US20100132311A1 - Crate for containers - Google Patents
Crate for containers Download PDFInfo
- Publication number
- US20100132311A1 US20100132311A1 US12/697,577 US69757710A US2010132311A1 US 20100132311 A1 US20100132311 A1 US 20100132311A1 US 69757710 A US69757710 A US 69757710A US 2010132311 A1 US2010132311 A1 US 2010132311A1
- Authority
- US
- United States
- Prior art keywords
- crate
- bottles
- walls
- divider
- pockets
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
- B65D1/00—Containers having bodies formed in one piece, e.g. by casting metallic material, by moulding plastics, by blowing vitreous material, by throwing ceramic material, by moulding pulped fibrous material, by deep-drawing operations performed on sheet material
- B65D1/34—Trays or like shallow containers
- B65D1/36—Trays or like shallow containers with moulded compartments or partitions
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
- B65D1/00—Containers having bodies formed in one piece, e.g. by casting metallic material, by moulding plastics, by blowing vitreous material, by throwing ceramic material, by moulding pulped fibrous material, by deep-drawing operations performed on sheet material
- B65D1/22—Boxes or like containers with side walls of substantial depth for enclosing contents
- B65D1/24—Boxes or like containers with side walls of substantial depth for enclosing contents with moulded compartments or partitions
- B65D1/243—Crates for bottles or like containers
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
- B65D71/00—Bundles of articles held together by packaging elements for convenience of storage or transport, e.g. portable segregating carrier for plural receptacles such as beer cans or pop bottles; Bales of material
- B65D71/70—Trays provided with projections or recesses in order to assemble multiple articles, e.g. intermediate elements for stacking
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
- B65D2501/00—Containers having bodies formed in one piece
- B65D2501/24—Boxes or like containers with moulded compartments or partitions
- B65D2501/24006—Details relating to bottle crates
- B65D2501/24012—Materials
- B65D2501/24019—Mainly plastics
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
- B65D2501/00—Containers having bodies formed in one piece
- B65D2501/24—Boxes or like containers with moulded compartments or partitions
- B65D2501/24006—Details relating to bottle crates
- B65D2501/2405—Construction
- B65D2501/24063—Construction of the walls
- B65D2501/24082—Plain
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
- B65D2501/00—Containers having bodies formed in one piece
- B65D2501/24—Boxes or like containers with moulded compartments or partitions
- B65D2501/24006—Details relating to bottle crates
- B65D2501/2405—Construction
- B65D2501/24063—Construction of the walls
- B65D2501/24089—Height of the side walls
- B65D2501/24108—Height of the side walls corresponding to part of the height of the bottles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
- B65D2501/00—Containers having bodies formed in one piece
- B65D2501/24—Boxes or like containers with moulded compartments or partitions
- B65D2501/24006—Details relating to bottle crates
- B65D2501/2405—Construction
- B65D2501/24121—Construction of the bottom
- B65D2501/24127—Apertured
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
- B65D2501/00—Containers having bodies formed in one piece
- B65D2501/24—Boxes or like containers with moulded compartments or partitions
- B65D2501/24006—Details relating to bottle crates
- B65D2501/2405—Construction
- B65D2501/24121—Construction of the bottom
- B65D2501/2414—Plain
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
- B65D2501/00—Containers having bodies formed in one piece
- B65D2501/24—Boxes or like containers with moulded compartments or partitions
- B65D2501/24006—Details relating to bottle crates
- B65D2501/24197—Arrangements for locating the bottles
- B65D2501/24203—Construction of locating arrangements
- B65D2501/2421—Partitions
- B65D2501/24222—Partitions forming cells having a curved shape
Definitions
- the present invention relates generally to a crate for use in retaining and transporting beverage bottles or other containers.
- Plastic soft drink bottles such as two-liter PET (polyethylene terephthalate) bottles
- the crates of bottles are often stacked during transportation and display at the store.
- Typical crates are injection molded with ribs reinforcing a bottom wall and double walls around the periphery of the bottom wall. These crates are relatively stiff and strong to improve the stackability of the loaded crates. These crates are also durable enough to be returned, washed and reused multiple times. Eventually, damaged or worn crates are recyclable. However, it is not possible or practical for the empty crates to be returned, such as in stores where the customers carry the bottles from the store in the crates.
- Another common packaging for soft drink bottles is corrugated cardboard, with or without plastic wrap securing the bottles to the cardboard.
- the cardboard is light and inexpensive, but it is not reusable.
- the present invention provides a crate that is less expensive, lighter and smaller than the current reusable crates, but unlike the cardboard packaging, is also recyclable and can be made from 100% recycled beverage bottle materials.
- the crate includes a single sheet that may be thermoformed to include pockets for receiving two-liter bottles.
- the crate is not sufficiently strong and stiff by itself to independently support the bottles when stacked. Rather, tight tolerances between bottles and the walls of the pockets and the interaction of the hoop strength of the peripheral wall with the bottles makes the crate and bottles as a unit sufficiently strong and stiff for stacking, carrying and shipping.
