Collapsible crates and related methods

Abstract

A foldable crate is disclosed that includes a first side frame and a base. The first side frame has an end portion and an upper portion extending from the end portion. The base includes a support surface and a receptacle below the support surface for positioning the first side frame. The base includes one or more locking recesses located below the support surface to receive the end portion of the first side frame. The first side frame is movable between a first configuration in which the end portion of the first side frame is received in the one or more locking recesses of the base such that at least a portion of the first side frame extends above the support surface of the base, and a second configuration in which the end portion and at least a portion of the upper portion of the first side frame are within the receptacle of the base.

Description

[Technical Field]

[0001] (CROSS-REFERENCE TO RELATED APPLICATIONS) This application claims priority to U.S. Provisional Patent Application No. 63 / 435,966, filed December 29, 2022, which is incorporated herein by reference in its entirety. [Background technology]

[0002] FIELD OF THE DISCLOSURE The present disclosure relates generally to storage and transport crates, and more particularly to collapsible crates.

[0003] Crates are used to transport and store goods and merchandise. When a crate is not in use, it typically occupies the same amount of space as when it is filled. Therefore, when an empty crate is transported or stored, for example, in a transport vehicle or warehouse, the crate takes up a lot of space. Some crates have walls that are removable from the base. These walls can then be removed and placed on the crate base or elsewhere for transport or storage. As an alternative approach, the walls of the crate can be folded inward and placed on top of the base.

[0004] However, in prior art approaches, these walls remain vulnerable to impact and damage. Furthermore, these walls can occupy additional space beyond the typical dimensions of the crate's base. Furthermore, many crates are transported using forklifts and similar tools. To accommodate such tools, the crate must be constructed with a base that accepts lifting and transporting structures. When the base is constructed in this manner, it can be particularly difficult to construct a crate that allows one or more walls to collapse onto the base.

[0005] Pallets are also used to transport and store goods and merchandise. Typically, pallets cannot be stacked without being stacked on top of the goods on the pallet below, which could damage the goods on the pallet below. Furthermore, stacking pallets can be relatively unstable, limiting the height to which pallets can be stacked. Multiple pallet racks are often used to stack pallets vertically to save space. However, if such pallet racks are not available, pallets cannot be stacked vertically and may take up space on the floor of storage areas or transport vehicles.

[0006] There is a need for a crate that can be folded to reduce its size without the walls bowing, denting, or becoming disjointed from the rest of the crate. [Brief explanation of the drawings]

