REUSABLE PLASTIC CONTAINER FOR SHIPPING OF PRODUCE

Abstract

A collapsible, reusable plastic container that can be used for the storage and transportation of produce, having dimensions optimized for such storage and transportation and for folding down of the container. The container may also have a novel footprint for six-down stacking. The container may also be designed to provide increased ventilation to its contents during storage and transport. The container may also have a sample door with a clip for easy access to the produce contained in the container when it is stacked among other containers. The container may also have a latch system to secure its endwalls and sidewalls in an erected configuration during storage and transport. The container may also have lead-in in its dimensions to facilitate stacking and de-stacking of containers.

Claims

1. An arrangement of plastic shipping containers for bananas, the arrangement comprising: a pallet having a top surface, the top surface having a pallet length and a pallet width; six shipping containers each having a container length and a container width arranged on the top surface of the pallet in a layer, the containers arranged in two rows, each row having three of the containers, each of the six shipping containers having its container width extend in the direction of the rows and in the direction of the pallet width and having its container length extend in the direction of the pallet length; and bananas in each container, the bananas disposed in a three-line configuration with their crowns facing down.

2. The arrangement of claim 1, wherein the pallet length is about 48 inches and the pallet width is about 40 inches.

3. The arrangement of claim 2, wherein each of the containers has a maximum exterior length of about 24 inches and a maximum exterior width of about 13 inches.

4. The arrangement of claim 1, wherein the bananas in each container weight about 40 pounds.

5. The arrangement of claim 1, wherein each of the containers comprises a base, two endwalls, and two sidewalls, each of the endwalls and each of the sidewalls being moveably connected to the base, each of the sidewalls detachably coupled to the two endwalls to allow the container to assume an erected configuration when the sidewalls and endwalls are all upright, and a folded-down configuration when the sidewalls and endwalls are all folded down.

6. The arrangement of claim 5, wherein each of the containers has a greater maximum, exterior length and/or a greater maximum, exterior width in the erected configuration than in the folded-down configuration.

7. The arrangement of claim 6, wherein each of the containers, in the erected configuration, has a maximum exterior length of about 24 inches and a maximum exterior width of about 13 inches

8. The arrangement of claim 5, wherein each of the sidewalls and the endwalls is moveably connected to the base using a plurality of hinges.

9. The arrangement of claim 5, wherein each container comprises a plurality of vent holes in each of its sidewalls or each of its endwalls, at least one of the containers arranged so that at least some of its plurality of vent holes completely or substantially align with at least some of the plurality of vent holes of the sidewalls or endwalls of at least one other container.

10. The arrangement of claim 5, wherein each container comprises a plurality of vent holes in each of its sidewalls, at least one of the containers arranged so that at least some of its plurality of vent holes completely or substantially align with at least some of the plurality of vent holes of the sidewalls of at least one other container.

11. The arrangement of claim 5, wherein each of the containers comprises a sample door that is moveably connected to at least one of the sidewalls and endwalls.

12. The arrangement of claim 1, wherein each of the containers has a substantially flat and smooth interior floor and substantially smooth exterior floor.

13. The arrangement of claim 1, wherein each of the plastic shipping containers comprises at least one of a resin and a thermoplastic.

14. The arrangement of claim 1, further comprising a second plurality of containers each having bananas therein, the second plurality of containers arranged to form seven additional layers of containers arranged above the first layer, wherein each of the additional layers comprises six shipping containers of the second plurality of containers each having a container length and a container width, the containers in each of the additional layers arranged in two rows each row having three of the second plurality of containers, each of the six shipping containers of the second plurality of shipping containers having its container width extend the direction of a row and in the direction of the pallet width and having its container length extend in the direction of the pallet length, the bananas in each of the second plurality of containers disposed in a three-line configuration with their crowns facing down.

15. A plastic shipping container for bananas for placement on a flat surface, comprising: a base, two endwalls and two sidewalls that are each moveably coupled to the base, the container being able to assume an erected configuration when the sidewalls and endwalls are all upright, and a folded-down configuration when the sidewalls and endwalls are all folded down, in the erected configuration, the container having one or more cross-sections extending through the endwalls and the sidewalls, the cross-sections being parallel to the flat surface, each cross-section in the erected configuration being rectangular and defining, in an erected configuration, an exterior length and an exterior width, in the folded-down configuration, the container having one or more cross-sections that are parallel to the flat surface, each cross-section in the folded-down configuration being rectangular and defining, in a folded-down configuration, an exterior length and an exterior width, wherein the container has a greater maximum, exterior length in the erected configuration than in the folded-down configuration and/or a greater maximum, exterior width in the erected configuration than in the folded-down configuration.

