Modular crate

Abstract

A modular crate having side and bottom panels and a bracket system including brackets secured to the bottom panel with a fastening apparatus. Channels cut into the side panels allow the panels to fit into the brackets to secure the side and bottom panels.

Description

MODULAR CRATEI. BackgroundA. Field

[0001] The present teaching is directed to apparatuses and methods regarding shipping and storage crates. More specifically, the present teaching is directed to apparatuses for a quick- assemble modular crate.B . Description of Related Art

[0002] Crates, generally, have been used for many years as a means of storing and transporting goods, materials, and others components of industry. From single-piece crates, to panel crates, the development of this form of storage has been a key interest in industrial and shipping fields. The crate must be large and sturdy enough to hold materials and maintain its structural integrity during transit. However, the construction of these crates represents an investment of man-hours and money, so reducing the time and cost associated with construction of crates is critical.

[0003] Multi-pane crates require additional fasteners, usually metal screws, to hold them together, which application of such screws can be time-consuming. Quick- assemble crates address certain issues, by hastening crate construction time, but may not be as structurally sound. And, in either case, the workers constructing the crates expend unnecessary effort, in craning or bending down to secure screws or slot in quick-assemble panes. These issues create a need for a crate that can address these multiple concerns.

[0004] The present teaching addresses these concerns by providing a quick-assemble crate that can be assembled from a mostly standing position by workers, quickly and more easily than other products. The panes used in the present teaching are also modular and can be easily switched out with duplicates, should damage to the crate occur. The components of this teaching are cheap in material cost and simple to manufacture.

[0005] Overall, the present teaching described allows crate users and manufacturers to quickly, simply, and cheaply construct a crate in furtherance of the activities described above.II. Summary

[0006] In accordance with one aspect of the present teaching, a crate comprises a bottom panel, having beveled edges, a front side panel, having beveled edges, a top edge, and a bottom edge, and a back side panel having beveled edges, a top edge, and a bottom edge. The crate also contains a left side panel having beveled edges, a top edge, and a bottom edge and a right side panel having beveled edges, a top edge, and a bottom edge. There is also a bracket system, wherein (as part of the bracket system) each side panel includes a channel cut laterally along the panel length and disposed a distance from the panel bottom edge. A plurality of brackets are disposed along the edges of the bottom panel are defined in a generally “C shape” cross-section, secured to the bottom panel by a fastening apparatus, and the side panel channel is configured to engage the brackets to secure the side panel to the bottom panel.

[0007] In accordance with another aspect of the present teaching, the crate left side panel comprises two pairs of elongate slots, and the front and back side panels further comprise a pair of elongate slots. The bracket fastening apparatus could also be screws or circular teeth disposed along the brackets’ lengths, which teeth are configured to press into an interference fit with the crate bottom panel, to secure the bottom panel to the brackets. The crate brackets may also be disposed at an angle relative to the bottom panel.

[0008] In accordance with another aspect of the present teaching, the crate side panel channels are configured to engage the brackets, to secure the side panel to the bottom panel, by either snapping or sliding into the brackets.

[0009] In accordance with another aspect of the present teaching, a bracket system for use with a crate, comprising channels cut laterally along the length of crate side panels, which channels are located a distance from bottom edges of the crate side panels, a bottom panel having beveled edges, and brackets disposed along the edges of the bottom panel. The side panels may rotate between a free position and a locked position and may engage the bottom panel beveled edges while rotating to the locked position. The side panels engage the brackets, while in the locked position, to secure the side panels to the bottom panel. The brackets are defined in a generally “C shape” and secured to the bottom panel by a fastening apparatus, and the brackets are configured to engage the side panel channels, to secure the side panels to the bottom panel.The bracket fastening system could be screws or circular teeth disposed along the length of the brackets and configured to press into an interference fit with the crate bottom panel, to secure the bottom panel to the brackets. In another aspect, the thickness of the brackets is not more than the width of the channels. In another aspect, the brackets have a length to width ratio of at least about 10:1. In yet another aspect, bracket engagement with the panel can be either snapping or sliding, and the brackets can be disposed at an angle relative to the bottom panel.