[0007] [Figure 1] FIG. 1 is a top perspective view of the folding crate in an assembled configuration, including a base frame and side frames. [Figure 2] FIG. 2 is a bottom perspective view of the collapsible crate in FIG. 1. [Figure 3] FIG. 2 is a perspective view of the upper part of the side frame of the folding crate in FIG. 1. [Figure 4] 2 is a top perspective view of a coupler of a side frame of the folding crate in FIG. 1 having stacking projections and nesting projections. FIG. [Figure 5] 2 is a top perspective view of an extender coupler of the side frame of the collapsible crate in FIG. 1 with stacking projections and nesting projections supported by the extender. FIG. [Figure 6] FIG. 2 is a side view of the foldable crate in FIG. 1. [Figure 7] FIG. 2 is a bottom perspective view of the end of the collapsible crate in FIG. 1. [Figure 8A] FIG. 2 is a top perspective view of the collapsible crate of FIG. 1 in a folded configuration. [Figure 8B] 8B is a close-up view of section A of FIG. 8A showing the stop members of the base of the collapsible crate that prevent the side frames from sliding relative to the base in the folded configuration. [Figure 9A-9B] Figure 9A is a top plan view of the collapsible crate of Figure 1 in the folded configuration of Figure 8A, and Figure 9B is a cross-sectional view of the collapsible crate of Figure 1 taken along line AA of Figure 9A. [Figure 9C] FIG. 9C is a close-up view of part B in FIG. 9B. [Figures 10A-10B] Figure 10A is a side perspective view of a corner portion of the base of the collapsible crate in Figure 1 having guide slots that facilitate movement of the side frame between the locking recesses and the track support surface of the base as the collapsible crate transitions between the assembled and folded configurations. Figure 10B is a side view of the legs of the side frame inserted into the locking recesses of the corner portion of Figure 10A. [Figure 10C] 10 is a top perspective view of a corner of the base of the collapsible crate of FIG. 1 according to another embodiment. FIG. [Figure 10D] 10D is a side view of the legs of the side frame inserted into the locking recesses in the corners of the base in FIG. 10C. FIG. [Figure 11] 10B is a rear view of the corner of the base in FIG. 10A showing the pins in the legs of the side frames of the crate of FIG. 1 engaging with the guide slots. [Figures 12A-12B] Figure 12A is a partial cross-sectional side view of the collapsible crate of Figure 1 shown in an assembled configuration, and Figure 12B is a close-up view of section C in Figure 12A. [Figures 13A-13B] Figure 13A is a partial cross-sectional side view of the folding crate of Figure 1 showing the side frame partially disengaged from the locking recesses in the base, and Figure 13B is a close-up view of section D in Figure 13A. [Figures 14A-14B]Figure 14A is a partial cross-sectional side view of the folding crate in Figure 1 showing the side frame rotated relative to the base, and Figure 14B is a close-up view of section E in Figure 14A. [Figures 15A-15C] 15A and 15B are partial cross-sectional side views of the collapsible crate of FIG. 1 showing the side frames inserted into the receptacles of the base, and FIG. 15C is a front view of the collapsible crate of FIG. 1 in a folded configuration. [Figure 16] 2 shows the stack of collapsible crates in FIG. 1 in an assembled configuration. [Figures 17A-17B] Figure 17A is a front view of the first collapsible crate of Figure 1 stacked on a second collapsible crate in an assembled configuration, and Figure 17B is a partial cross-sectional view of section G in Figure 17A showing stacking projections on the side frames of the second collapsible crate received within recesses in the base of the first collapsible crate. [Figure 18] 2 shows the stack of collapsible crates in FIG. 1 in a folded configuration. [Figure 19A] 2 is a front view of the first collapsible crate of FIG. 1 stacked on top of the second collapsible crate in a folded configuration. [Figure 19B] 19B is a partial cross-sectional view of section H in FIG. 19A showing a nesting projection of a side frame of the second collapsible crate received within a recess in the base of the first collapsible crate. [Figure 20] FIG. [Figure 21] 21 is a top perspective view of the collapsible crate of FIG. 1 with the height extension member of FIG. 20. [Figure 22] 22 is a close-up view of the coupler of the height extension member in FIG. 21 having a stacked projection. [Figure 23] 21 is a close-up view of a connection portion of the height extension member in FIG. 20 configured to connect the top of the side frame of the folding crate in FIG. 1. FIG. [Figure 24A] 21 shows the height extension member of FIG. 20 aligned for attachment to the side frame of the folding crate of FIG. 1. FIG. [Figures 24B-24C] Figure 24B is a close-up view of part I in Figure 24A showing the rear end of the height extension member aligned for connection with the rear frame of the folding crate in Figure 1. Figure 24C is a close-up view, similar to Figure 24B, showing the rear end of the height extension member connected to the rear frame of the folding crate in Figure 1. [Figure 24D] FIG. 24D is a top perspective view of the rear end of a height extension member connected to the rear frame of the folding crate as in FIG. 24C. [Figures 25A-25B] Figure 25A is a close-up view of section J in Figure 24A showing the front end of the height extension member aligned for connection with the front frame of the folding crate in Figure 1. Figure 25B is a close-up view, similar to Figure 25A, showing the front end of the height extension member connected to the front frame of the folding crate in Figure 1. [Figure 26A] FIG. 10 is a top perspective view of a collapsible crate according to another embodiment. [Figure 26B] FIG. 26B is a bottom perspective view of the collapsible crate in FIG. 26A. [Figures 27A-27B] Figure 27A is a top perspective view of a coupler of a side frame of the collapsible crate in Figure 26A having stacking and nesting protrusions, and Figure 27B is a top perspective view of an extender coupler of a side frame of the collapsible crate in Figure 26A having stacking and nesting protrusions supported by an extender. [Figure 28A] 21 is a close-up view of a connector of a height extension member in FIG. 20 according to another embodiment. [Figures 28B-28C]Figure 28B is a bottom perspective view of a connection of the height extension member in Figure 28A coupled to a coupler of a side frame of the collapsible crate in Figure 26A. Figure 28C is a top perspective view of a connection of the height extension member in Figure 28A coupled to a coupler of a side frame of the collapsible crate in Figure 26A. [Figure 29A] FIG. 10 is a top perspective view of a collapsible crate according to another embodiment. [Figure 29B] FIG. 29B is a bottom perspective view of the collapsible crate in FIG. 29A. [Figure 29C] FIG. 29B is a perspective view of the bottom of the collapsible crate in FIG. 29A. [Figure 30A] 29B is a side view of one end of the collapsible crate of FIG. 29A, showing the support bar between the support wall and base of the collapsible crate. [Figures 30B-30C] Figure 30B is a close-up view of the connection between the base and support bar in Figure 30A. Figure 30C is a close-up view showing the connection between the support bar and support wall in the locked configuration in Figure 30A. [Figure 30D] 30D is a close-up view of the support bar in the unlocked configuration, similar to FIG. 30C. [Figure 31] 29B is a cross-sectional view of a leg of the support wall of the collapsible crate in FIG. 29A. FIG. [Figure 32] 29B is a top perspective view of a corner of a support wall of the collapsible crate in FIG. 29A. FIG. [Figure 33] 29B illustrates the connections between the collapsible crates in FIG. 29A when stacked to other collapsible crates in an assembled configuration. [Figure 34] 29B illustrates the connections between the foldable crates in FIG. 29A when stacked to other foldable crates in a folded configuration. [Figure 35A] 29B is an exploded view of the support wall legs and support bars removed from the base of the collapsible crate in FIG. 29A. FIG. [Figure 35B]29B is an exploded view of a support wall leg removed from a corner of the base of the collapsible crate in FIG. 29A, the corner having a locking recess and a guide slot extending from the locking recess to a track. [Figure 35C] 29B is a cross-sectional view of a portion of the collapsible crate of FIG. 29A showing the support bars attached to the support wall legs and base within the corner locking recesses. [Figure 36A] 29B is a side view of the corner of the collapsible crate in FIG. 29A with the cover panel removed to show the legs of the support wall within the locking recesses. [Figure 36B] 36A and 36B are side views illustrating the movement of the legs of the support wall as the support wall is transitioned from an erected configuration to a collapsed configuration. [Figure 36C] 36A and 36B are side views illustrating the movement of the legs of the support wall as the support wall is transitioned from an erected configuration to a collapsed configuration. [Figure 36D] 36A and 36B are side views illustrating the movement of the legs of the support wall as the support wall is transitioned from an erected configuration to a collapsed configuration. [Figure 36E] 36A and 36B are side views illustrating the movement of the legs of the support wall as the support wall is transitioned from an erected configuration to a collapsed configuration. [Figure 37A] 29B is a perspective view of the collapsible crate corner in FIG. 29A, showing the locking mechanism that secures the support walls in the assembled configuration. [Figure 37B] FIG. 37B is a bottom perspective view of the locking mechanism in FIG. 37A removed from the collapsible crate. [Figure 37C] 37B is a perspective cross-sectional view of the locking mechanism in FIG. 37A, and FIG. 37C shows the locking mechanism in an extended configuration. [Figure 37D] 37B is a perspective cross-sectional view of the locking mechanism in FIG. 37A, and FIG. 37D shows the locking mechanism in a retracted configuration. [Figure 38] 29B is a close-up view of the strap loops of the collapsible crate in FIG. 29A. FIG. [Figure 39]FIG. 10 is a perspective view of a collapsible crate according to another embodiment. [Figure 40] FIG. 10 is a perspective view of a collapsible crate according to another embodiment. [Figure 41A] FIG. 41 is a perspective view of a corner of the base of the collapsible crate of FIG. 40 in an assembled configuration. [Figure 41B] FIG. 41 is a perspective view of a corner of the base of the collapsible crate of FIG. 40 in a folded configuration. [Figure 42A-42B] Figure 42A is a perspective view of a portion of the side frame of the collapsible crate of Figure 40 in an assembled configuration. Figure 42B is a side view of the side frame of Figure 42A showing the support bar rotated to a stowed configuration. DETAILED DESCRIPTION OF THE INVENTION

