BOX WITH LOCKING DIVIDER ELEMENTS

Abstract

The invention relates to a container with divider panels that lock to prevent bending or bulging. The container includes end-to-end divider panels and side-to-side panels with aligned grooves where the panels intersect. The panels include grooves or channels to contain the edges of the intersecting panel grooves, securing the upper or lower portion of the intersecting panel in place.

Description

The present invention is generally directed to containers with divider panels that lock together along the length of the intersection of such panels to prevent bending or folding of the upper or lower portions of the panels, and more particularly to containers with a first divider panel having grooves or channels to lock the edges of a second intersecting divider panel. DESCRIPTION OF THE PREVIOUS TECHNIQUE Boxes and other types of containers with optional divider panels are a primary packaging product used in industry to distribute a wide range of products. These containers are typically provided within a refillable loop system (e.g., an ASRS - Automatic Storage and Retrieval System) where they are used to fulfill inventory orders. The containers often hold and transport multiple SKUs (i.e., codes assigned to a particular product) of different products. To prevent different products within the container from mixing, divider panels are provided to separate and compartmentalize them in different locations. The container may include one or more panels that can be inserted to extend from one end to the other, as well as one or more panels that can be inserted to extend from one side of the container to the other (e.g., perpendicular to the end-to-end panels). Slots are provided in the various panels to allow each panel to interlock with the others where they meet. The dividers separate the container into distinct areas for each of the products loaded. In some instances, the products may shift and become a moving load during transport. This shifting load can create pressure on the upper and lower portions of the divider panels, causing them to flex, bend, or bulge under such side-loading conditions. This can damage the panels and lead to the mixing of products from different sections of the container. ΙΛ / t / ZUZó / U IO IOU The present invention provides a container with divider panels that lock together at the intersecting edges to prevent bending or bulging of the panels during transport. BRIEF DESCRIPTION OF THE INVENTION The present invention relates generally to a box with locking divider elements. The locking elements hold the upper and lower walls of the divider in position and prevent flexing or bending of these walls during load transport. Specifically, the dividers are provided with locking slots or channels that engage the lower or upper end of a divider wall at the length of its intersection with another divider extending perpendicularly to it. The slots or channels also help guide the dividers during assembly, ensuring proper fit and placement. According to one aspect of the invention, a box with dividers having locking elements is provided. The box comprises a container having a first side wall, an opposite second side wall, a first end wall, an opposite second end wall, and a bottom extending between the first and second side walls and the first and second end walls. A first divider extends between the first end wall and the second end wall of the container. The first divider has a first slot extending from an upper edge of the first downspan of the divider to the lower edge of the first divider. A first channel aligned with the first slot extends downward from the bottom of the first slot on a first side of the first divider, and a second channel aligned with the first slot extends downward from the bottom of the first slot on a second side of the first divider.A second divider extends between the first and second side walls. The second divider has a first groove that extends from a lower edge of the second span up the divider to the upper edge of the second divider. The first groove of the second divider includes a first edge configured to engage with the first channel of the first divider and a second edge configured to engage with the second channel of the first divider to prevent flexing of the lower portions of the second divider. The second divider may include a first channel aligned with the first slot of the second divider extending upwards from the top of the first slot on a first side of the second divider, and a second channel aligned with the first slot extending upwards from the top of the first slot on a second side of the second divider. A first edge of IA / t / ZUZÓ / U IO IOU The first slot of the first splitter is configured to couple with the first channel of the second splitter and a second edge of the first slot of the first splitter is configured to couple with the second channel of the second splitter. The first groove of the first divider may include a first projection, and the second edge of the first groove of the first divider may include a second projection. The first and second projections may have a cross-section generally T-shaped with the rest of the first divider, or some other useful shape. The first groove in the first divider is formed from a first rib extending outward from the first side of the first divider and a second rib extending outward from the first side of the first divider and separate from the first rib. Similarly, the second groove in the first divider is formed from a first rib extending outward from the second side of the first divider and a second rib extending outward from the second side of the first divider and separate from the first rib on the second side of the first divider. Furthermore, the first channel in the second divider is formed by a first rib extending outward from the first side of the second divider and a second rib extending outward from the first side of the second divider and separate from the first rib. The second channel in the second divider is formed by a first rib extending outward from the second side of the second divider and a second rib extending outward from the second side of the second divider and separate from the first rib on the second side of the second divider. The first divider may also have a second groove separate from the first groove, extending from an upper edge of the first span down the divider to the lower edge of the first divider. A third channel aligns with the second groove and extends downward from the bottom of the second groove on the first side of the first divider, and a fourth channel also aligns with the second groove and extends downward