- the crate lacks the reinforcement of the known reusable crates, it is lighter and less expensive.
- the crate is also recyclable and can be molded from 100% recycled materials, such as recycled PET bottles.
- the crate can be thermoformed, which means that several versions can be made on the same tooling. For example, by using thermoformable sheets of higher thicknesses, a reusable crate may be formed. Thinner sheets can be formed into single-use crates.
- FIG. 1 is a perspective view of the crate according to one embodiment of the present invention.
- FIG. 2 is a top view of the crate of the FIG. 1 .
- FIG. 3 is a side view of the crate of FIG. 1 .
- FIG. 4 is a front view of the crate of FIG. 1 .
- FIG. 5 is a perspective view of the crate of FIG. 1 with a similar crate nested therein.
- FIG. 6 is a section view taken along line 6 - 6 of FIG. 5 .
- FIG. 7 is a section view taken along line 7 - 7 of FIG. 5 .
- FIG. 8 is a perspective view of the crate of FIG. 1 loaded with bottles.
- FIG. 9 is a section view taken along line 9 - 9 of FIG. 8 .
- FIG. 10 is a perspective view of the loaded crate of FIG. 8 stacked on a similar loaded crate.
- FIG. 11 is a perspective view of crate according to a second embodiment of the present invention.
- FIG. 12 is a perspective view of a crate according to a third embodiment of the present invention.
- FIG. 13 is a section view of a crate being thermoformed.
- FIG. 14 is a perspective view a crate according to a fourth embodiment of the present invention.
- FIG. 15 is a bottom perspective view of the crate of FIG. 14 .
- FIG. 16 is a perspective view of a crate according to a fifth embodiment of the present invention.
- FIG. 17 is a bottom perspective view of the crate of FIG. 16 .
- FIG. 18 is a perspective view of a crate according to a sixth embodiment of the present invention.
- FIG. 19 is a perspective view of a crate according to a seventh embodiment of the present invention.
- FIG. 1 A crate 10 according to a first embodiment of the present invention is shown in FIG. 1 .
- the crate 10 is a single thermoformed sheet having a plurality of bottle-receiving pockets 12 each defined by a bottom wall 14 and a generally curved annular pocket wall 16 .
- the pockets 12 are separated by a plurality of lateral dividers 18 and a longitudinal divider 20 in a two-by-four arrangement. Although other arrangements may be utilized, the two-by-four arrangement has been generally found to be convenient for two-liter bottles.
- the crate 10 further includes alternating first upper side walls 22 and second upper side walls 23 .
- the first upper side walls 22 are generally flat and extend upward and outward from the lateral dividers 18 .
- the second upper side walls 23 are generally concave and further define the pockets 12 .
- Each end of the crate 10 further includes a generally flat first upper end wall 24 extending upward and outward from the longitudinal divider 20 and generally concave second upper end walls 25 on either side of the first upper end wall 24 to further define the pockets 12 .
- a peripheral lip 26 protrudes outwardly and then downwardly from the uppermost edge of the peripheral wall (formed by the first upper side walls 22 and second upper side walls 23 ) of the crate 10 .
- Optional nesting stops 28 protrude outwardly from lower portions of the second upper side walls 23 .
- the longitudinal divider 20 extends from one first upper end wall 24 to the other.
- the lateral dividers 18 each extend from one of the first upper side walls 22 to an opposite first upper side wall 22 .
- the four non-corner pockets 12 are defined by the respective bottom wall 14 , the pocket wall 16 extending upward from the periphery of the bottom wall 14 and the second upper side wall 23 extending upward from a portion of the pocket wall 16 .
- the four corner pockets 12 are additionally defined by the second upper end wall 25 extending upward from a portion of the pocket wall 16 and contiguous with the second upper side wall 23 .
- the generally annular pocket walls 16 are curved and taper down to the bottom wall 14 for each pocket 12 .
- the peripheral lip 26 protrudes outward from the ends of the crate 10 (as seen in FIG. 3 ) more than the sides (as seen in FIG. 4 ).
- FIG. 5 is a perspective view of the crate 10 of FIG. 1 with a similar crate 10 ′ nested therein.
- the crate 10 ′ in this example is identical to the crate 10 , and corresponding reference numerals with a prime designation will be used in reference to corresponding parts.
- the crates 10 , 10 ′ can be nested in such a manner so that they occupy less space.
- the nesting stops 28 ′ contact the peripheral lip 26 of the lower crate 10 to prevent the crates 10 , 10 ′ from nesting together too tightly so that they are hard to separate.
- the nesting stops 28 ′ may not be necessary in some embodiments of the present invention.
- FIG. 6 is a section view taken along line 6 - 6 of FIG. 5 through the nested crates 10 , 10 ′.
- FIG. 7 is a section view taken along line 7 - 7 of FIG. 5 .