[0008] 1-2, a stackable shipping structure, such as a stackable pallet or collapsible crate 100, is provided having a base 102 and side frames 104, 106. The base 102 has a support surface 108 and a receptacle 110 below the support surface 108. As shown in FIGS. 1-2, the crate 100 is in a crate form, or assembled configuration, with the side frames 104, 106 secured to the base 102 and extending perpendicularly from the support surface 108. A first side frame 104 extends upwardly from a first end 102A of the base 102, and a second side frame 104 extends upwardly from a second end 102B of the base 102. As described in more detail below, the base 102 may include locking recesses 132 (see, e.g., FIGS. 10A-10B and 12A-12B ) configured to receive the lower ends of the side frames 104, 106 and hold the side frames 104, 106 perpendicular to the support surface 108. One or more items (e.g., cargo, merchandise) may be stacked on the support surface 108 of the base 102 for transportation and / or storage. The side frames 104, 106 extend above the support surface 108 to allow other pallets or crates 100 to be stacked on top of the crate 100 and above the items on the support surface 108, as described in more detail below.

[0009] The receptacle 110 in the base 102 includes tracks 180 (see also FIGS. 9B-9C) along which the side frames 104, 106 slide when the crate 100 is transitioned between a crate configuration / erected configuration and a pallet or folded configuration (see FIG. 8A), as described below. The side frames 104, 106 can be stored in the receptacle 110 to reduce the size of the collapsible crate 100, for example, when the crate 100 is not in use, or when the crate 100 is used to transport items similar to a conventional pallet, and / or when not stacked with other crates 100. Thus, the crate 100 may be a hybrid of a conventional crate and a conventional pallet. The side frames 104, 106 allow the crates 100 to be stacked stably without resting on the cargo of the crates below, and the crates 100 can be stored within the base 102 for use or storage, similar to a conventional pallet.

[0010] The base 102 includes a support frame 112 and corner portions 170 having foot members 114 connected to and extending from the support frame 112. The support frame 112 is formed from a grid of support members. A support wall 116 including the support surface 108 can be attached to the upper side of the support frame 112. The support wall 116 can be formed from a metal plate to provide a flat surface with good strength and durability. In other embodiments, the support wall 116 is a plurality of slats, mesh, or grid rather than a solid surface. In other forms, the support wall 116 can be formed from other materials, such as wood, polymers, and combinations thereof.

[0011] The foot members 114 space the support frame 112 from a surface on which the base 102 of the crate 100 rests, such as a floor or another crate 100. The foot members 114 can provide sufficient space below the support frame 112 to insert, for example, the forks of a lifting device (e.g., a forklift and / or a pallet jack) between the foot members below the support frame 112. The forks engage the bottom surface of the support frame 112 to lift the crate 100 for transport. The bottom 118 of the foot members 114 can include recesses 120 sized and shaped to receive the stacking projections 122A, 122B and / or nesting projections 124A, 124B of the side frames 104, 106 of another crate 100. For example, the recesses 120 of the base 102 can be lowered into alignment with the projections 122A, 122B of another crate 100 in an assembled configuration for stacking the crates 100. The recesses 120 allow the protrusions 122A, 122B of the crate 100 to interlock with the recesses 120 in the base 102 of the crate 100 to prevent lateral movement of the crates 100 relative to one another. The recesses 120 in the base 102 may similarly be lowered into alignment with the protrusions 124A, 124B of another crate 100 in the folded configuration to stack the crates 100.

[0012] The base 102 may include support members 126 between the foot members 114 along both sides of the base 102. The support members 126 may be located at a midpoint along one side between the foot members 114. Locating the support members 126 at the midpoints allows the forks of a lifting device to be positioned around or across the support members 126. The support members 126 help support the support frame 112 from the surface on which the base 102 rests. The support members 126 help restrain the support frame 112 from bending or flexing due to the weight of items on the support surface 108.

[0013] The base 102 can include a protection bar 128 extending from the foot members 114 to the support member 126. The protection bar 128 can be positioned under the cross members 140 of the side frames 104, 106 when the side frames 104, 106 are stored in the storage compartment 110 of the base 102 (see FIG. 8A ). The protection bar 128 can protect the side frames 104, 106 from damage by making them less susceptible to contact and therefore damage. For example, forks of a lifting device inserted under the support frame 112 contact the protection bar 128 instead of the side frames 104, 106, thereby preventing the forks from damaging the side frames 104, 106 when the side frames 104, 106 are stored in the base 102. When multiple crates 100 are stacked, it is important to protect the side frames 104, 106 from damage (such as bending) because the side frames 104 may need to withstand large loads when used to support one or more other crates 100.

