Nestable container with vertical portions alongside inclined wall memebers

Abstract

A container comprising a base and a plurality of side walls 4a, 4b, each side wall comprises an inner side and an outer side 10. Each side wall comprises a plurality of spaced raised portions 12 and a

Description

Embodiments of the present invention relate to a nestable container with vertical portions alongside inclined wall members. In particular, but not exclusively, the container is a moulded plastics container, such as a walled tray. BACKGROUND TO THE INVENTION The side walls of a container may be inclined by an angle of a few degrees relative to vertical, allowing a plurality of the containers to be nested and stacked. This increases the stacking density of containers, and therefore increases the number of containers that can be stacked on a pallet. This reduces the number of haulage journeys and consequent emissions for delivering large numbers of containers to a site. It is also possible for containers to have completely straight vertical side walls. Typically, this means that they cannot be nested when stacked. BRIEF DESCRIPTION OF VARIOUS EMBODIMENTS OF THE INVENTION According to various, but not necessarily all, embodiments of the invention there is provided a container comprising a base, and a plurality of side walls peripheral to the base, wherein each side wall comprises an inner side facing the base, and an outer side facing opposite the inner side, wherein the side walls comprise a plurality of spaced raised portions, wherein each side wall comprises a nesting cavity at the outer side of the corresponding side wall, wherein the nesting cavities allow the container to be nested in the raised portions of an underlying one of the container in a stack, wherein each nesting cavity comprises an entrance accessible from an underside of the container, for receiving a raised portion of the underlying container, wherein an inclined wall member of each side wall, inclined away from the base, defines an inclined boundary of the nesting cavity, and wherein each side wall comprises at its outer side vertical portions alongside the inclined wall members, at a same elevation as the inclined wall members. This provides the advantage of an improved nestable container, allowing the maximum width of the container between the side walls to be generally constant along the height of the side walls, without impeding the ability to nest. The vertical portions ensure that maximum width is constant. The nesting cavities present inclined, non-vertical recesses for receiving the raised portions of the underlying container. Optionally, the vertical portions extend substantially vertically such that the outer side of the side wall appears substantially rectilinear (non-drafted) in a side elevation end view of the container, and wherein the nesting cavities are recessed relative to the vertical portions. Optionally, the vertical portions extend alongside the nesting cavities, at a same elevation as the nesting cavities, wherein the vertical portions are located to either side of each nesting cavity. Optionally, the vertical portions extend up the raised portions. Optionally, the vertical portions extend to tops of the raised portions. Optionally, the vertical portions extend down to elevations of the entrances of the nesting cavities. Optionally, each nesting cavity comprises an inverse shape of the corresponding raised portion above the nesting cavity. Optionally, each nesting cavity corresponds to one of the raised portions and has a height at least 50% of a height of the corresponding raised portion. An advantage is that this allows nesting to a depth of 50% to 100% of the height of the corresponding raised portion. Optionally, the vertical portions provide the container with substantially the same maximum width between an opposite pair of the side walls when measured at first and second elevations, wherein the first elevation is an elevation of the entrances of the nesting cavities, and wherein the second elevation is an elevation above the entrances by a distance equal to at least 50% and up to 100% of the height of the raised portions. Optionally, the inclined wall member extends up from the entrance of the nesting cavity and has a height at least equal to the height of the nesting cavity. Optionally, the inclined wall member of each side wall is a single wall member defining the inclined boundaries of the nesting cavities along the side wall. Optionally, the inclined wall member further defines an inclined boundary of the raised portions along the side wall. Optionally, each side wall comprises an elongate upper rim, and wherein the raised portions are formed in the elongate upper rim. Optionally, at least one of the side walls comprises an elongate upper rib