- the bottom walls 14 each include a recess 36 on the underside for receiving a bottle cap of a bottle on which the crate 10 is stacked.
- the bottom walls 14 include a narrow annular recess 54 , which forms an annular rib 56 on the under side of the bottom wall 14 .
- the annular ribs 56 receive the bottle caps of the bottles on which the crate 10 is stacked.
- FIG. 8 is a perspective view of the crate 10 loaded with bottles 50 , which in this example are two-liter PET bottles 50 .
- the bottles 50 fit snugly in the pockets 12 of the crate 10 and contact one another in the crate 10 .
- the bottles 50 are in contact with one another and are in contact with upper portions of the second upper side walls 23 , particularly adjacent the portion of the second upper side wall 23 from which the peripheral lip 26 extends.
- the snug fit of the bottles 50 inside the crate 10 gives the crate 10 and bottles 50 as a unit the necessary stiffness for handling and stacking.
- FIG. 9 is a section view taken along line 9 - 9 of FIG. 8 .
- the contours of the second upper side wall 23 and the pocket wall 16 match the walls of the bottles 50 .
- the bottles 50 contact one another over the divider 20 (over the later dividers 18 also).
- the bottles 50 also contact the upper portions of the walls adjacent the peripheral lip 26 .
- the bottom wall 14 includes an upward generally conical projection 51 that protrudes upwardly into a recess 52 in the bottom of the bottle 50 .
- the conical projection 51 preferably mates with the recess 52 in the bottom of the bottle 50 as closely as possible, to reduce the stress that would be acting on the bottom wall 14 from the pulling (stretching) when the crate 10 is resting on a bottlecap of a bottle below, as shown in FIG. 10 .
- FIG. 10 is a perspective view of the loaded crate 10 of FIG. 8 stacked on a similar loaded crate 10 ′.
- the bottle caps of the bottles 50 are received in the recesses 36 ( FIG. 9 ) to improve the stability of the stacked crates 10 , 10 ′.
- FIG. 11 is a perspective view of crate 110 according to a second embodiment of the present invention.
- the crate 110 is identical to the crate 10 of FIGS. 1-10 , with corresponding parts having corresponding reference numerals preappended with a “1.”
- the crate 110 includes a center lateral divider 118 A that extends upward to the uppermost edge of the crate 110 to further reinforce the side walls.
- the crate 110 includes eight “corner” pockets 112 , with the center lateral divider 118 A acting as another “end wall” to the two adjacent pairs of pockets 112 .
- the bottles 50 (not shown in FIG. 11 ) would not directly contact one another across the center divider 118 A.
- the upper horizontal wall portion of the center divider 118 A would contact the bottles 50 in the adjacent pockets 112 to provide stability to the crate 110 when loaded.
- FIG. 12 is a perspective view of a crate 210 according to a third embodiment of the present invention, in which all three lateral dividers 218 extend upward to the uppermost edge of the crate 210 (like the center lateral divider 118 A of FIG. 11 ) to further improve the stability of side walls of the crate 210 .
- all three embodiments of the crate 10 , 110 , 210 may be formed from recycled PET bottles 50 or other plastic material.
- the crates 10 , 110 , 210 may be thermoformed on the same thermoforming form 301 from sheets 300 that are of varying thicknesses, depending on how the crates 10 , 110 , 210 will be used (whether the crates will be reused, the degree of stacking, etc), such as 0.040′′, 0.050′′ or 0.060′′. Thicker sheets 300 could be used to create a stiffer, reusable crate capable of higher stacking.
- the plastic sheet 300 is heated and then placed on the form 301 .
- a vacuum may be used to draw the sheet 300 against the form 301 .
- the formed sheet 300 is then removed (and trimmed, if necessary) to form the crate 10 , 110 , 210 .
- FIG. 14 illustrates a crate 310 according to a fourth embodiment of the present invention.
- the crate 310 is similar to the crate of FIG. 11 , except as follows.
- the center divider 318 A includes a plurality of scallops 340 across the top of the divider.
- the scallops 340 reinforce the center divider 318 A against bending about its axis (i.e. the scallops 340 prevent the four bottles on one side of the center divider 318 A from pivoting about the center divider 318 A relative to the four bottles on the other side of the center divider 318 A).
- the diamond shaped intersection 342 between the lateral dividers 318 and the longitudinal dividers 320 each include a diamond shaped recess 344 .
- the diamond shaped recess 344 includes substantially vertical interior peripheral walls 346 connected to a substantially horizontal bottom wall 348 .
- the peripheral walls 346 resist bending of the crate 310 about the axis of the lateral dividers 318 and the longitudinal dividers 320 .
- the bottom walls 314 of the pockets 312 include a narrow annular recess 354 , which forms an annular rib 356 on the under side of the bottom wall 314 , as shown in FIG. 15 .
- the annular rib 356 provides improved interlocking of the bottom wall 314 with the bottle caps of the bottles on which the crate 310 is stacked.
- the annular rib 356 feature may be used in any of the crates disclosed herein.