[0014] The base 102 may include one or more loops 130 to which straps may be connected or threaded. These straps may be used to secure items on the support surface 108 to the crate 100, for example, by connecting the strap to the loop 130.

[0015] The length and width dimensions of the base 102 vary depending on the application. The length and width dimensions of the base 102 correspond to standard pallet sizes, such as those commonly used in North America, Australia, Europe, and Asia. For example, the width x length dimensions (in millimeters) of a pallet may be 1,016 x 1,219, 1,000 x 1,200, 1,165 x 1,165, 1,067 x 1,067, 1,100 x 1,100, or 800 x 1,200.

[0016] The base 102 may be formed from a rigid material including, for example, metal (eg, steel) and / or plastic.

[0017] 1-3 , the side frame 104 includes an upper section 136 and a lower section 138. The side frame 104 can be formed of metal (e.g., steel), plastic, and / or other rigid materials. The upper section 136 includes a cross member 140, a coupler 142, and an extension coupler 144. The lower section 138 includes a first side section, such as a first leg 146, and a second side section, such as a second leg 148. The first leg 146 is connected to the extension coupler 144 and extends therefrom to the base 102. The second leg 148 is connected to the coupler 142 and extends therefrom to the base 102. The lower ends 150, 152 of the first leg 146 and the second leg 148 can be inserted into locking recesses 132 in the base 102 to secure the side frame 104 in an upright position relative to the base 102 when the crate 100 is in the assembled configuration. Each leg 146, 128 may have a guide pin 154 attached thereto and extending laterally outward from the leg 146, 148 (see FIG. 11 ). The guide pin 154 engages with a guide slot 172 to guide the lower ends 150, 152 of the legs 146, 148 as the side frames 104, 106 transition between the assembled and folded configurations, as described in more detail below.

[0018] When in the folded configuration, the legs 146, 128 rest on a track support surface 182 of the receptacle 110 of the base 102. The cross member 140 extends between the first leg 146 and the second leg 148 from the coupler 142 to the extension coupler 144. In the illustrated form, the first leg 146 is formed of two welded tubes 146A, 146B, and the second leg 148 is formed of two welded tubes 148A, 148B. The tubes 146A, 146B and the tubes 148A, 148B have rectangular cross sections and may be connected along the length of the rectangular cross sections of the tubes (see FIG. 9C ). Forming the legs 146, 148 from two tubes 146A, 146B or 148A, 148B can increase the strength of the legs 146, 148 and the load that the side frame 104 can support. The tubes of the legs 146, 146 can be hollow to reduce the weight of the legs. In other configurations, the legs 146, 148 can be solid to increase strength and rigidity. In some configurations, the legs 146, 148 can be formed from a single tube rather than two joined tubes. The cross-sectional shape of the tube can be any shape, such as rectangular, square, circular, or triangular. In some configurations, the legs 146, 148 can be structural members with other cross-sectional shapes, such as I-shaped or L-shaped, rather than tubular.

[0019] Referring to FIG. 4, the coupler 142 includes a stacking projection 122A and a nesting projection 124A. The coupler 142 can be formed of metal (e.g., steel), plastic, and / or other rigid material. The stacking projection 122A extends upward from the body 142A of the coupler 142 toward the second leg 148. Thus, when the side frame 104 is in the assembled configuration, the stacking projection 122A extends upward from the base 102. The stacking projection 122A is configured to be inserted into a recess 120 in the bottom of another crate 100 when the crates 100 are stacked together in the assembled configuration, as described below with reference to FIGS. 16-17B. The stacking projection 122A may be elongated and / or have a shape corresponding to the shape of the recess 120 in the base 102 into which the stacking projection 122A is inserted, thereby preventing the crate 100 from rotating or pivoting about the projection 122A. The sides of the stacking projection 122A slope inward as the stacking projection 122A protrudes from the body 142A of the coupler 142, which can help guide the stacking projection 122A into the recess 120 and aid in alignment when stacking the crates 100.

[0020] The nesting projection 124A extends substantially perpendicular to the stacking projection 122A such that when the crate 100 is in the folded configuration and the side frame 104 is stored in the base 102 (see FIG. 8A ), the nesting projection 124A extends upward from the base 102. The nesting projection 124A is an angled strip secured to and protruding from the body 142A of the coupler 142 and has a triangular profile. Between the nesting projection 124A and the body 142A of the coupler 142, the nesting projection 124A defines an opening 125A that can be used to secure the extension member 200 to the crate 100, as described below. The nesting projection 124A may be formed from a bent metal strip welded to the body 142A of the coupler 142. The nesting protrusions 124A are configured to be inserted into the recesses 120 on the bottom of other crates 100 when the crates 100 are in a stacked, folded configuration, as described below with reference to Figures 18-19B. The nesting protrusions 124A are elongated and / or have a shape that corresponds to the shape of the recesses 120 in the base 102 into which the nesting protrusions 124A are inserted, preventing the crate 100 from rotating or pivoting about the protrusions 124A. The nesting protrusions 124A slope inward as the stacking protrusions extend from the body 142A of the coupler 142, thereby helping to guide the nesting protrusions 124A into the recesses 120 and thereby assisting in aligning the crates 100 when stacked on top of each other.

[0021] Referring to FIG. 5, extension coupler 144 is similar to coupler 142 of FIG. 4, with the primary difference being that in extension coupler 144, body 144A of extension coupler 144 has extension portion 144B extending laterally from leg 146 of the side frame to which extension coupler 144 is attached. Extension coupler 144 includes stacking protrusion 122B and nesting protrusion 124B, which may be similar to stacking protrusion 122A and nesting protrusion 124A of coupler 142 of FIG. 4. Extension coupler 144 may be formed of metal (e.g., steel), plastic, and / or other rigid material. Nesting protrusion 124B may define opening 125B that can be used to secure extension member 200 to crate 100. The stacking projection 122B and the nesting projection 124B are attached to the extension 144B such that the stacking projection 122B and the nesting projection 124B are supported laterally from the legs of the side frame.