[0010] In accordance with another aspect of the present teaching, a crate comprises a bottom panel, having beveled edges, a front side panel, having beveled edges, a top edge, and a bottom edge, a back side panel having beveled edges, a top edge, and a bottom edge, a left side panel having beveled edges, a top edge, and a bottom edge, and a right side panel having beveled edges, a top edge, and a bottom edge. The crate contains a bracket system, wherein each side panel includes a channel cut laterally along the panel length and disposed a distance from the panel bottom edge. The crate also includes a plurality of brackets disposed along the edges of the bottom panel, which brackets arc disposed at an angle, relative to the bottom panel, defined in a generally “C shape” cross-section, and secured to the bottom panel by a fastening apparatus. The fastening apparatus includes circular teeth, disposed along the length of the brackets which teeth are configured to press into an interference fit with the crate bottom panel, to secure the bottom panel to the brackets. The thickness of the brackets is not more than the width of the channel, and the side panel channel is configured to snappably engage the brackets, to secure the side panel to the bottom panel, such that the side panel is held upright upon the bottom panel. In yet another aspect, the crate channels are not more than 0.100 inches in width.

[0011] Still other benefits and advantages of the present teaching will become apparent to those skilled in the ail to which it pertains upon a reading and understanding of the following detailed specification.III. Brief Description of the Figures

[0012] The above drawings form part of the disclosure and specification and are included to further demonstrate certain aspects of the present teaching, which aspects will be described in detail later in this specification. The present teaching may be better understood by reference to these drawings in conjunction with the detailed description.

[0013] FIGURE 1 is a perspective view of the crate, without the front panel or a lid;

[0014] FIGURES 2, 2a, and 2b are respective front, top and side views of the bottom panel;

[0015] FIGURES 3, 3a, and 3b are respective front, top, and side views of the front panel;

[0016] FIGURES 4, 4a, and 4b are respective back, top, and side views of the back panel;

[0017] FIGURES 5, 5a, and 5b are respective left, top, and front views of the left side panel;

[0018] FIGURES 6, 6a, and 6b are respective right, top, and front views of the right side panel;

[0019] FIGURE 7 is a close view of the bracket system;

[0020] FIGURES 8, 8a, and 8b are respective side, front, and top views of the bracket;

[0021] FIGURE 9 is an exploded view of the crate, without the front panel or a lid;

[0022] FIGURE 10 is a cross-sectional view of the assembly shown in FIGURE 7, with the side panel in the free position; and

[0023] FIGURE 11 is a cross-sectional view of the assembly shown in FIGURE 7, with the side panel in the locked position.IV. Detailed Description

[0024] Referring now to the drawings, wherein the showings are for purposes of illustrating aspects of the present teaching only and not for purposes of limiting the same, and wherein like reference numerals are understood to refer to like components, FIGS. 1 - 6b show a crate 10 according to some aspects of the present teaching. The crate 10 may have several side panels — front 30, back 14, left 16, and right 18 — disposed in vertical orientations around the sides of the crate 10 and forming the crate walls. The crate 10 may have a bottom panel 12, which can rest upon a pallet and may have beveled edges 20. The front 30 and back 14 side panels may each have a beveled edge 20, a notch edge 32, and in certain aspects, may also each have a pair of elongate slots 34 configured for binding clips. The left side panel 16 may have twopairs of elongate slots 34 configured for binding clips. The right side panel 18 may have beveled edges 20. The various side panels are secured to the bottom panel 12 to form the full crate, as described further below.

[0025] With reference now to FIGS. 7 - 8a, the crate 10 may have a bracket system 70 including channels 74, brackets 72, and a fastening apparatus. The channels 74 may be cut laterally along the length of each side panel (e.g., right side panel, 18 in FIG. 7) and disposed a distance from the bottom edge of each panel. The brackets 72 can be defined in a generally “C shape” cross-section, disposed along the edges of the bottom panel 12. The fastening apparatus can be screws, circular teeth 80 disposed along the length of the brackets 72 and configured to press into an interference fit with the crate bottom panel 12, or any similar fastening device chosen with sound engineering judgement. The brackets may be substantially longer than they are wide; in a particular aspect of the presenting teaching, the brackets have a length to width ratio of at least about 10:1. The side panel channel 74 is configured to engage the brackets 72, as discussed below.

[0026] With reference now to FIGS. 1 - 11, the bracket system 70 operates to secure the side panels 14, 16, 18, 30 to the bottom panel 12, to form the crate 10. The brackets 72 may be secured to the bottom panel 12 by the fastening apparatus. The channels 74 in the side panels 14,16. 18, 30 may engage with the brackets 72 to snap or slide into place and secure the side panels14. 16. 18, 30 to the bottom panel 12. In a particular aspect of the present teaching, shown in FIGS. 10 and 11, a side panel may rotate between a free position 100 and a locked position 110. The side panel engages with a beveled edge in the bottom panel, and the bracket engages with the channel in the side panel, as shown in FIG. 11.