connected to its outer side, wherein the elongate upper rib is beneath the raised portions of said side wall, and defines part of the elongate upper rim, and extends generally horizontally along the length of the side wall. Optionally, at least one of the side walls comprises a plurality of elongate lower ribs connected to its outer side, wherein the plurality of elongate lower ribs extend discontinuously along a length of the side wall, each nesting cavity along the side wall representing a discontinuity between the elongate lower ribs. An advantage is that the elongate lower rib does not block nesting. Optionally, each raised portion has a width, a height, and a thickness, wherein each raised portion narrows in width from a bottom of the raised portion to a top of the raised portion. Optionally, the entrance of each nesting cavity is a widest point of each nesting cavity. Optionally, the vertical portions are defined at least in part by ribs connected to the outer side of the corresponding side wall. Optionally, the ribs are connected to the inclined wall member at the outer side of the side wall. Optionally, the ribs have a variable rib depth from the inclined wall member to cancel out the angle of the inclined wall member such that edges of the ribs extend substantially vertically. Optionally, the ribs comprise a plurality of tapering rib structures connected to the inclined wall member at the outer side of the side wall, wherein the tapering rib structures extend around each nesting cavity, and wherein the vertical portions comprise the tapering rib structures. Optionally, the tapering rib structures extend up the raised portions. Optionally, each raised portion corresponds to a crenelation of the inclined wall member, and wherein the tapering rib structures extend up the crenelations of the inclined wall member. Optionally, the tapering rib structures extends down to elevations of the entrances of the nesting cavities. Optionally, the boundaries of each nesting cavity are defined by a portion of the inclined wall member and by one of the tapering rib structures. Optionally, horizontally-extending ribs interconnect the tapering rib structures. Optionally, the horizontally-extending ribs comprise the elongate upper rib and / or elongate lower rib defined earlier. Optionally, the raised portions comprise trapezoidal sides. Optionally, the nesting cavities comprise trapezoidal sides. Optionally, the tapering rib structures comprise trapezoidal sides. Optionally, a rib depth of each tapering rib structure relative to the inclined wall member varies along a height of the tapering rib structure, such that an elongate rib edge of the tapering rib structure lies on a substantially vertical plane and defines one of the vertical portions of the outer side of the side wall. Optionally, the outer side of one or more of the side walls is inclined for most or substantially all its height along most or substantially all of the length of the side wall, except for the elongate rib edges of the tapering rib structures along said side wall which lie on the substantially vertical plane. Optionally, each nesting cavity is open at the outer side of the side wall. Optionally, the inclined wall member has an angle of at least two or at least three degrees relative to vertical. Each inclined wall member is inclined in a draft angle direction. Optionally, the inclined wall members of the side walls are inclined such that an opening defined by elongate upper rims of the side walls is larger than a perimeter of the base. Optionally, the inner side of one or more of the side walls is inclined for substantially its entire length. Optionally, the container is a moulded plastics container. Optionally, the container is a walled tray. According to various, but not necessarily all, embodiments of the invention there is provided a pair of said containers, configured to be stacked and nested as defined above. BRIEF DESCRIPTION OF THE DRAWINGS For a better understanding of various examples of embodiments of the present invention reference will now be made by way of example only to the accompanying drawings in which: FIG. 1 illustrates a perspective view of an example container; FIG. 2 illustrates an end view of the container; FIG. 3 illustrates a side view of the container; FIG. 4 illustrates a detail perspective view of an outer side of a side wall; FIG. 5 illustrates a detail perspective view of an inner side of a side wall; FIG. 6 illustrates a transverse cross-section of a container, showing raised portions of opposite side walls; FIG. 7 illustrates a transverse cross-section of a container, showing elongate upper rims of opposite side walls, each between a pair of raised portions; FIG. 8 illustrates a side view of a stack of nested containers; and FIG. 9 illustrates