from the bottom of the second groove on the second side of the divider. Additionally, the container may include a third divider that spans between the first and second side walls. The third divider may have a first slot extending from a lower edge of the third span up the divider to the upper edge of the third divider. The first slot of the third divider includes a first edge configured to engage with the third channel of the first divider and a second edge configured to engage with the fourth channel. IA / t / ZUZó / U IO IOU of the first divider to prevent flexing of the lower portions of the third divider. Additional dividers and / or slots can be used with the channel structures in the container depending on the container size, the size of the products to be transported, the desired number of compartments, etc. The first divider may include a first locking tab at one end to lock it to the first end wall and a second locking tab at the other end to lock it to the second end wall. Similarly, the second divider may include a first locking tab at one end to lock it to the first side wall and a second locking tab at the other end to lock it to the second side wall. Alternatively, the container may include grooves or channels on the inside of the end walls and side walls to lock the edges of the dividers. Preferably, the first slot in the first divider extends approximately halfway between the top and bottom edges of the first divider. Similarly, the first slot in the second divider extends approximately halfway between the top and bottom edges of the second divider. The container and dividers are made from plastic. Other similar or suitable materials can also be used. According to another aspect of the invention, a box with dividers comprises a container having a first side wall, an opposite second side wall, a first end wall, an opposite second end wall, and a bottom portion extending between the first and second side walls and the first and second end walls. A first divider extends between the first end wall and the second end wall of the container and includes a first slot extending from an upper edge of the first section down the divider to a lower edge of the first divider. A second divider extends between the first side wall and the second side wall and includes a first slot extending from a lower edge of the second section up the divider to an upper edge of the second divider.The second divider includes a first channel aligned with the first slot of the second divider and extending upwards from the top of the first slot on a first side of the second divider, and a second channel aligned with the first slot and extending upwards from the top of the first slot on a second side of the second divider. A first edge of the first slot of the first divider is... ΙΛ / t / ZUZó / U IO IOU is configured to couple with the first channel of the second divider and a second edge of the first slot of the first divider is configured to couple with the second channel of the second divider. The first divider may include a first channel aligned with the first slot and extending downward from the bottom of the first slot on a first side of the first divider, and a second channel aligned with the first slot and extending downward from the bottom of the first slot on a second side of the first divider. The first slot of the second divider includes a first lip configured to engage with the first channel of the first divider and a second lip configured to engage with the second channel of the first divider to prevent flexing of the lower portions of the second divider. The first edge of the first groove of the first divider includes a first projection, and the second edge of the first groove of the first divider includes a second projection. The first and second projections may have a cross-sectional shape, generally T-shaped, with the rest of the first divider. The first groove in the second divider can be formed by a first rib extending outward from the first side of the second divider and a second rib extending outward from the first side of the second divider and separate from the first rib. Similarly, the second groove in the second divider can be formed by a first rib extending outward from the second side of the second divider and a second rib extending outward from the second side of the second divider and separate from the first rib on the second side of the second divider. Other features and advantages of the invention will become evident from the following description taken together with the following Figures. BRIEF DESCRIPTION OF THE FIGURES To understand the present invention, it will now be described by way of example, with reference to the accompanying figures in which: Figure 1 is a top perspective view of a typical box with typical, optional, intersecting partition panels that extend end to end and side to side; Figure 2 is a perspective view illustrating the interconnection of slots in the divider panels where they intersect as shown in Figure 1; Figure 3 is a top perspective view illustrating the bending of an upper wall of a partition panel; IA / t / ZUZó / U IO IOU Figure 4 is a top perspective view illustrating the bending of a lower wall of a partition panel; Figures 5A-5B are perspective views of a container with divider panels having locking elements according to the present invention; Figure 6A is a perspective view of the container showing a portion of the top in cross-section; Figure 6B is an enlarged top portion of the cross-sectional view of the partition panels blocking an upper wall to prevent bending according to an aspect of the present invention; Figure 7A is a perspective view of the container showing a lower portion in cross-section; Figure 7B is an enlarged top portion of the cross-sectional view of the partition panels blocking a lower wall to prevent bending according to an aspect of the present invention; Figure 8 is a perspective view of a container with dividers according to the present invention. DETAILED DESCRIPTION OF THE INVENTION Although this invention is susceptible to embodiments of very different forms, the figures shown and described in detail herein are preferred embodiments of the invention, with the understanding that this description should be regarded as an exemplification of the principles of the invention and is not intended to limit the broad scope of the invention to the embodiments illustrated. Figure 1 illustrates a known container 10 having a body formed by a first end wall 12, a second opposite end wall 14, a first side wall 16, and a second opposite side wall 18, all of which extend upwards from a bottom wall 20. The container 10, typically referred to in