[0027] Beveled edges 20 in the bottom panel 12 may allow the side panel bottom edges to fit into place and be held upright. The left side panel 16 can fit into the notch edges in both the front 30 and back 14 panels, while the beveled edges 20 in each of the front 30, back 14, and right 18 side panels may mate to form flush walls of the crate 10. In a particular aspect, the brackets 72 can be disposed at an angle to increase the ease with which the panels engage the brackets 72. Once the side panels 14, 16, 18, 30 are held upright upon the bottom panel 12, clipscan be inserted into the elongate slots 34 of the front 30, back 14, and left 16 side panels to lend further integrity to the crate 10 and secure the side panels 14, 16, 18, 30 to each other.

[0028] Clause 1 -A crate including a bottom panel, having beveled edges, a front side panel, having a beveled edge, a top edge, a bottom edge, and a notch edge, a back side panel having a beveled edge, a top edge, a bottom edge, and a notch edge, a left side panel having a top edge, and a bottom edge, a right side panel having beveled edges, a top edge, and a bottom edge, a bracket system including each side panel having a channel, the channel cut laterally along a panel length, disposed a distance from the panel bottom edge, a fastening apparatus, a plurality of brackets disposed along the edges of the bottom panel, wherein the brackets are secured to the bottom panel by the fastening apparatus, and wherein the side panel channel is configured to engage the brackets, to secure the side panel to the bottom panel.

[0029] Clause 2 - The crate of clause 1, wherein the left side panel further includes two pairs of elongate slots and the front and back side panels further include a pair of elongate slots.

[0030] Clause 3 -The crate of clauses 1 or 2, wherein the fastening apparatus is screws.

[0031] Clause 4 - The crate of any of clauses 1-3, wherein the fastening apparatus is circular teeth, disposed along the length of the brackets, wherein the circular teeth are configured to press into an interference fit with the crate bottom panel, to secure the bottom panel to the brackets.

[0032] Clause 5 - The crate of any of clauses 1-4, wherein the brackets are disposed at an angle, relative to the bottom panel.

[0033] Clause 6 - The crate of any of clauses 1-5, wherein the side panel channel is configured to snappably engage the brackets, to secure the side panel to the bottom panel.

[0034] Clause 7 - The crate of any of clauses 1-6, wherein the side panel channel is configured to slidably engage the brackets, to secure the side panel to the bottom panel.

[0035] Clause 8 - A bracket system, including lateral channels, the channels disposed along crate side panels, wherein the side panels rotate between a free position and a locked position, a bottom panel having beveled edges, brackets disposed along the edges of the bottom panel, a fastening apparatus, the brackets secured to the bottom panel by the fastening apparatus, wherein the brackets are configured to engage the channels, the side panels engage the bottompanel beveled edges while rotating from free position to locked position, and the side panels engage the brackets, while in the locked position, to secure the side panels to the bottom panel.

[0036] Clause 9 - The bracket system of clause 8, wherein the fastening apparatus is screws.

[0037] Clause 10 - The bracket system of clauses 8 or 9, wherein the thickness of the brackets is not more than the width of the channels.

[0038] Clause 11 - The bracket system of any of clauses 8-10, wherein the brackets are configured to slidably engage the side panel channels, to secure the side panels to the bottom panel.

[0039] Clause 12 - The bracket system of any of clauses 8-11, wherein the brackets are configured to snappably engage the side panel channels, to secure the side panels to the bottom panel.

[0040] Clause 13 - The bracket system of any of clauses 8-12, wherein the brackets have a length to width ratio of at least about 10:1.

[0041] Clause 14 - The bracket system of any of clauses 8-13, wherein the fastening apparatus includes circular teeth, disposed along the length of the brackets, wherein the circular teeth are configured to press into an interference fit with the crate bottom panel, to secure the bottom panel to the brackets.

[0042] Clause 15 - The bracket system of any of clauses 8-14, wherein the brackets are disposed at an angle, relative to the bottom panel.

[0043] Clause 16 - A crate including a bottom panel, having beveled edges, a front side panel, having beveled edges, a top edge, a bottom edge, and a notch edge, a back side panel having beveled edges, a top edge, a bottom edge, and a notch edge, a left side panel having a top edge, and a bottom edge, a right side panel having beveled edges, a top edge, and a bottom edge, a bracket system including each side panel having a channel, the channel cut laterally along a panel length, disposed a distance from the panel bottom edge, a plurality of brackets disposed along the edges of the bottom panel, the brackets disposed at an angle, relative to the bottom panel secured to the bottom panel by a fastening apparatus including circular teeth, disposed along the length of the brackets, said teeth configured to press into an interference fit with thecrate bottom panel, to secure the bottom panel to the brackets, wherein the thickness of the brackets is not more than the width of the channel, and wherein the side panel channel is configured to snappably engage the brackets, to secure the side panel to the bottom panel, such that the side panel is held upright upon the bottom panel.