- FIG. 16 A crate 410 according to a fifth embodiment of the present invention is shown in FIG. 16 .
- This crate 410 is similar to that of FIGS. 14 and 15 except as follows.
- the center divider 418 A includes a substantially horizontal upper surface 460 that includes two narrow portions 462 and a wide center portion 464 .
- the center portion 464 is divided by a longitudinal channel 466 defined by substantially vertical walls 468 continuous with the upper surface 460 of the center divider 418 A, and a bottom wall 470 continuous with the vertical walls 468 .
- the substantially vertical walls 468 provide even more reinforcement to the crate 410 against pivoting about the axis of the center divider 418 A.
- the wide portion 464 of the center divider 418 A provides increased contact of the center divider 418 A with the bottles in the adjacent pockets 412 and permits the substantially vertical walls 468 to be longer.
- a pair of recesses are formed in the outer portions of the upper surface 460 of the center divider 418 A.
- These recesses 472 each include a substantially vertical peripheral walls 474 extending downward to a substantially horizontal bottom wall 476 .
- the peripheral walls 474 provide further reinforcement to the crate 410 against bending about the axis of the center divider 418 A.
- FIG. 17 further illustrates the recess 472 .
- FIG. 18 illustrates a crate 510 according to a sixth embodiment of the present invention.
- the crate 510 is substantially similar to the crate 10 of FIG. 1 , except as follows.
- the diamond shaped intersections 542 between the lateral dividers 518 and the longitudinal dividers 520 each Finclude an upwardly projecting pylon 580 having a substantially horizontal upper surface 581 and substantially vertical (although somewhat tapered, to the extent required for thermoforming) peripheral walls 582 .
- the peripheral walls 582 include alternating concave portions 584 aligned with each of the pockets 512 and flat portions 586 aligned with the lateral dividers 518 and longitudinal dividers 520 .
- the peripheral walls 582 of the pylons 580 provide additional support to the bottles in the pockets 512 and provide resistance to bending of the crate 510 about any of the lateral dividers 518 or the longitudinal dividers 520 .
- FIG. 19 A crate 610 according to a seventh embodiment of the present invention is shown in FIG. 19 .
- the crate 610 includes a center lateral divider 618 A, which includes a substantially horizontal upper surface 660 having a center wider portion 664 and two narrow portions 662 aligned with the pockets 612 .
- the center divider 618 A may be like the center divider 318 A of FIG. 14 or the center divider 418 A of FIG. 16 .
- the lateral dividers 618 A and longitudinal dividers 620 are truncated to leave a substantially flat, horizontal common surface 690 joining the bottom walls 614 of each of the pockets 612 .
- the pockets 612 are oriented such that the bottles (not shown) in the pockets 612 would all be in snug contact with one another to provide strength to the loaded crate 610 .
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Ceramic Engineering (AREA)
- Details Of Rigid Or Semi-Rigid Containers (AREA)
- Stackable Containers (AREA)
- Rigid Containers With Two Or More Constituent Elements (AREA)
- Containers Having Bodies Formed In One Piece (AREA)
Abstract
A crate includes a bottom wall including a plurality of dividers defining a plurality of container pockets and a peripheral wall extending upward from a periphery of the bottom wall. The bottom wall and peripheral wall are thermoformed from a single sheet of plastic, such as recycled PET bottles.
Description
- This application is a continuation of co-pending U.S. patent application Ser. No. 11/562,052, which was filed Nov. 21, 2006.
- The present invention relates generally to a crate for use in retaining and transporting beverage bottles or other containers.
- Plastic soft drink bottles, such as two-liter PET (polyethylene terephthalate) bottles, are often packaged in crates for storage and shipment to the stores. The crates of bottles are often stacked during transportation and display at the store. Typical crates are injection molded with ribs reinforcing a bottom wall and double walls around the periphery of the bottom wall. These crates are relatively stiff and strong to improve the stackability of the loaded crates. These crates are also durable enough to be returned, washed and reused multiple times. Eventually, damaged or worn crates are recyclable. However, it is not possible or practical for the empty crates to be returned, such as in stores where the customers carry the bottles from the store in the crates.
- Another common packaging for soft drink bottles is corrugated cardboard, with or without plastic wrap securing the bottles to the cardboard. The cardboard is light and inexpensive, but it is not reusable.
- The present invention provides a crate that is less expensive, lighter and smaller than the current reusable crates, but unlike the cardboard packaging, is also recyclable and can be made from 100% recycled beverage bottle materials.
- The crate includes a single sheet that may be thermoformed to include pockets for receiving two-liter bottles. The crate is not sufficiently strong and stiff by itself to independently support the bottles when stacked. Rather, tight tolerances between bottles and the walls of the pockets and the interaction of the hoop strength of the peripheral wall with the bottles makes the crate and bottles as a unit sufficiently strong and stiff for stacking, carrying and shipping.