16. The container of claim 15, wherein each endwall is detachably coupled to both sidewalls.

17. The container of claim 15, further comprising bananas in the container having a weight about 40 pounds.

18. The container of claim 15, wherein the container, in the erected configuration, has a maximum exterior length of about 24 inches and a maximum exterior width of about 13 inches.

19. The container of claim 15, wherein each of the sidewalls and the endwalls is moveably coupled to the base using a plurality of hinges.

20. The container of claim 15, wherein each container comprises a plurality of vent holes in each of its sidewalls.

21. The container of claim 15, wherein the container comprises a sample door that is moveably coupled to at least one of the sidewalls and endwalls.

22. The container of claim 15, wherein the container has a substantially flat and smooth interior floor and substantially smooth exterior floor.

23. A plastic shipping container for bananas comprising a base, two endwalls and two sidewalls that are each moveably coupled to the base, the container is able to assume an erected configuration when the sidewalls and endwalls are all upright, and a folded-down configuration when the sidewalls and endwalls are all folded down, the container in the erected configuration having a maximum exterior length of about 24 inches and a maximum exterior width of about 13 inches.

24. The container of claim 23, wherein each endwall is detachably coupled to both sidewalls.

25. The container of claim 23, further comprising bananas in the container having a weight about 40 pounds.

26. The container of claim 23, wherein each of the sidewalls and the endwalls is moveably coupled to the base using a plurality of hinges.

27. The container of claim 23, wherein each container comprises a plurality of vent holes in each of its sidewalls.

28. The container of claim 23, wherein the container comprises a sample door that is moveably coupled to at least one of the sidewalls and endwalls.

29. The container of claim 23, wherein the container has a substantially flat and smooth interior floor and substantially smooth exterior floor.

30. A plastic shipping container having bananas therein, the container comprising a base, two endwalls and two sidewalls that are each moveably coupled to the base, the container is able to assume an erected configuration when the sidewalls and endwalls are all upright and a folded-down configuration when the sidewalls and endwalls are all folded down, the container in the erected configuration having a maximum exterior length of about 24 inches and a maximum exterior width of about 13 inches, and the bananas in the container disposed in a three-line configuration, with their crowns facing down.

31. The container of claim 30, wherein each endwall is detachably coupled to both sidewalls.

32. The container of claim 30, wherein the bananas have a weight about 40 pounds.

33. The container of claim 30, wherein each of the sidewalls and the endwalls is moveably connected to the base using a plurality of hinges.

34. The container of claim 30, wherein each container comprises a plurality of vent holes in each of its sidewalls.

35. The container of claim 30, wherein the container comprises a sample door that is moveably connected to at least one of the sidewalls and endwalls.

36. The container of claim 30, wherein the container has a substantially flat and smooth interior floor and substantially smooth exterior floor.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0043] FIG. 1 is a perspective view of a collapsible container in accordance with an exemplary embodiment, showing the endwalls and sidewalls.

[0044] FIG. 2 depicts six containers of the exemplary embodiment arranged in a single layer six-down configuration on a pallet.

[0045] FIG. 3 depicts the intended airflow pattern through a plurality of containers of the exemplary embodiment that are stacked in a multi-layer six-down configuration.

[0046] FIG. 3a depicts a container viewed from the side, showing the vent holes through which air may flow.

[0047] FIG. 4 depicts a perspective view of the latch mechanism once it has coupled one endwall of the container to one sidewall of the container.

[0048] FIG. 5 depicts a perspective view of the latch mechanism as the sidewall is being moved toward the endwall to engage the latch and couple the sidewall to the endwall.

[0049] FIG. 6 depicts a perspective view of the container that shows the recessed areas present in the endwalls and sidewalls.

[0050] FIG. 7 depicts a perspective view of part of the sidewall in isolation from the rest of the container, with an access door on the sidewall and the door in the open position.

[0051] FIG. 7a depicts a cross section of the sidewall showing the access door in the closed position, with the access door coupled to the sidewall through the use of a clip.

[0052] FIG. 8 depicts a cross section of a sidewall and endwall once coupled through the use of L hooks.

[0053] FIGS. 9a, 9b, and 9c depict three line packing of bananas in an exemplary embodiment of a container with bananas.

[0054] FIG. 10a depicts the profile of one end of the container when in the collapsed configuration.

[0055] FIG. 10b depicts the profile of the same end of the container as shown in FIG. 10a when in the erected configuration, showing the additional length of the container in the erected configuration when compared to the length of the container in the collapsed configuration.

[0056] FIG. 11a depicts an endwall and its handle, where lead-in material can be located.