[0022] 1-3, the second side frame 106 is similar to the first side frame 104, and therefore the same reference numbers used with respect to the side frame 104 are used for like features of the side frame 106. The second side frame 106 includes an upper portion 136 that includes a cross member 140, a coupler 142, and an extension coupler 144, and a lower portion 138 that includes a first side portion, such as a first leg 146, and a second side portion, such as a second leg 148. The second side frame 106 is identical to the first side frame 104 and may be attached to the second end 102B of the crate 100.

[0023] 6, a front view of the crate 100 is provided showing that, when viewed from the front of the crate 100, the stacking projections 122A, 122B of the first and second side frames 104, 106 are aligned with one another, while the legs 146, 148 of the first and second side frames 104, 106 are misaligned. In particular, each of the legs 146, 148 of the side frames 104, 106 is spaced a different distance 158A, 158B, 158C, 158D, respectively, from an outer edge or left side surface 156 that extends upward from the left side of the base 102. Referring also to FIG. 3, the first side frame 104 (at the front of the crate 100) includes an extension coupler 144 on its left side, and the second side frame 106 (at the rear of the crate 100) includes a coupler 142. The extension coupler 144 of the first side frame 104 supports the stacking projection 122B laterally from the leg 146 so that the stacking projection 122B is spaced and aligned substantially the same distance 160A from the left side surface 156 as the stacking projection 122A of the second side frame 106. Similarly, the right side of the second side frame 104 includes an extension coupler 144, and the first side frame 104 includes a coupler 142. The extension coupler 144 of the second side frame 106 supports the stacking projection 122B laterally from the leg 146 of the second side frame 106 so that the stacking projection 122B is spaced and aligned substantially the same distance 160B from the left side surface 156 as the stacking projection 122A of the first side frame 104. The nesting protrusions 124A, 124B of the first side frame 104 are similarly aligned with the nesting protrusions 124A, 124B of the second side frame 106 because the extension couplers 144 of the first and second side frames 104, 106 laterally support the nesting protrusions 124B from the associated legs. Similarly, each of the legs 146, 148 of the side frames 104, 106 are at different distances from the right side surface extending upward from the right side of the base, while the protrusions are aligned as described above.

[0024] Staggering the legs of the side frames as described above allows the legs of the side frames 104, 106 to be stored in substantially the same vertical plane within the base 102 of the crate 100, thereby reducing the height of the base 102 required to store the first and second side frames 104, 106. More specifically, as described in more detail below, the receptacle 110 of the crate 100 includes four tracks 180 for receiving the legs of each of the first and second side frames 104, 106. The tracks 180 extend parallel to one another along substantially the same plane.

[0025] Furthermore, the use of the extension coupler 144 allows the stacking projections 122A, 122B and nesting projections 124A, 124B of the first and second side frames 104, 106 to align with one another despite the offset of the legs 146, 148. Therefore, the positions of the projections 122A, 122B, 124A, 124B are symmetrical about the crate 100, allowing the crates 100 to be easily stacked. For example, when stacking, the front face of one crate 100 can be aligned with either the front or rear face of another crate 100. As shown in FIG. 7 , the stacking projections 122A, 122B of the side frame 104 are aligned with the recesses 120 in the bottom of the foot members 114 of the base 102. The recesses 120 include first recesses 120A for receiving the stacking projections 122A, 122B of other crates 100. This allows another crate 100 to be stacked on top of the crate 100, with the stacking protrusions 122A, 122B aligned with and inserted into the recess 120A of the other crate 100. The nesting protrusions 124A, 124B of the side frame 104 are similarly aligned with the recess 120 in the bottom of the foot member 114 of the base 102. The recess 120 further includes a second recess 120B for receiving the nesting protrusions 124A, 124B of the other crate 100. This allows the other crate 100 to be stacked on top of the crate 100, with the nesting protrusions 124A, 124B aligned with and inserted into the recess 120B of the other crate 100. The protrusions 122A, 122B, 124A, and 124B of the second side frame 106 are similarly aligned with the recess 120 on the second end 102B of the base 102.

[0026] 8A-9A, crate 100 is shown in a folded configuration with side frames 104, 106 received within receptacles 110 in base 102. In this folded configuration, crate 100 can be used similarly to a conventional pallet, e.g., crate 100 can be lifted and moved with the forks of a lifting device and used with a palletizer to load items onto support surface 108.

[0027] As shown in FIGS. 8A-8B, the corner portion 170A of the base 102 can include a locking mechanism 190 for retaining the first side frame 104 and the second side frame 106 in the receptacle 110 of the base 102 when the side frames 104, 106 are stored in the base 102. While the following description will discuss the locking mechanism 190 of the corner portion 170A on the first end 102A of the base 102, the corner portion 170A on the second end 102B of the base 102 can also be used to retain the second side frame 106. As shown in FIG. 8B, the corner portion 170A can include a stopper protrusion 192. The stopper protrusion 192 can be positioned in the path of the side frame 104 to prevent the side frame 104 from sliding outward from the receptacle 110. In the illustrated embodiment, the stopper protrusion 192 engages the extension 144B of the extension coupler 144, limiting the movement of the side frame 104. To extend the side frame 104, the top 136 of the side frame 104 is lifted upward (by rotating the side frame 104 about the ends 150, 152) until the extension coupler 144 is positioned over the stopper protrusion 192 and can be pulled outward and past the protrusion 192. In some embodiments, the stopper protrusion 192 is positioned to engage the cross member 140 of the side frame 104. To remove the side frame 104, the side frame 104 is lifted upward until the cross member 140 is positioned over the stopper protrusion 192 and can therefore be pulled outward and past the protrusion 192.