- Because the crate lacks the reinforcement of the known reusable crates, it is lighter and less expensive. However, the crate is also recyclable and can be molded from 100% recycled materials, such as recycled PET bottles. The crate can be thermoformed, which means that several versions can be made on the same tooling. For example, by using thermoformable sheets of higher thicknesses, a reusable crate may be formed. Thinner sheets can be formed into single-use crates.
- Other advantages of the present invention can be understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein:
-
FIG. 1 is a perspective view of the crate according to one embodiment of the present invention. -
FIG. 2 is a top view of the crate of theFIG. 1 . -
FIG. 3 is a side view of the crate ofFIG. 1 . -
FIG. 4 is a front view of the crate ofFIG. 1 . -
FIG. 5 is a perspective view of the crate ofFIG. 1 with a similar crate nested therein. -
FIG. 6 is a section view taken along line 6-6 ofFIG. 5 . -
FIG. 7 is a section view taken along line 7-7 ofFIG. 5 . -
FIG. 8 is a perspective view of the crate ofFIG. 1 loaded with bottles. -
FIG. 9 is a section view taken along line 9-9 ofFIG. 8 . -
FIG. 10 is a perspective view of the loaded crate ofFIG. 8 stacked on a similar loaded crate. -
FIG. 11 is a perspective view of crate according to a second embodiment of the present invention. -
FIG. 12 is a perspective view of a crate according to a third embodiment of the present invention. -
FIG. 13 is a section view of a crate being thermoformed. -
FIG. 14 is a perspective view a crate according to a fourth embodiment of the present invention. -
FIG. 15 is a bottom perspective view of the crate ofFIG. 14 . -
FIG. 16 is a perspective view of a crate according to a fifth embodiment of the present invention. -
FIG. 17 is a bottom perspective view of the crate ofFIG. 16 . -
FIG. 18 is a perspective view of a crate according to a sixth embodiment of the present invention. -
FIG. 19 is a perspective view of a crate according to a seventh embodiment of the present invention. - A
crate 10 according to a first embodiment of the present invention is shown inFIG. 1 . Thecrate 10 is a single thermoformed sheet having a plurality of bottle-receivingpockets 12 each defined by abottom wall 14 and a generally curvedannular pocket wall 16. Thepockets 12 are separated by a plurality oflateral dividers 18 and alongitudinal divider 20 in a two-by-four arrangement. Although other arrangements may be utilized, the two-by-four arrangement has been generally found to be convenient for two-liter bottles. - The
crate 10 further includes alternating firstupper side walls 22 and secondupper side walls 23. The firstupper side walls 22 are generally flat and extend upward and outward from thelateral dividers 18. The secondupper side walls 23 are generally concave and further define thepockets 12. - Each end of the
crate 10 further includes a generally flat firstupper end wall 24 extending upward and outward from thelongitudinal divider 20 and generally concave secondupper end walls 25 on either side of the firstupper end wall 24 to further define thepockets 12. - A
peripheral lip 26 protrudes outwardly and then downwardly from the uppermost edge of the peripheral wall (formed by the firstupper side walls 22 and second upper side walls 23) of thecrate 10. Optional nesting stops 28 protrude outwardly from lower portions of the secondupper side walls 23. - Referring to
FIG. 2 , thelongitudinal divider 20 extends from one firstupper end wall 24 to the other. Thelateral dividers 18 each extend from one of the firstupper side walls 22 to an opposite firstupper side wall 22. The fournon-corner pockets 12 are defined by therespective bottom wall 14, thepocket wall 16 extending upward from the periphery of thebottom wall 14 and the secondupper side wall 23 extending upward from a portion of thepocket wall 16. The fourcorner pockets 12 are additionally defined by the secondupper end wall 25 extending upward from a portion of thepocket wall 16 and contiguous with the secondupper side wall 23. - Referring to
FIGS. 3 and 4 , the generallyannular pocket walls 16 are curved and taper down to thebottom wall 14 for eachpocket 12. Theperipheral lip 26 protrudes outward from the ends of the crate 10 (as seen inFIG. 3 ) more than the sides (as seen inFIG. 4 ). -
FIG. 5 is a perspective view of thecrate 10 ofFIG. 1 with asimilar crate 10′ nested therein. Thecrate 10′ in this example is identical to thecrate 10, and corresponding reference numerals with a prime designation will be used in reference to corresponding parts. When empty, thecrates peripheral lip 26 of thelower crate 10 to prevent thecrates -
FIG. 6 is a section view taken along line 6-6 ofFIG. 5 through the nestedcrates FIG. 7 is a section view taken along line 7-7 ofFIG. 5 . Referring toFIGS. 6 and 7 , the overall height of thestacked crates bottom walls 14 each include arecess 36 on the underside for receiving a bottle cap of a bottle on which thecrate 10 is stacked. Thebottom walls 14 include a narrowannular recess 54, which forms anannular rib 56 on the under side of thebottom wall 14. Theannular ribs 56 receive the bottle caps of the bottles on which thecrate 10 is stacked. -