an end view of a stack of nested containers. DETAILED DESCRIPTION OF VARIOUS EMBODIMENTS OF THE INVENTION The Figures illustrate a container 1 in the form of a tray. Orthogonal X, Y, and Z axes are also defined, herein referred to as longitudinal, transverse, and vertical axes. The container 1 is optionally formed from a plastics material, such as an injection-moulded plastic. As shown in FIG. 1, the container 1 comprises a base 2 and a plurality of side walls 4 peripheral to the base 2 and connected to the base 2. The side walls 4 comprise a pair of long side walls 4A extending in the longitudinal axis x, and a pair of short side walls 4B extending in the transverse axis y. The long and short side walls 4A, 4B collectively define a rectangular shape. Alternatively, another shape may be defined. As shown in FIGS. 2-7, each side wall 4 comprises an inclined wall member 19 (inclined wall layer / plate) which is an upright sheet / layer of material. The inclined wall member 19 is inclined relative to vertical, having an angle / draft angle selected from the range 1 to 10 degrees, or 2 to 7 degrees or 3 to 6 degrees, relative to the vertical axis z. The inclined wall member 19 may extend continuously or discontinuously from corner to corner of the container 1. By inclining the side walls 4, the opening defined by the elongate upper rims 23 of the side walls 4 is larger than the perimeter of the base 2. FIG. 5 shows that each side wall 4 has an inner side 8 facing the base 2, and FIG. 4 shows an outer side 10 facing an opposite exterior direction than the inner side 8. The surface of the inclined wall member 19 at the inner side 8 is an interior surface. The surface of the inclined wall member 19 at the outer side 10 is an exterior surface. As will be described in more detail, the side wall 4 has an elongate upper rim 23 comprising a plurality of raised portions 12 defining a crenelated profile. More specifically, the elongate upper rim 23 of the side wall 4 comprises a plurality of raised portions 12 and a plurality of lower portions between the raised portions 12. The term ‘crenelations’ is used herein to described the raised portions, and can be interchanged with the term ‘raised portion’. FIG. 5 shows that a plurality of base ribs 6 of the base 2 may be connected to the inclined wall member 19 at the inner side 8 of the side wall 4, to brace and stiffen the base 2. FIG. 4 shows that a plurality of wall ribs 22, 24, 26 are connected to the inclined wall member 19 at the outer side 10 of the side wall 4. Whereas the base ribs 6 extend generally vertically, the wall ribs 22, 24, 26 protrude generally horizontally from the inclined wall member 19 when viewed in a side elevation cross-section. The wall ribs 22, 24, 26, extend either along or up and down the side wall 4 For the long wall 4A depicted in FIG. 4, the wall ribs comprise vertically spaced horizontal ribs 22, 24, each of which extends along the length of the side wall 4. They are mostly or substantially horizontal. These comprise elongate upper ribs 22 and elongate lower ribs 24. The elongate upper ribs 22 define part of the elongate upper rim 23 of the long wall 4A. The elongate lower ribs 24 are located at or proximal to the bottom of the long wall 4A. The elongate upper ribs 22 may extend mostly or entirely parallel to the elongate lower ribs 24. The long wall 4A can be described as having an overall height divided into a non-nestable height and a nestable height. The nestable height comprises the nested, overlapping parts of the nested containers 1 shown in FIGS. 8-9. The ratio between the nestable and non-nestable heights depends on the implementation. The nestable height comprises at least part of the height of the crenelations 12. FIGS. 8-9 show the crenelations 12 of the lower container 1 nesting with the side walls 4 of the upper container 1 in a stack. The nestable height of the side wall 4 depends on the required nesting depth, but may be at least 50% of the height of the crenelation 12 above the elongate upper ribs 22, for example. In some examples, the nestable height may be up to 100% of the height of the crenelation 12. The non-nestable height comprises the portion of the long wall 4A below the crenelations 12. These are the portions which do not nest / overlap in FIGS. 8-9. The non-nestable height of the side wall 4 can be defined as the maximum vertical distance between one of the elongate upper ribs 22 and one of the corresponding underlying elongate lower ribs 24. This is marked as ‘H’ in FIG. 8. When the containers 1 are in a nested stack, at least one of the elongate lower ribs 24 of an upper container 1 in the stack may therefore rest on at least one of the elongate upper ribs 22 of a lower container 1 in the stack. Alternatively, another spacer may be provided such that the ribs 22, 24 do not contact. FIGS. 1, 2, and 9 show the short walls 4B. As shown, the short walls 4B may comprise elongate lower ribs 24 but not elongate upper ribs 22. The elongate upper ribs 22 are optional in every implementation. 