the industry as a box, is also shown to have a plurality of divider panels 22, 23 separating the interior of the container 10 into a plurality of sections or compartments 24. The container 10 and the divider panels 22, 23 are typically formed from plastic or other similar or suitable materials. The divider panels 22, 23 are optionally added to the inside of the container body when it is desired to create sections or compartments 24 for shipping items that need to be separated. ΙΛ / t / ZUZó / U IO IOU As shown in Figure 1, panels 22 and 23 include a first end-to-end divider panel 22 extending from the first end wall 12 to the second end wall 14, and two side-to-side divider panels 23 extending from the first side wall 16 to the second side wall 18. As illustrated in Figure 2, the first end-to-end divider panel 22 is provided with slots 26 extending approximately halfway along panel 22 from a top edge, and the side-to-side divider panels 23 include slots 28 extending halfway along panel 23 from a bottom edge. Slots 26 and 28 are positioned and configured to intersect where the divider panels 22 and 23 intersect. Slots 26, 28 divide the upper or lower portions of panels 22, 23 into sections (sometimes called pedals) that may flex, bulge, or break when a load is carried in one or more of the compartments 24. Figure 3 illustrates a top wall portion 30 flexing out of flat alignment with the rest of the divider panel 22. Similarly, Figure 4 shows a bottom wall portion 32 bulging from flat alignment. The present invention provides a structure between the edges of the grooves in a panel and the body of an intersecting panel to lock the upper or lower wall portions 30, 32 in place and prevent any bending or bulging of the wall portions. Figures 5A-5B, 6A-6B, 7A-7B and 8 show a container 34 according to the present invention. The container 34 includes a first end wall 36, a second opposite end wall 38, a first side wall 40 and a second side wall 42. All end walls 36, 38 and side walls 40, 42 extend upward from a bottom wall 44. A first end-to-end divider panel 46 is shown extending between the end walls 36, 38 and having three separate slots 48 extending from an upper edge of panel 46 downward to approximately halfway along the lower edge of panel 46 (as used herein, directional or positional words such as upper, lower, top, etc., are made with respect to the structures shown in the figures and in their normal position during use, and are not intended to limit the invention to being in such positions). A first side-to-side divider panel 50 and a second side-to-side divider panel 52 are shown extending from the first side wall 40 to the second side wall 42. Each of the side-to-side divider panels 50, 52 includes a slot 54 extending from the lower edge of the panel upward to approximately halfway along the upper edge of panel 50, 52. ΙΛ / t / ZUZó / U IO IOU Similar to known containers with dividers, the end-to-end divider panel slots and the side-to-side divider panels are positioned to align so that the panels can intersect. However, unlike known containers, the portions of each panel between the slots are not allowed to flex or move freely. Instead, these portions are held in place by structures within the cross panel. Figures 6A-6B provide an enlarged view of an intersection of a top portion of one of the side-to-side divider panels 50, 52 with a top portion of the end-to-end divider panel 46. As shown, the side-to-side divider panel includes a first groove or channel 58 on a first side 60 of the panel and a second groove or channel 62 on a second side 64 of the panel enclosing the edges 66, 68 of one of the grooves 48 of the end-to-end panel 46. The first channel 58 is formed from a first rib 70 extending outward from the first side 60 and a second rib 72 separate from the first rib, extending outward from the first side 60. Similarly, the second channel 62 is formed by a first rib 74 and a second rib 76 extending outward from the second side 64.Edges 66, 68 of the end-to-end divider panel groove 48 are shown with projecting ribs that give edges 66, 68 a generally T-shaped cross-sectional appearance. Channels 58 and 62 hold the upper portions of the end-to-end divider 46 in place and prevent flexing at this location. Each of the side-to-side panels is provided with similar channels to lock the upper portions of the end-to-end divider panel 46 at each slot 48 location. While the edges 66 and 68 of the slots 48 are shown with a T-shaped cross-section, other shapes (including more complex ones) may be used as desired or necessary to maintain the upper portions in a locked configuration, depending on the container size, load, or other factors related to container use. Additionally, the channels may be continuous along the entire length of the slots or intermittent along this length. Similar to the channels formed in the upper portions of the side-to-side divider panels 50, 52, the end-to-end divider panel 46 includes a first groove or channel 78 formed from a first rib 80 and a second rib 82 on a first side 84 of the divider panel 46, and a second groove or channel 86 formed from a first rib 88 and a second rib 90 on a second side 92 of the divider panel 46. The channels 78, 86 cooperate with the edges 94, 96 of the grooves 54 of the side-to-side divider panels to hold the lower portions of such panels in place to prevent bending or bulging. ΙΛ / t / ZUZó / U IO IOU Similar to divider panels, the end walls and side walls of the container may include inward-facing slots or channels to receive the side edges of panels or other structures to secure such side edges. While one end-to-end divider panel and two side-to-side panels are shown, additional divider panels (or fewer, for the side-to-side panels) can be provided with the slot-edge locking structures described herein. Furthermore, although the end-to-end divider panel shows slots extending from a top edge, and the side-to-side divider panels have slots extending from a bottom edge, this can be reversed. Container 34 may also include a drainage system having holes 100 that extend through a stop 102 near the bottom of the container. The holes are spaced above ribs that extend outward from the bottom and allow liquid to collect first at the bottom before draining through the stop 102, according to the description in U.S. Provisional Patent Application 63 / 265,598 filed December 17, 2021. Many modifications and variations of the present invention are possible in light of the foregoing teachings. Therefore, it should be understood that, within the scope of the appended claims, the invention may be protected in any manner other than that specifically described.