FIG. 8 is a perspective view of thecrate 10 loaded withbottles 50, which in this example are two-liter PET bottles 50. Thebottles 50 fit snugly in thepockets 12 of thecrate 10 and contact one another in thecrate 10. Thebottles 50 are in contact with one another and are in contact with upper portions of the secondupper side walls 23, particularly adjacent the portion of the secondupper side wall 23 from which theperipheral lip 26 extends. The snug fit of thebottles 50 inside thecrate 10 gives thecrate 10 andbottles 50 as a unit the necessary stiffness for handling and stacking. -
FIG. 9 is a section view taken along line 9-9 ofFIG. 8 . The contours of the secondupper side wall 23 and thepocket wall 16 match the walls of thebottles 50. Thebottles 50 contact one another over the divider 20 (over thelater dividers 18 also). Thebottles 50 also contact the upper portions of the walls adjacent theperipheral lip 26. Thebottom wall 14 includes an upward generallyconical projection 51 that protrudes upwardly into arecess 52 in the bottom of thebottle 50. Theconical projection 51 preferably mates with therecess 52 in the bottom of thebottle 50 as closely as possible, to reduce the stress that would be acting on thebottom wall 14 from the pulling (stretching) when thecrate 10 is resting on a bottlecap of a bottle below, as shown inFIG. 10 . -
FIG. 10 is a perspective view of the loadedcrate 10 ofFIG. 8 stacked on a similar loadedcrate 10′. The bottle caps of thebottles 50 are received in the recesses 36 (FIG. 9 ) to improve the stability of thestacked crates -
FIG. 11 is a perspective view ofcrate 110 according to a second embodiment of the present invention. To the extent not otherwise described or shown, thecrate 110 is identical to thecrate 10 ofFIGS. 1-10 , with corresponding parts having corresponding reference numerals preappended with a “1.” In this embodiment, thecrate 110 includes a centerlateral divider 118A that extends upward to the uppermost edge of thecrate 110 to further reinforce the side walls. Thus, thecrate 110 includes eight “corner” pockets 112, with the centerlateral divider 118A acting as another “end wall” to the two adjacent pairs ofpockets 112. Unlike thefirst embodiment crate 10, the bottles 50 (not shown inFIG. 11 ) would not directly contact one another across thecenter divider 118A. The upper horizontal wall portion of thecenter divider 118A would contact thebottles 50 in theadjacent pockets 112 to provide stability to thecrate 110 when loaded. -
FIG. 12 is a perspective view of acrate 210 according to a third embodiment of the present invention, in which all threelateral dividers 218 extend upward to the uppermost edge of the crate 210 (like the centerlateral divider 118A ofFIG. 11 ) to further improve the stability of side walls of thecrate 210. - Referring to
FIG. 13 , all three embodiments of thecrate recycled PET bottles 50 or other plastic material. Thecrates same thermoforming form 301 fromsheets 300 that are of varying thicknesses, depending on how thecrates Thicker sheets 300 could be used to create a stiffer, reusable crate capable of higher stacking. As is known generally in thermoforming, theplastic sheet 300 is heated and then placed on theform 301. A vacuum may be used to draw thesheet 300 against theform 301. The formedsheet 300 is then removed (and trimmed, if necessary) to form thecrate -
FIG. 14 illustrates acrate 310 according to a fourth embodiment of the present invention. Thecrate 310 is similar to the crate ofFIG. 11 , except as follows. First, thecenter divider 318A includes a plurality ofscallops 340 across the top of the divider. Thescallops 340 reinforce thecenter divider 318A against bending about its axis (i.e. thescallops 340 prevent the four bottles on one side of thecenter divider 318A from pivoting about thecenter divider 318A relative to the four bottles on the other side of thecenter divider 318A). - Additionally, the diamond shaped
intersection 342 between thelateral dividers 318 and thelongitudinal dividers 320 each include a diamond shapedrecess 344. The diamond shapedrecess 344 includes substantially vertical interiorperipheral walls 346 connected to a substantially horizontalbottom wall 348. Theperipheral walls 346 resist bending of thecrate 310 about the axis of thelateral dividers 318 and thelongitudinal dividers 320. - The
bottom walls 314 of thepockets 312 include a narrowannular recess 354, which forms anannular rib 356 on the under side of thebottom wall 314, as shown inFIG. 15 . Theannular rib 356 provides improved interlocking of thebottom wall 314 with the bottle caps of the bottles on which thecrate 310 is stacked. Theannular rib 356 feature may be used in any of the crates disclosed herein. - A