9 FIGS. 2-4 show the wall ribs further comprising a plurality of tapering rib structures 26, each corresponding to one of the crenelations 12 of the inclined wall member 19. Each tapering rib structure 26 comprises a pair of tapering ribs 28, inclined towards each other and connected at their tops by a top rib 30 extending horizontally in the x-axis. The tapering ribs 28 and top rib 30 may therefore collectively define a trapezoid shape. Each crenelation 12 is defined as the combination of the raised portion of the inclined wall member 19 and the portion of the tapering rib structure 26 which extends up and along the raised portion of the inclined wall member 19. For the long walls 4A, the angle of each tapering rib 28 relative to the vertical axis z may be selected from the range 2 to 10 degrees, measured in the x-z plane. For the short walls 4B, the measurement may be in the y-z plane. In other implementations, the tapering ribs 28 may connect at a point, such that the top rib 30 can be omitted. The tapering ribs 28 and top rib 30 collectively extend along the perimeter of the crenelation 12. Therefore, the tops of the tapering rib 28, and the top rib 30, are located at a higher elevation than the elongate upper ribs 22. The crenelated elongate upper rim 23 of the side wall 4 can be defined as the combination of the elongate upper ribs 22, the portions of the tapering ribs 28 above the elongate upper ribs 22, and the top ribs 30. For the long walls 4A, each tapering rib 28 is connected to an elongate lower rib 24, then extends up to an elongate upper rib 22 in a diagonal tapering direction, connects to the elongate upper rib 22, and extends further up in a diagonal tapering direction to the top rib 30. FIGS. 3 and 4 show that the elongate lower ribs 24 are separated from each other by a plurality of discontinuities, the discontinuity starting and ending at a corresponding tapering rib 28. The space between the tapering ribs 28 is therefore free from obstructions. The illustrated elongate upper ribs 22 are also separated from each other by a plurality of discontinuities, the discontinuity starting and ending at a corresponding tapering rib 28. The space between the tapering ribs 28 is therefore free from obstructions. However, this may not be necessary and in some examples a single elongate upper rib 22 could extend continuously through the tapering rib structures 26. Overall, what is depicted is a series of trapezoidal tapering rib structures 26, interconnected by elongate upper ribs 22 and elongate lower ribs 24. It would be appreciated that a different arrangement of ribs could be provided. For the short walls 4B, the ribs are differently arranged. There are no elongate upper ribs 22. Each tapering rib 28 starts at an elongate lower rib 24 and extends upwardly. Furthermore, for the short walls 4B, the inclined wall member 19 does not extend above the lower rib 24 except at the raised portions 12. These are optional details. In other implementations of the invention, the ribs described above may be omitted entirely and replaced with other structures. As shown in FIGS. 4-7, each of the wall ribs 22, 24, 28, 30 has an elongate rib edge 32. This is the elongate free edge of the rib, having a thickness corresponding to a rib thickness. The rib edges 32 of the tapering rib structure 26, and each elongate upper rib 22, and each elongate lower rib 24, collectively define a vertical portion 20 of the side wall 4, lying on a substantially or wholly vertical plane. Therefore, the end and side elevation views of FIGS. 2 and 3 show the outer sides 10 of the side walls 4 having square sides. To achieve this, the wall ribs 22, 24, 28, 30 have different or variable rib depths (projection). The elongate lower ribs 24 have a greater rib depth than the elongate upper ribs 22, to cancel out the angle of the inclined wall member 19. Furthermore, the tapering ribs 28 have a decreasing rib depth with increasing height along the side wall 4, to cancel out the angle of the inclined wall member 19. The top ribs 30 have the shallowest rib depth of the wall ribs described. This is particularly illustrated in the sectional views of FIGS. 6 and 7, where a dotted vertical line has been extended between the sectional views, illustrating how the tips / rib edges of the ribs are all aligned on a common vertical plane. As will be explained further, the container 1 is nestable despite comprising vertical portions 20 and inclined portions 19 alongside each other at the same elevation as each other. To enable nesting, nesting