Claims

1. A box with dividers having locking elements comprising: a container having a first side wall, an opposite second side wall, a first end wall, an opposite second end wall, and a bottom extending between the first and second side walls and the first and second end walls; a first divider extending between the first end wall and the second end wall of the container, the first divider having a first slot extending from an upper edge of the first down span of the divider to a lower edge of the first divider, a first channel aligned with the first slot and extending downward from the bottom of the first slot on a first side of the first divider, and a second channel aligned with the first slot and extending downward from the bottom of the first slot on a second side of the first divider;and, a second divider extending between the first side wall and the second side wall, the second divider having a first groove extending from the lower edge of the second span upwards of the divider to the upper edge of the second divider, wherein the first groove of the second divider includes a first edge configured to engage with the first channel of the first divider and a second edge configured to engage with the second channel of the first divider to prevent flexing of the lower portions of the second divider.; 2. The box according to claim 1, wherein the second divider includes a first channel aligned with the first slot of the second divider and extending upwards from the top of the first slot on a first side of the second divider and a second channel aligned with the first slot and extending upwards from the top of the first slot on a second side of the second divider, wherein a first edge of the first slot of the first divider is configured to engage the first channel in the second divider and a second edge of the first slot of the first divider is configured to engage the second channel in the second divider.

3. The box according to claim 2, wherein the first edge of the first groove of the first divider includes a first projection and the second edge of the first groove of the first divider includes a second projection.

4. The box according to claim 3, wherein the first projection and the second projection have a cross-section generally in the shape of a T with the remainder of the first divider.

5. The box according to claim 2, wherein the first channel in the first divider is formed by a first rib extending outwards from the first side of the first divider and a second rib extending outwards from the first side of the first divider and separated from the first rib, and the second channel in the first divider is formed by a first rib extending outwards from the second side of the first divider and a second rib extending outwards from the second side of the first divider and separated from the first rib on the second side of the first divider.

