sides 12 are then assembled in the same fashion as the first two sides and are fitted over the bottom 11 and again the fasteners 54 are used to attach adjacent sides together. When thus assembled, a rigid structure is provided wherein the bottom 11 is captured within the confines of the four sides 12 and the bottom 11 is supported above the ground by the projections 34, 84. Containers may be filled, lifted by a forklift which easily fits between the legs 66, 67, 76 on top of skid 86 and stacked, all as has been heretofore explained. At destination, the container may be lifted from a truck and handled in the same manner and using the same equipment as standard wooden containers heretofore used.

For storage and transportation, the container is readily disassembled by again turning the male fasteners 54 one-quarter turn, permitting the sides 12 to be disengaged from each other and the bottom 11 dropped. Directing attention to FIG. 7, it will be seen that a pair of sides 12 may be nested together. Each of a pair of sides 12 is turned end to end. Post 47 fits inside post 56. The four sides 12 and a bottom 11 make up a set which fit together compactly.