cavities 14 are provided. These are best illustrated in FIG. 4. The nesting cavities 14 are inclined, non-vertical and unobstructed recesses. They are inclined relative to the vertical portions 20. The boundaries of a nesting cavity 14 are defined by the tapering rib structure 26, as well as an inclined side surface 18 of the inclined wall member 19. Due to the tapering of the tapering ribs 28, the nesting cavity 14 narrows with increasing height when viewed in the x-z plane (long wall 4A). Due to the angle of the inclined wall member 19 and the variable heights of the ribs, the nesting cavity 14 narrows with increasing height when viewed in the y-z plane (long wall 4A). Therefore, the nesting cavity 14 has a volume defined by the variable rib depth of the tapering ribs 28, multiplied by the variable rib spacing of the tapering ribs 12 28, multiplied by the height of the tapering ribs 28 up to a top boundary of the nesting cavity 14. The nesting cavity 14 is open at the bottom, defining an entrance 16. The entrance 16 is accessible from the underside of the container 1. The entrance 16 is formed in the x-y plane. Furthermore, each nesting cavity 14 is located directly below a corresponding crenelation 12 and comprises an inverse shape of the corresponding crenelation 12 above the nesting cavity 14, along at least the nestable part of its height. Therefore, when the container 1 is lowered onto another container 1, the top rib 30 of the crenelation 12 of the underlying container 1 will enter the entrance 16 of the nesting cavity 14, so the nesting cavity 14 can travel down the crenelation 12 such that at least part of the crenelation 12 is nested inside the nesting cavity 14. The top rib 30 of the underlying container 1, and upper portions of the tapering ribs 28, are also nested in the nesting cavity 14 and do not protrude outwardly from the nesting cavity when the containers 1 are in a resting nested state. The depth of nesting can be controlled for example via a spacer which interferes with the underlying container 1 before the crenelation 12 of the underlying container 1 becomes fractionally wedged in the nesting cavity 14 of the upper container 1. This makes it easier to lift an upper container 1 from a stack without the underlying container 1 being stuck to the upper container 1. As described earlier, a widely-spaced pair of the upper and lower ribs 22, 24 may act as the spacer. The nesting cavities 14 may also be open at the outer side of the side wall 4, as well as being open at their bottom entrances 16. In other words, the nesting cavities 14 are recesses rather than pockets. The tapering rib structure 26 is cantilevered and not connected to a further wall member parallel to the inclined wall member 19. In summary, the vertical portions 20 defined by the rib edges 32 ensure that the container 1 has square sides when maximum dimensions are measured at various heights along the side wall 4. For example, the container 1 has substantially the same maximum width between the opposite side walls 4 when measured at the elevation of the entrances 16 of the nesting cavities 14, as the maximum width measured at an elevation above the entrances 16 by a distance equal to the nestable height of the side walls 4. The maximum width between the opposite side walls 4 may remain substantially constant from the elevation of the elongate lower ribs 24 to the elevation of the top ribs 30 at the tops of the crenelations 12. The maximum width may be substantially constant for substantially the entire height of the opposite side walls 4. Although embodiments of the present invention have been described in the preceding paragraphs with reference to various examples, it should be appreciated that modifications to the examples given can be made without departing from the scope of the invention as claimed. For example, some or all of the wall ribs can be omitted. The vertical portions 20 could be formed by surfaces other than rib edges 32. Features described in the preceding description may be used in combinations other than the combinations explicitly described. Although functions have been described with reference to certain features, those functions may be performable by other features whether described or not. Although features have been described with reference to certain embodiments, 5 those features may also be present in other embodiments whether described or not. Whilst endeavouring in the foregoing specification to draw attention to those features of the invention believed to be of particular importance it should be 10 understood that the Applicant claims protection in respect of any patentable feature or combination of features hereinbefore referred to and / or shown in the drawings whether or not particular emphasis has been placed thereon.