[0057] FIG. 11 b depicts an enlarged view of the handle of FIG. 11 a, rotated about 90 degrees, showing the lead-in material.

DRAWINGSREFERENCE NUMERALS

[0058] 10: collapsible container [0059] 11: endwall [0060] 12: sidewall [0061] 13: base [0062] 14: ventilation hole [0063] 15: handle [0064] 20: latch [0065] 22: stop [0066] 23: inside edge of sidewall [0067] 30: recess in endwall [0068] 31: recess in sidewall [0069] 40: door [0070] 41: clip [0071] 42: latch bracket [0072] 45: hinge [0073] 47: door hinge [0074] 50: L hook [0075] 60: lead-in [0076] 50: L hook [0077] 60: lead-in

DETAILED DESCRIPTION

[0078] An exemplary embodiment of a container is depicted in FIG. 1 as a collapsible container 10 for the storage and transport of produce. The container 10 as fully erected includes a base 13 that extends in a horizontal plane, two endwalls 11 that extend in respective vertical planes, and two sidewalls 12 that extend in respective vertical planes.

[0079] The container 10 is molded from a plastic or resin material, such as, for example, polypropylene, a resin or thermoplastic polymer or combination thereof. Suitable materials can include resins, plastics or thermoplastics including, but not limited to, polyethylene, polypropylene, polyvinyl chloride, polyurethane, polyester, epoxy resin, phenolic resin, polystyrene, polycarbonate, combinations thereof and the like. The term plastic is used generically herein in its conventional manner and refers to any of the above-listed materials or other similar materials now existing or later developed. The container 10 has a construction that is designed to be strong relative to its weight. The material of the container allows it to be rigid enough to maintain its structural form when erected for storage or transportation, thereby protecting the produce it contains. At the same time, the material of the base 13, endwalls 11, and sidewalls 12 of the container 10 are flexible enough to minimize damage to the contents of the container.

[0080] The interior of the container 10 is primarily defined by the base 13, sidewalls 12 and endwalls 11. A handle 15 is located near the top center of each endwall 11. The base 13 may be a flat and smooth monolithic sheet of plastic. This maximizes internal height and minimizes damage to produce on the top of the container due to contact from the container above. The shape of the endwalls 11, sidewalls 12, and base 13 are designed to reduce bruising conditions for the contents of the container. There are expansive, recessed areas (30, 31) in the endwalls and sidewalls. Much of the structure of the container, including hinges 45, stops 22, and latches 20 (each of which will be detailed below), is designed to be located on the perimeter of the walls away from the curved contents of the container. Preferably, the container has features for interlocking with other containers that project up from the top of container walls. The endwalls 11 and sidewalls 12 are preferably curved outward to maximize internal volume, and are constructed to be flexible, smooth, curved and compliant to minimize damage due to contact with the contents of the container.

[0081] Because the container is designed to hold produce that may be purposely ripened while in the container, the container has various ventilation holes 14 along its sidewalls 12 and base 13, which allow for forced air to travel to the produce while packed in the container. FIG. 3 depicts the intended airflow pattern through a plurality of containers of an exemplary embodiment that are stacked in a multi-layer six-down configuration. The placement of the ventilation holes 14 is designed to permit substantial alignment of the ventilation holes 14 of several containers when stacked on a pallet, which is a typical arrangement of the containers when filled with produce that are subject to ripening by forced air in a ripening room or ripening chamber. This alignment creates a pathway for the forced air to easily reach produce that is stacked in the containers throughout the pallet.

[0082] The endwalls 11 and sidewalls 12 of the container can be connected to the base 13 through the use of a plurality of hinges 45 or other movable couplings. FIG. 7 depicts the hinges 45 on the sidewall. The hinges 45 will permit the endwalls 11 and sidewalls 12 to be folded down toward the base 13 when the container is in the collapsed configuration, and the hinges 45 will allow the endwalls 11 and sidewalls 12 to be moved to an upright position when the container is in the erected configuration. In changing the container from the erected configuration to the collapsed configuration, the first sidewall 12 will be folded down over the base 13, then the second sidewall 12 will be folded down toward the base 13 and will overlap part of the first sidewall 12. Next, the two endwalls 11 will be folded down toward the base 13 and over the sidewalls 12. This collapsed configuration results in the container being made much more compact than when in the erected configuration. The relatively flat, compact container in the collapsed configuration can be easily transported for reuse. When in the collapsed configuration, many of the containers can be stacked for easy transport and/or storage.