crate 410 according to a fifth embodiment of the present invention is shown inFIG. 16 . Thiscrate 410 is similar to that ofFIGS. 14 and 15 except as follows. The center divider 418A includes a substantially horizontalupper surface 460 that includes twonarrow portions 462 and awide center portion 464. Thecenter portion 464 is divided by alongitudinal channel 466 defined by substantiallyvertical walls 468 continuous with theupper surface 460 of thecenter divider 418A, and abottom wall 470 continuous with thevertical walls 468. The substantiallyvertical walls 468 provide even more reinforcement to thecrate 410 against pivoting about the axis of thecenter divider 418A. Thewide portion 464 of thecenter divider 418A provides increased contact of thecenter divider 418A with the bottles in theadjacent pockets 412 and permits the substantiallyvertical walls 468 to be longer. - A pair of recesses are formed in the outer portions of the
upper surface 460 of thecenter divider 418A. Theserecesses 472 each include a substantially verticalperipheral walls 474 extending downward to a substantially horizontalbottom wall 476. Theperipheral walls 474 provide further reinforcement to thecrate 410 against bending about the axis of thecenter divider 418A.FIG. 17 further illustrates therecess 472. -
FIG. 18 illustrates acrate 510 according to a sixth embodiment of the present invention. Thecrate 510 is substantially similar to thecrate 10 ofFIG. 1 , except as follows. The diamond shapedintersections 542 between thelateral dividers 518 and thelongitudinal dividers 520 each Finclude an upwardly projectingpylon 580 having a substantially horizontalupper surface 581 and substantially vertical (although somewhat tapered, to the extent required for thermoforming)peripheral walls 582. Theperipheral walls 582 include alternatingconcave portions 584 aligned with each of thepockets 512 andflat portions 586 aligned with thelateral dividers 518 andlongitudinal dividers 520. Theperipheral walls 582 of thepylons 580 provide additional support to the bottles in thepockets 512 and provide resistance to bending of thecrate 510 about any of thelateral dividers 518 or thelongitudinal dividers 520. - A
crate 610 according to a seventh embodiment of the present invention is shown inFIG. 19 . Thecrate 610 includes a center lateral divider 618A, which includes a substantially horizontalupper surface 660 having a centerwider portion 664 and twonarrow portions 662 aligned with thepockets 612. Optionally, the center divider 618A may be like thecenter divider 318A ofFIG. 14 or thecenter divider 418A ofFIG. 16 . - In this embodiment, the lateral dividers 618A and
longitudinal dividers 620 are truncated to leave a substantially flat, horizontalcommon surface 690 joining thebottom walls 614 of each of thepockets 612. Thepockets 612 are oriented such that the bottles (not shown) in thepockets 612 would all be in snug contact with one another to provide strength to the loadedcrate 610. - In accordance with the provisions of the patent statutes and jurisprudence, exemplary configurations described above are considered to represent a preferred embodiment of the invention. However, it should be noted that the invention can be practiced otherwise than as specifically illustrated and described without departing from its spirit or scope. Alphanumeric identifiers on method steps are for convenient reference in dependent claims and do not signify a required sequence of performance unless otherwise indicated in the claims.
Claims (10)
1. A method including the steps of:
heating a plastic sheet;
forming the plastic sheet to create a crate comprising a plurality of container pockets having bottom walls and a plurality of upper side walls extending upwardly from the plurality of bottom walls, the upper side walls defining a peripheral wall extending about an outer periphery of the crate; and
placing a plurality of bottles within the crate such that every bottle within the crate is in direct contact with a portion of the peripheral wall, and such that every bottle within the crate is in direct contact with at least two others of the plurality of bottles.
2. The method of claim 1 wherein each one of the plurality of bottles is received within a respective one of the plurality of container pockets.
3. The method of claim 2 wherein a lip is formed to protrude outwardly from an upper edge of the peripheral wall.
4. The method of claim 1 further including the step of forming at least one divider such that the divider is contiguous with the bottom walls and further defines the container pockets.
5. The method of claim 4 wherein the at least one divider includes a pair of spaced apart walls, each spaced apart wall defining a portion of a respective container pocket.
6. A method including the steps of:
(a) heating a sheet of recycled plastic;
(b) forming the recycled plastic sheet to create a crate including a plurality of walls defining the outer periphery of the crate; and
(c) placing a plurality of bottles within the crate at a first location such that each one of the plurality of bottles is in direct contact with a portion of one of the plurality of walls, and such that each one of the plurality of bottles is in direct contact with at least two others of the plurality of bottles.
7. The method of claim 6 wherein after said step (c):
(d) transporting bottles and crate from a first location to a second location; and
(e) removing the bottles from the crate at the second location.
8. The method of claim 7 wherein after said step (e):
(f) recycling the crate.
9. The method of claim 7 wherein after said step (e):
(g) repeating said steps (c)-(e) a desired number of times.