Claims

1. According to various, but not necessarily all, embodiments of the invention there is provided a container comprising a base, and a plurality of side walls peripheral to the base,wherein each side wall comprises an inner side facing the base, and an outer side facing opposite the inner side,wherein the side walls comprise a plurality of spaced raised portions, wherein each side wall comprises a nesting cavity at the outer side of the corresponding side wall,wherein the nesting cavities allow the container to be nested in the raised portions of an underlying one of the container in a stack,wherein each nesting cavity comprises an entrance accessible from an underside of the container, for receiving a raised portion of the underlying container,wherein an inclined wall member of each side wall, inclined away from the base, defines an inclined boundary of the nesting cavity, andwherein each side wall comprises at its outer side vertical portions alongside the inclined wall members, at a same elevation as the inclined wall members.

2. The container of claim 1, wherein the vertical portions extend substantially vertically such that the outer side of the side wall appears substantially rectilinear in a side elevation end view of the container, and wherein the nesting cavities are recessed relative to the vertical portions.

3. The container of claim 1 or 2, wherein the vertical portions extend alongside the nesting cavities, at a same elevation as the nesting cavities, and wherein the vertical portions are located to either side of each nesting cavity.

4. The container of any preceding claim, wherein the vertical portions extend up the raised portions, optionally wherein the vertical portions extend to tops of the raised portions.

5. The container of any preceding claim, wherein the vertical portions extend down to elevations of the entrances of the nesting cavities.

6. The container of any preceding claim, wherein each nesting cavity comprises an inverse shape of the corresponding raised portion above the nesting cavity.

7. The container of any preceding claim, wherein each nesting cavity corresponds to one of the raised portions and has a height at least 50% of a height of the corresponding raised portion.

8. The container of any preceding claim, wherein the vertical portions provide the container with substantially the same maximum width between an opposite pair of the side walls when measured at first and second elevations, wherein the first elevation is an elevation of the entrances of the nesting cavities, and wherein the second elevation is an elevation above the entrances by a distance equal to at least 50% and up to 100% of the height of the raised portions.

9. The container of any preceding claim, wherein the inclined wall member extends up from the entrance of the nesting cavity and has a height at least equal to the height of the nesting cavity.

10. The container of any preceding claim, wherein each side wall comprises an elongate upper rim, and wherein the raised portions are formed in the elongate upper rim.

11. The container of claim 10, wherein at least one of the side walls comprises an elongate upper rib connected to its outer side, wherein the elongate upper rib is beneath the raised portions of said side wall, and defines part of the elongate upper rim, and extends generally horizontally along the length of the side wall.

12. The container of any preceding claim, wherein at least one of the side walls comprises a plurality of elongate lower ribs connected to its outer side, wherein the plurality of elongate lower ribs extend discontinuously along a length of the side wall, each nesting cavity along the side wall representing a discontinuity between the elongate lower ribs.

13. The container of any preceding claim, wherein each raised portion has a width, a height, and a thickness, wherein each raised portion narrows in width from a bottom of the raised portion to a top of the raised portion.

14. The container of any preceding claim, wherein the entrance of each nesting cavity is a widest point of each nesting cavity.

15. The container of any preceding claim, wherein the vertical portions are defined at least in part by ribs connected to the outer side of the corresponding side wall.

16. The container of claim 15, wherein the ribs are connected to the inclined wall member at the outer side of the side wall, and wherein the ribs have a variable rib depth from the inclined wall member to cancel out the angle of the inclined wall member such that edges of the ribs extend substantially vertically.

17. The container of claim 15 or 16, wherein the ribs comprise a plurality of tapering rib structures connected to the inclined wall member at the outer sideof the side wall, wherein the tapering rib structures extend around each nesting cavity, and wherein the vertical portions comprise the tapering rib structures.

18. The container of claim 17, wherein horizontally-extending ribs interconnect the tapering rib structures.

19. The container of claim 17 or 18, wherein the raised portions comprise trapezoidal sides, wherein the nesting cavities comprise trapezoidal sides, and wherein the tapering rib structures comprise trapezoidal sides.

20. The container of claim 17, 18, or 19, wherein a rib depth of each tapering rib structure relative to the inclined wall member varies along a height of the tapering rib structure, such that an elongate rib edge of the tapering rib structure lies on a substantially vertical plane and defines one of the vertical portions of the outer side of the side wall.

21. The container of any preceding claim, wherein each nesting cavity is open at the outer side of the side wall.

22. The container of any preceding claim, wherein the inclined wall member has an angle of at least two or at least three degrees relative to vertical, each inclined wall member being inclined in a draft angle direction.

23. The container of any preceding claim, wherein the inner side of one or more of the side walls is inclined for substantially its entire length.

24. A container as claimed in each of claims 1 to 23, further wherein the plurality of side walls of the container comprise a pair of long side walls and a pair of short side walls collectively defining a rectangular shape, and wherein the number of spaced raised portions and nesting cavities along each side wall consists of nine along each long side wall, and six along each short side wall.1925. A pair of containers configured to be stacked and nested as defined in any one or more of claims 1 to 24.A

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