[0083] From the collapsed or folded down configuration, the container can be changed into the erected configuration by first unfolding the endwalls 11 and raising each of them to an upright position. Then, one sidewall 12 is raised and is coupled to the two endwalls 11. Finally, the second sidewall 12 is raised and is coupled to the two endwalls 11.

[0084] Several features of an exemplary embodiment of the container can aid in assembly, specifically the transition of the container from a collapsed configuration to an erected configuration. Some of these features are shown in FIG. 4 and FIG. 5. One of the features provides for detachable coupling of sidewall 12 to endwalls 11. An exemplary embodiment of a detachable connection uses a latch 20 and stop 22 to couple the sidewall 12 to the endwall 11. When the inside edge 23 of the sidewall passes the latch 20, the latch 20 springs back into position and hits a stop 22 on the sidewall 12. This contact between the latch 20 and stop 22 can result in a clicking sound that helps the user know that the latch 20 has engaged the stop 22 and that the endwall 11 and sidewall 12 are thereby coupled. The latch 20 can be flexed or otherwise actuated to enable it to first become displaced while the edge of the sidewall 12 contacts it and passes by it, but then spring back to engage the stop 22 on the sidewall 12.

[0085] In an exemplary embodiment, the edges of each endwall 11 and sidewall 12 include a series of vertically-spaced L or L-shaped hooks 50 that allow an endwall 11 to interlock with a sidewall 12 when both are upright and overlap when the container is in the erected position. This further promotes close coupling of the endwalls 11 to the sidewalls 12, promoting the structural integrity of the container 10 in the erected configuration and thereby reducing damage to the contents of the container.

[0086] While many conventional RPCs are collapsible by folding, they are often designed to take on their set-up configuration by latching of their end walls. Such endwall latching can result in inadvertent disengagement of the latches (and resulting collapse of the RPC) during carrying and stacking due to the exertion of lateral forces against the handles or end walls. This can result in damage to the contents of the container. As indicated above, an exemplary embodiment of the container has a unique design that employs latching of the sidewalls 12, which reduces inadvertent disengagement, since lateral force against the handles and end walls during carrying and stacking will not disengage the latches. In addition, the use of L hooks 50 to couple each sidewall 12 to each endwall 11 will further counteract any lateral forces on the handles and endwalls. FIG. 8 depicts a cross section of a sidewall 12 and endwall 11 when coupled through the use of L hooks 50. It will be appreciated that, although according to this aspect of the invention sidewalls are latched to the endwalls, other aspects of the invention such as the arrangement and other container designs described herein may have other sidewall to endwall coupling designs.

[0087] In an exemplary embodiment, one or more of the sidewalls 12 or endwalls 11 will have an opening within which a door 40 is mounted in such a way that does not cut through the perimeter of the sidewall 12 or endwall 11. Such door 40, which can be constructed from the same material as the sidewall 12 or endwall 11, can be hingeably mounted or attached to the opening to allow the door 40 to pivot and be opened and closed. Opening the door 40 permits visual inspection and/or sampling of the product in the container 10, even when the container is within a stack of other containers on a pallet. The door 40 can be closed again, renewing the protective barrier that the endwall 11 or sidewall 12 provides to the contents of the container 10 in storage or transport. Preferably, when the door 40 is in the closed position, the door 40 is coupled or attached to the sidewall 12 or endwall 11 by a clip 41 that prevents the door 40 from opening without user action.

[0088] FIG. 7 and FIG. 7a depict an exemplary embodiment with the opening and door 40 in the sidewall, and the clip 41 having the form of a spring tang. This embodiment of the curved fruit sampling door 40 incorporates a clip 41 that, when engaged, holds the door 40 closed and when disengaged allows the door 40 to open to provide access to the contents of the container 10. Preferably, the clip 41 is a low profile spring tang mechanism which fits within the thickness of the sidewall 12 or endwall 11, not extending inside the curved surface of the sidewall 12 or endwall 11 or outside the plane as defined by the outside surface of the sidewall 12 or endwall 11. The mechanism of the clip 41 is reusable, allowing for repeated opening and closing of the sample door 40. The clip 41 is rotated outward to disengage the clip 41 and allow the door 40 to open. The door 40 and clip 41 are rotated inward with slight pressure to engage the clip 41 and the latch bracket 42. Because of the door's 40 material, its hinged connection 47 and the use of the clip 41 to secure it, the door 40 can be opened and closed repeatedly throughout the life of the container 10 without affecting the structural integrity of the container, the protection of the product in the container, or the life of the container.