[0028] The locking mechanism 190 of the base 102 may further include flanges 191 at each corner of the base 102. In the folded configuration, the flanges 191 extend outward and over a portion of the couplers 142, extension couplers 144, and / or cross members 140 of the side frames 104, 106. The flanges 191 may limit the extent to which the upper portions 136 of the side frames 104, 106 can pivot upward, thereby preventing the side frames 104, 106 from inadvertently passing over the stop protrusions 192, for example, if the crate 100 bounces or vibrates during transport and / or palletization. Thus, the flanges 191 help retain the side frames 104, 106 within the receptacles 110 of the base 102. In addition, in the assembled configuration, the flanges 191 contact the ends 150, 152 of the first and second side frames 104, 106 to prevent the side frames 104, 106 from rotating relative to the base 102 and make the side frames 104, 106 more rigid.

[0029] 9B, the receptacle 110 of the base 102 includes four tracks 180 that each receive one leg of the first side frame 104 and the second side frame 106 when the crate 100 is in the folded configuration. The base 102 includes two tracks 180A and 180B on the left side of the crate 100 and two tracks 180C and 180D on the right side of the crate 100. The tracks 180A and 180C receive the legs 146 and 148 of the second side frame 106, respectively, and the tracks 180B and 180D receive the legs 146 and 148 of the first side frame 104, respectively. The tracks 180 extend approximately parallel to each other and lie in substantially the same vertical plane, which advantageously allows the base 102 to receive the forks of a lift device while reducing the size (e.g., height) of the base 102 of the crate 100.

[0030] FIG. 9C shows a detailed view of portion B in FIG. 9B , showing a cross section of the track 180 on the left side of the base 102. The track 180 on the right side of the base 102 is similar to the track 180 on the left side of the base 102. Each track 180 includes a track support surface 182 along which the legs of the side frames 104, 106 slide when transitioning between the folded configuration and the assembled configuration. Furthermore, when the side frames 104, 106 are inserted into the receptacle 110 in the folded configuration, the legs of the side frames 104, 106 rest on the track support surface 182. The track 180 can include a left side wall 184 and a right side wall 186, respectively, to guide the legs 146, 148 as they slide along the track and to maintain the legs 146, 148 aligned with the track. In the illustrated form, the tracks 180 comprise separate tubes 162 having rectangular cross-sections that define openings larger than the cross-sections of the legs 146, 148 of the first and second side frames 104, 106, respectively. In other forms, the tracks 180 may comprise adjacent U-shaped channels that form slots for receiving the associated legs 146, 148 of the side frames 104, 106.

[0031] 10A-11 show side views of a corner portion 170 of the base 102. Each corner of the base 102 can include a similar corner portion 170, and therefore the following description is equally applicable to the corner portions 170 of all corners of the base 102. The corner portion 170 includes a locking recess 132, a track support surface 182, and a guide slot 172 extending from the locking recess 132 to the track support surface 182. The locking recess 132 includes a support wall 166 that defines a cavity 168 for receiving the ends 150, 152 of the legs 146, 148 of the side frames 104, 106. When the leg ends 150, 152 are inserted into the cavity 168, the support wall 166 engages the sides of the legs 146, 148, locking or preventing the legs 146, 148 from rotating relative to the base 102. The inner support wall and / or the outer support wall 166 may be tapered to help guide and align the ends 150, 152 of the side frames 104, 106 as they are inserted into the locking recesses 132. For example, as shown in FIGS. 10A-10B , the inner surface 166A of the outer support wall 166 is tapered. The outer surface 152A of the end 152 also has a taper that corresponds to the taper of the inner surface 166A of the outer support wall 166. The tapered shape of the end 152 and the locking recess 132 helps guide the end 152 into the locking recess 132 and acts as a wedge to enhance frictional engagement between the locking recess 132 and the end 152. Thus, the tapered shape helps secure the leg 148 in the locking recess 132, preventing the leg 148 from wobbling or being unintentionally withdrawn after insertion. Ends 150 of legs 146 are similarly tapered and are inserted into locking recesses 132 on the other side of crate 100. Locking recesses 132 do not need to be equipped with a locking mechanism to physically secure legs 146, 148 to lock recesses 132, but instead, locking recesses 132 can lock legs 146, 148 against rotation and by frictional engagement therebetween.

[0032] The guide slots 172 receive guide pins 154 (see FIG. 11 ) extending laterally from the ends 150, 152 of the legs 146, 148 of the side frames 104, 106. The guide slots 172 guide the pins 154 of the legs 146, 148 as the side frames 104, 106 transition between the folded configuration and the assembled configuration. Referring to FIG. 10A , the guide slots 172 include upper cam surfaces 174 that the leg pins 154 engage when the side frames 104, 106 are lifted upward from the locking recesses 132. In other words, the upper cam surfaces 174 limit the distance the side frames 104, 106 can be lifted out of the locking recesses 132, thereby preventing the side frames 104, 106 from being removed from the base 102. In the illustrated embodiment, the upper cam surface 174 has a curved portion such that the upper cam surface 174 directs the pins 154 of the legs 146, 148 toward the track support surface 182 of the receptacle 110. For example, when the legs 146, 148 are lifted from the cavities 168 of the locking recesses 132, the pins 154 of the legs 146, 148 can pivot outward from the base 102 of the crate 100 while sliding along the curved portion of the upper cam surface 174 of the guide slots 172. The side frames 104, 106 can slide inward into the receptacles 110 of the base 102, stowing the side frames 104, 106. The curved portion of the upper cam surface 174 can similarly limit the distance the side frames 104, 106 can be withdrawn from the base 102. For example, the pins 154 on the legs 146, 148 may engage a curved portion of the upper cam surface 174 to limit the distance the side frames 104, 106 can be pulled out of the base 102. The pins 154 may be slid along the upper cam surface 174 (e.g., by pivoting the side frames 104, 106 upward) into the locking recesses 132, securing the side frames 104, 106 in the locking recesses 132.