[0044] Clause 17 - The crate of clause 16, wherein the channel is not more than 0.100 inches in width.

[0045] Numerous aspects have been described, hereinabove. It will be apparent to those skilled in the art that the above methods and apparatuses may incorporate changes and modifications without departing from the general scope of the present teaching. It is intended to include all such modifications and alterations in so far as they come within the scope of the appended claims or the equivalents thereof.

[0046] Having thus described the present teaching, it is now claimed:

Claims

I claim:

1. A crate comprising: a bottom panel, having beveled edges; a front side panel, having a beveled edge, a top edge, a bottom edge, and a notch edge; a back side panel having a beveled edge, a top edge, a bottom edge, and a notch edge; a left side panel having a top edge, and a bottom edge; a right side panel having beveled edges, a top edge, and a bottom edge; a bracket system comprising: each side panel having a channel, the channel: cut laterally along a panel length; disposed a distance from the panel bottom edge; a fastening apparatus; a plurality of brackets disposed along the edges of the bottom panel, wherein the brackets arc secured to the bottom panel by the fastening apparatus; and wherein the side panel channel is configured to engage the brackets, to secure the side panel to the bottom panel.

2. The crate of Claim 1, wherein: the left side panel further comprises: two pairs of elongate slots; and the front and back side panels further comprise: a pair of elongate slots.

3. The crate of Claims 1 or 2, wherein the fastening apparatus is screws.

4. The crate of any of Claims 1-3, wherein the fastening apparatus is circular teeth, disposed along the length of the brackets, wherein the circular teeth are configured to press into an interference fit with the crate bottom panel, to secure the bottom panel to the brackets.

5. The crate of any of Claims 1-4, wherein the brackets are disposed at an angle, relative to the bottom panel.

6. The crate of any of Claims 1-5, wherein the side panel channel is configured to snappably engage the brackets, to secure the side panel to the bottom panel.

7. The crate of any of Claims 1-6, wherein the side panel channel is configured to slidably engage the brackets, to secure the side panel to the bottom panel.

8. A bracket system, comprising: lateral channels; the channels disposed along crate side panels; wherein the side panels rotate between a free position and a locked position; a bottom panel having beveled edges; brackets disposed along the edges of the bottom panel; a fastening apparatus; the brackets secured to the bottom panel by the fastening apparatus; wherein the brackets are configured to engage the channels; the side panels engage the bottom panel beveled edges while rotating from free position to locked position; and the side panels engage the brackets, while in the locked position, to secure the side panels to the bottom panel.

9. The bracket system of Claim 8, wherein the fastening apparatus is screws.

10. The bracket system of Claims 8 or 9, wherein the thickness of the brackets is not more than the width of the channels.

11. The bracket system of any of Claims 8-10, wherein the brackets are configured to slidably engage the side panel channels, to secure the side panels to the bottom panel.

12. The bracket system of any of Claims 8-11, wherein the brackets are configured to snappably engage the side panel channels, to secure the side panels to the bottom panel.

13. The bracket system of any of Claims 8-12, wherein the brackets have a length to width ratio of at least about 10:1.

14. The bracket system of any of Claims 8-13, wherein the fastening apparatus includes: circular teeth, disposed along the length of the brackets, wherein the circular teeth are configured to press into an interference fit with the crate bottom panel, to secure the bottom panel to the brackets.

15. The bracket system of any of Claims 8-14, wherein the brackets are disposed at an angle, relative to the bottom panel.

16. A crate comprising: a bottom panel, having beveled edges; a front side panel, having beveled edges, a top edge, a bottom edge, and a notch edge; a back side panel having beveled edges, a top edge, a bottom edge, and a notch edge; a left side panel having a top edge, and a bottom edge; a right side panel having beveled edges, a top edge, and a bottom edge; a bracket system comprising: each side panel having a channel, the channel: cut laterally along a panel length; disposed a distance from the panel bottom edge; a plurality of brackets disposed along the edges of the bottom panel, the brackets: disposed at an angle, relative to the bottom panel. secured to the bottom panel by a fastening apparatus including: circular teeth, disposed along the length of the brackets; said teeth configured to press into an interference fit with the crate bottom panel, to secure the bottom panel to the brackets; wherein the thickness of the brackets is not more than the width of the channel; and wherein the side panel channel is configured to snappably engage the brackets, to secure the side panel to the bottom panel, such that the side panel is held upright upon the bottom panel.

17. The crate of Claim 16, wherein the channel is not more than 0.100 inches in width.

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