[0089] An aspect of the invention is directed to an arrangement of plastic shipping containers for produce (e.g., bananas). The arrangement comprises (a.) a pallet having a top surface, the top surface having a pallet length and a pallet width, (b.) six shipping containers each having a container length and a container width arranged on the top surface of the pallet in a layer. The containers are arranged in two rows, each row having three containers. Each of the six shipping containers has its container width extend in the direction of a row and in the direction of the pallet width and having its container length extend in the direction of the pallet length. The arrangement further comprises bananas in each container, the bananas disposed in a three-line configuration with their crowns facing down. In some embodiments, it is desirable to have the maximum possible length of a container 10 without overhanging the pallets on which a container or multiple containers are placed. In a preferred embodiment, the dimensions of the container 10 are optimized for use in a particular product market or supply chain. In the case of an exemplary embodiment of the container for use with bananas, where 40-inch by 48-inch pallets are customarily used, the optimum exterior length for a container 10 is about 24 inches (about 60.9 cm) and the optimum exterior width is about 13.33 inches (about 33.9 cm). With these dimensions, the container 10 could be placed on pallets in a six-down configuration, a pallet loading pattern with three (3) containers across the approximately 40-inch dimension of the pallet and two (2) containers across the approximately 48-inch dimension. See FIG. 2 and FIG. 3 for illustrations of a six-down configuration. Although the above specifications for dimensions of pallets and containers are appropriate in North American markets, it will be appreciated that aspects of the invention can be applied to pallets and containers having other dimensions within aspects of the present invention and may be used in other parts of the world and in selected applications in North America.

[0090] In the North American retail supply chain, containers are likely to be mixed with conventional RPCs that are only about 23.5 inches (about 60 cm) in exterior length (i.e., maximum exterior length). Accordingly, it is desirable for the container 10 to be about 24 inches long (i.e., maximum exterior length) when erected and filled with bananas, but only about 23.5 inches long when folded down to facilitate mixing of empty folded crates on pallets. In some embodiments, the novel design approach accomplishes the increased length when erected, but does so without increasing the height of folded containers 10 to optimize the number of containers 10 that can be packed on pallets for return. FIG. 10a depicts the profile of one end of the container when in the collapsed configuration. FIG. 10b depicts the profile of the same end of the container when in the erected configuration, showing the additional length of the container in the erected configuration when compared to the length of the container in the collapsed configuration. That is, a maximum exterior length between opposite walls of the container is greater than the maximum length of the base. It is to be appreciated that, as a result of the exterior dimension being greater, a corresponding interior dimension can be increased. The approximately 24-inch length when erected maximizes banana capacity and eliminates pallet underhang that exists with other RPCs. These dimensions also close gaps between pallets for better transport stability and airflow. This brings the added benefit that corner boards can be properly used to prevent the flow of air between pallet loads in ripening rooms, so that ripening can be more precisely controlled. In some embodiments, a maximum, exterior width between opposite walls of the container is greater than the maximum width of the base. It will be appreciated that collapsible containers according to aspects of the present invention may have dimensions as set forth above or other dimension for use in North America or other markets.

[0091] In a preferred embodiment, a container 10 with an exterior measuring approximately 24 inches long by approximately 13.33 inches wide results in interior dimensions that facilitate packing of three (3) longer lines of curved fruit (e.g., bananas) per container. Three (3) lines don't pile as tall as the four-line arrangement commonly used in conventional banana containers, and this lower packing height results in less high pack damage to the banana in the container. FIG. 9a depicts the first line of packing of bananas. FIG. 9b depicts the second line of bananas packed over the first line, partially overlapping it. Finally, FIG. 9c depicts the third line of bananas packed, which also partially overlaps the first line. A preferred embodiment also includes added height to the container 10 to prevent high pack damage, with the preferred exterior height for a container for bananas being approximately 9.66 inches.

[0092] In a preferred embodiment, the container 10 includes some extra material 60 in its dimensions to promote easier stacking without the need for perfect alignment. In an exemplary embodiment, this lead-in material 60 includes about inch to inch lead-in in both the length and width dimensions for easier stacking. Exemplary containers can also be slid in and out of place for easier stacking and de-stacking as a result of this lead-in material.

[0093] In another embodiment, the endwalls 12 and sidewalls 11 are optimized for the storage of transportation of pineapples, specifically through the use of wall shaping and recessed areas designed to protect the barrels and crowns of pineapples, and the ability to adjust the height of the container 10 at the time of packing to closely fit the pineapples in the container.

[0094] While the application has been described in terms of various specific and preferred embodiments, the skilled artisan will appreciate that various modifications, substitutions, omissions, and changes may be made without departing from the spirit thereof. Accordingly, it is intended that the scope of the present application be limited solely by the scope of the following claims, including equivalents thereof.