[0033] The guide slot 172 further includes a lower cam surface 176. When the side frames 104, 106 are slid inward into the receptacle 110, the pins 154 of the legs 146, 148 can engage the lower cam surface 176. The lower cam surface 176 slopes upward from the lock recess 132 toward the track support surface 182, so that when the side frames 104, 106 are inserted into the base 102, the lower cam surface 176 guides the ends 150, 152 of the legs 146, 148 upward toward the track support surface 182 of the track. Conversely, when the side frames 104, 106 are removed from the base 102, the lower cam surface 176 guides the ends 150, 152 of the legs 146, 148 downward toward the lock recess 132.

[0034] The corner portions 170 of the base 102 may include angled surfaces 178 extending from the inner support walls 166 of the locking recesses 132 to the track support surfaces 182. The angled surfaces 178 may provide clearance for the ends of the legs 146, 148 as the legs pivot about the pins 154 to slide between the track support surfaces 182 and the locking recesses 132. The angled surfaces 178 guide the legs 146, 148 between the locking recesses 132 and the track support surfaces 182 by providing an inclined surface against which the ends 150, 152 of the legs 146, 148 slide as the side frames 104, 106 are moved between the assembled and folded configurations. The use of the angled surfaces 178 to guide the legs 146, 148 may be an alternative to, or in addition to, the use of the guide slots 172 and pins 154.

[0035] In another embodiment, as shown in FIGS. 10C-10D, the corner portion 170 does not include the angled surface 178, but instead includes an opening 171 extending from the support wall 166 to the track support surface 182. Eliminating the angled surface 178 can help reduce the weight of the crate 100. Additionally, the cavity 168 of the locking recess 132 can extend to the bottom side of the crate 100. The locking recess 132 can include protrusions 132A, 132B that contact the end portions 150, 152 of the legs of the side frames 104, 106 when fully inserted, limiting the insertable distance of the end portions 150, 152 and providing support for the legs of the side frames 104, 106. Using the protrusions 132A, 132B instead of the bottom wall can reduce the material required to form the corner portion 170, thereby reducing the overall weight of the crate 100. Furthermore, by extending the cavity 168 of the locking recess 132 below the protrusions 132A, 132B, debris is provided with space to fall and collect so that the debris does not prevent the side frames 104, 106 from being fully inserted into the locking recess 132.

[0036] 12A-15C, the process of transitioning the crate 100 between the assembled and folded configurations is described. FIG. 12A shows a schematic side view of the crate 100 in the assembled configuration, with the side frames 104, 106 extending perpendicular to the support surface 108 of the base 102. FIG. 12B is a detailed view of section C in FIG. 12A, showing the leg ends 152 of the side frames 104 inserted into the locking recesses 132 of the base 102. As shown, the pins 154 are within the portions of the guide slots 172 that extend into the locking recesses 132. The support walls 166 of the locking recesses 132 prevent the legs of the side frames 104 from rotating relative to the base 102.

[0037] 13A , the side frame 104 can be lifted upward in direction 194 to remove the leg ends 152 of the side frame 104 from the locking recesses 132 and above the inner support wall 166. For example, a user can grasp the legs 146, 148 and / or the cross member 140 of the side frame 104 and lift the side frame 104 in direction 194 to remove the side frame 104 from the locking recesses 132. FIG. 13B is a detailed view of portion D in FIG. 13A , showing the end 152 of the side frame 104 being lifted from the locking recesses 132. As the side frame 104 is lifted, the guide pin 154 comes into contact with the upper cam surface 174 of the guide slot 172, limiting the amount of movement of the side frame 104 in direction 194. Referring to FIG. 14A , once the side frame 104 is lifted out of the locking recess 132, the upper portion 136 of the side frame 104 can be pivoted outward and downward to align the legs 146, 148 of the side frame 104 with the track 180 of the base 102. FIG. 14B is a detailed view of portion E of FIG. 14A , illustrating the movement of the end portion 152 of the side frame 104 as the upper portion 136 of the side frame 104 is lowered. As shown, the guide pin 154 of the side frame 104 slides within the guide slot 172 from the locking recess 132 toward the track support surface 182, as indicated by arrows 196A, 196B, and 196C. As the side frame 104 pivots, the guide pin 154 can contact the upper cam surface 174 and / or the lower cam surface 176 of the guide slot 172, guiding the end of the side frame 104 along the guide slot 172 toward the track support surface 182.

[0038] 15A-15B, once the side frame 104 is pivoted outward until the legs 146, 148 are approximately parallel to the track 180, the side frame 104 can slide inward in direction 198 along the track 180 of the receptacle 110 in the base 102. The side frame 104 can slide along direction 198 until the extension coupler 144 and / or cross member 140 of the side frame 104 pass the stopper protrusion 192, as shown in FIGS. 15B-15C. Once the stopper protrusion 192 prevents the side frame 104 from sliding out of the receptacle 110 in the base 102, the side frame 104 can be lowered onto the track 180.

[0039] The second side frame 106, like the first side frame 104 described above, can be inserted into the receptacle 110 of the base 102 to place the crate 100 in the folded configuration. The crate 100 can be moved from the folded configuration to the assembled configuration by reversing the steps described above with respect to Figures 12A-15C.