10. The method of claim 6 wherein said step (a) includes that the sheet of recycled plastic is formed from a plurality of recycled PET bottles.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US12/697,577 US20100132311A1 (en) | 2006-11-21 | 2010-02-01 | Crate for containers |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US11/562,052 US7677405B2 (en) | 2006-11-21 | 2006-11-21 | Crate for containers |
US12/697,577 US20100132311A1 (en) | 2006-11-21 | 2010-02-01 | Crate for containers |
Related Parent Applications (1)
Application Number | Title | Priority Date | Filing Date |
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US11/562,052 Continuation US7677405B2 (en) | 2006-11-21 | 2006-11-21 | Crate for containers |
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US20100132311A1 true US20100132311A1 (en) | 2010-06-03 |
Family
ID=39203283
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US12/697,577 Abandoned US20100132311A1 (en) | 2006-11-21 | 2010-02-01 | Crate for containers |
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Application Number | Title | Priority Date | Filing Date |
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US11/562,052 Expired - Fee Related US7677405B2 (en) | 2006-11-21 | 2006-11-21 | Crate for containers |
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US (2) | US7677405B2 (en) |
EP (1) | EP2084072A1 (en) |
CA (1) | CA2670323A1 (en) |
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US8607971B2 (en) | 2007-09-27 | 2013-12-17 | Orbis Canada Limited | Bottle crate |
USD749323S1 (en) | 2014-11-10 | 2016-02-16 | Orbis Corporation | Beverage crate |
USD854423S1 (en) | 2016-09-28 | 2019-07-23 | Dean Foods Company | Container tray |
US10730676B2 (en) | 2016-09-28 | 2020-08-04 | Dean Foods Company | Caseless container tray |
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US7677405B2 (en) * | 2006-11-21 | 2010-03-16 | Rehrig Pacific Company | Crate for containers |
MX2009010779A (en) * | 2007-06-25 | 2009-10-29 | Rehrig Pacific Co | Tray for containers. |
US7735676B2 (en) * | 2008-02-18 | 2010-06-15 | Rehrig Pacific Company | Crate for containers |
US8893891B2 (en) | 2008-03-31 | 2014-11-25 | Rehrig Pacific Company | Stackable low depth tray |
PL215291B1 (en) * | 2008-05-28 | 2013-11-29 | Invento Spolka Z Ograniczona Odpowiedzialnoscia | Pallet for transporting and storage of preforms for manufacturing of plastic containers |
US9475602B2 (en) * | 2008-10-06 | 2016-10-25 | Rehrig Pacific Company | Stackable low depth tray |
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US8636142B2 (en) | 2009-09-10 | 2014-01-28 | Rehrig Pacific Company | Stackable low depth tray |
US8109408B2 (en) | 2009-11-16 | 2012-02-07 | Rehrig Pacific Company | Low depth crate |
US9114901B2 (en) | 2011-02-11 | 2015-08-25 | Rehrig Pacific Company | Stackable low depth tray |
CA2837801C (en) | 2013-01-11 | 2015-09-29 | Parmalat Canada Inc. | Stackable trays for jugs, stacked arrangements and stacking methods |
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USD750975S1 (en) | 2013-10-15 | 2016-03-08 | Parmalat Canada Inc. | Tray for jugs |
CA153484S (en) | 2013-10-15 | 2014-11-19 | Parmalat Canada Inc | Tray for jugs |
CA153482S (en) | 2013-10-15 | 2014-11-19 | Parmalat Canada Inc | Tray for jugs |
US11319130B2 (en) | 2014-12-04 | 2022-05-03 | Rehrig Pacific Company | Beverage crate |
CA2917506A1 (en) | 2015-01-14 | 2016-07-14 | Rehrig Pacific Company | Beverage crate with handle |
US10703527B2 (en) | 2017-03-13 | 2020-07-07 | Rehrig Pacific Company | Beverage crate |
USD831962S1 (en) | 2017-12-22 | 2018-10-30 | Rehrig Pacific Company | Beverage crate |
USD843111S1 (en) | 2018-09-04 | 2019-03-19 | Rehrig Pacific Company | Nestable beverage crate |
US11390415B2 (en) | 2018-10-25 | 2022-07-19 | Rehrig Pacific Company | Nestable bottle crate |
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US9174760B2 (en) | 2007-09-27 | 2015-11-03 | Orbis Canada Limited | Bottle crate |
USD749323S1 (en) | 2014-11-10 | 2016-02-16 | Orbis Corporation | Beverage crate |
USD854423S1 (en) | 2016-09-28 | 2019-07-23 | Dean Foods Company | Container tray |
US10730676B2 (en) | 2016-09-28 | 2020-08-04 | Dean Foods Company | Caseless container tray |
US11472619B2 (en) | 2016-09-28 | 2022-10-18 | Dfa Dairy Brands Ip, Llc | Caseless container tray |
USD1007330S1 (en) | 2016-09-28 | 2023-12-12 | Dfa Dairy Brands Ip, Llc | Container tray |
Also Published As
Publication number | Publication date |
---|---|
WO2008063803A1 (en) | 2008-05-29 |
EP2084072A1 (en) | 2009-08-05 |
CA2670323A1 (en) | 2008-05-29 |
MX2009005018A (en) | 2009-05-20 |
US7677405B2 (en) | 2010-03-16 |
US20080116214A1 (en) | 2008-05-22 |
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