6. The box according to claim 5, wherein the first channel in the second divider is formed by a first rib extending outwards from the first side of the second divider and a second rib extending outwards from the first side of the second divider and separated from the first rib, and the second channel in the second divider is formed by a first rib extending outwards from the second side of the second divider and a second rib extending outwards from the second side of the second divider and separated from the first rib on the second side of the second divider.

7. The box according to claim 2, wherein the first divider has a second slot separate from the first slot and extending from the upper edge of the first down section of the divider to the lower edge of the first divider, a third channel aligned with the second slot and extending downward from the bottom of the second slot on the first side of the first divider, and a fourth channel aligned with the second slot and extending downward from the bottom of the second slot on the second side of the divider.

8. The box according to claim 7 further comprising a third divider extending between the first side wall and the second side wall, the third divider having a first groove extending from a lower edge of the third section upwards along the divider to the upper edge of the third divider, wherein the first groove of the third divider includes a first edge configured to engage with the third channel of the first divider and a second edge configured to engage with the fourth channel of the first divider to prevent flexing of the lower portions of the third divider.

9. The box according to claim 1, wherein the first divider includes a first locking tab at a first end of the first divider for locking the first divider to the first end wall and a second locking tab at a second end of the first divider for locking the first divider to the second end wall.

10. The box according to claim 9, wherein the second divider includes a first locking tab at a first end of the second divider for locking the second divider to the first side wall and a second locking tab at a second end of the second divider for locking the second divider to the second side wall.

11. The box according to claim 2, wherein the first slot in the first divider extends halfway between the upper edge and the lower edge of the first divider.

12. The box according to claim 11, wherein the first slot of the second divider extends halfway between the upper edge and the lower edge of the second divider.

13. The box according to claim 1, wherein the container and the first divider and the second divider are made of plastic.

14. The box according to claim 8, wherein the first divider has a third slot separate from the first slot and the second slot and extending from the upper edge of the first down section of the divider to the lower edge of the first divider, a fifth channel aligned with the third slot and extending downward from the bottom of the third slot on the first side of the first divider, and a sixth channel aligned with the third slot and extending downward from the bottom of the third slot on the second side of the first divider.

15. A box with dividers comprising: a container having a first side wall, an opposite second side wall, a first end wall, an opposite second end wall, and a bottom extending between the first and second side walls and the first and second end walls; a first divider extending between the first end wall and the second end wall of the container, the first divider having a first slot extending from an upper edge of the first down-the-divider to a lower edge of the first divider;a second divider extending between the first side wall and the second side wall, the second divider having a first slot extending from the lower edge of the second span upwards of the divider to the upper edge of the second divider, wherein the second divider includes a first channel aligned with the first slot of the second divider and extending upwards from the top of the first slot on a first side of the second divider and a second channel aligned with the first slot and extending upwards from the top of the first slot on a second side of the second divider, wherein a first edge of the first slot of the first divider is configured to engage with the first channel of the second divider and a second edge of the first slot of the first divider is configured to engage with the second channel of the second divider.

16. The box according to claim 15, wherein the first divider includes a first channel aligned with the first slot and extending downwards from the bottom of the first slot on a first side of the first divider and a second channel aligned with the first slot and extending downwards from the bottom of the first slot on a second side of the first divider, wherein the first slot of the second divider includes a first edge configured to engage with the first channel of the first divider and a second edge configured to engage with the second channel of the first divider to prevent flexing of the lower portions of the second divider.

17. The box according to claim 16, wherein the first edge of the first groove of the first divider includes a first projection and the second edge of the first groove of the first divider includes a second projection.

18. The box according to claim 17, wherein the first projection and the second projection have a cross-section generally in the shape of a T with the remainder of the first divider.

19. The box according to claim 15, wherein the first channel in the second divider is formed by a first rib extending outwards from the first side of the second divider and a second rib extending outwards from the first side of the second divider and separated from the first rib, and the second channel in the second divider is formed by a first rib extending outwards from the second side of the second divider and a second rib extending outwards from the second side of the second divider and separated from the first rib on the second side of the second divider.

20. The box according to claim 15, wherein the container, the first divider and the second divider are made of plastic.

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