[0040] As shown in FIG. 16 , in an assembled configuration, multiple crates 100 can be stacked on top of each other. As shown, five crates 100 are stacked vertically, but any number of crates 100 can be stacked. Stacking assembled crates 100 can be advantageous for saving space when transporting or storing items on the crates 100. For example, stacking crates 100 reduces the area required for each crate, such as in a warehouse or transportation vehicle. When stacked, items can be stored on the support surface 108 of the crates 100, while the side frames 104, 106 provide clearance for the items by spacing the crates 100 apart. Thus, a crate 100 need not rest on items from the crates 100 below it, as it is supported by the rigid side frames 104, 106 of the crates 100 directly below.

[0041] Referring to FIG. 17A, couplers 142 and extension couplers 144 can be used to connect two stacked crates 100 in an assembled configuration. Specifically, stacking projections 122A, 122B of the first and second side frames 104, 106 of the lower crate 100 can be inserted into recesses 120A in the base 102 of the upper crate 100. Referring to FIG. 17B, a schematic diagram is shown illustrating stacking projection 122A of the side frame 104 being inserted into recess 120A in the base 102 of the upper crate 100. The other stacking projections 122A, 122B can be inserted into recesses 120A in the base 102 of the crate 100 in a similar manner. The stacking projections 122A extend upward into the base 102 and limit lateral movement of the crate 100, particularly when all four stacking projections 122A, 122B are similarly inserted into corresponding recesses 120A of the upper crate 100. The stacking projections 122A, 122B can have sloped surfaces that help align the recesses 120A of the base 102 to receive all four stacking projections 122A, 122B when the base 102 is lowered onto the lower crate 100. The recesses 120A can also have sloped sidewalls that define the recesses 120A and help align the recesses 120A with the stacking projections 122A, 122B.

[0042] Referring to FIG. 18 , crates 100 in the folded configuration can also be stacked on top of each other. As shown, 17 crates 100 are stacked vertically on top of each other (e.g., for loading into a high-cube shipping container), but any number of crates 100 can be stacked in the folded state. Stacking folded crates 100 can be advantageous for saving space when transporting or storing these crates 100 when not being used to transport or store items. For example, stacking crates 100 can reduce the area required for each crate, for example, in a warehouse or transportation vehicle. In addition to being stacked, the crates 100 are connected by couplers 142 and extension couplers 144, which prevents the crates 100 from sliding significantly against each other and allows for a more stable stack of crates 100.

[0043] Referring to Figure 19A, couplers 142 and extension couplers 144 can be used to connect two stacked crates 100 in the folded configuration. Specifically, the nesting projections 124A, 124B of the first and second side frames 104, 106 of the lower crate 100 can be inserted into the recesses 120B in the base 102 of the upper crate 100. Figure 19B shows a schematic diagram illustrating the nesting projection 124A of the side frame 104 being inserted into the recess 120B in the base 102 of the upper crate 100. The other stacking projections 124A, 124B can be inserted into the recesses 120B in the base 102 of the crates 100 in a similar manner. The nesting projections 122A extend upward toward the base 102, limiting lateral movement of the crate 100, particularly when all four stacking projections 122A, 122B are similarly inserted into corresponding recesses 120B of the upper crate 100. The stacking projections 124A, 124B may have sloped surfaces that help align the recesses 120 of the base 102 to receive all four nesting projections 124A, 124B when the base 102 is lowered onto the lower crate 100. The nesting projections 124A are angled strips with a triangular profile that help align the nesting projections 124A, 124B with the recesses 120B. Additionally, the recesses 120B may further have sloped sidewalls defining the recesses 120B that help align the recesses 120 with the nesting projections 124A, 124B.

[0044] Referring to FIG. 20 , an extension member 200 is provided that can be used with multiple crates 100 described above to extend the height of the crate 100. Referring to FIG. 21 , the crate 100 is shown with two extension members 200 attached across the side frames 104, 106 to extend the height of the crate 100. The two extension members 200 can be positioned on the first and second side frames 104, 106 of the crate 100 to extend the height of the crate 100. The multiple extension members 200 extend from the first side frame 104 to the second side frame 106 of the crate 100, with one extending along the left side of the crate 100 and the other extending along the right side of the crate 100. In another embodiment, each extension member 200 extends upward from one of the side frames 104, 106 rather than spanning both side frames 104, 106. The extension member 200 can be used, for example, where the height of items stored on the support surface 108 of the crate 100 exceeds the height of the side frames 104, 106. Placing the extension member 200 on top of the crate 100 allows another crate 100 to be stacked on top of the crate 100 without damaging the items stored on the crate 100.

[0045] 20 , extension member 200 includes a first side member 202, a second side member 204, and a cross member 206 extending from first side member 202 to second side member 204. First side member 202 and second side member 204 may each be connected to cross member 206 by a coupler 208. For example, each side member 202, 204 may be connected to an end of cross member 206. First side member 202, second side member 204, cross member 206, and coupler 208 may be formed from metal (e.g., steel), plastic, and / or other rigid material.

[0046] 22, coupler 208 includes stacking projections 210 similar to stacking projections 122A and 122B described above. Stacking projections 210 are inserted into recesses 120 in base 102 of crate 100 to support and secure another crate 100 on extension member 200.

[0047] Referring again to FIG. 20 , the first side member 202 extends from the cross member 206 to a first connecting portion 212 configured to connect to the coupler 142 and / or extension coupler 144 of the crate 100. The second side member 204 extends from the cross member 206 to a second connecting portion 214 configured to connect to the coupler 142 and / or extension coupler 144 of the crate 100. With reference to FIG. 23 , the first connecting portion 212 comprises a body 212A having a recess 216, a support flange 218 extending from the body 212A, a locking pin, such as an inner pin 220, extending from the body 212A, and a guide pin, such as an outer pin 222, extending from the support flange 218. The second connecting portion 214 is similar to the first connecting portion 212, and therefore the description of the first connecting portion 212 applies equally to the second connecting portion 214 and will not be repeated here. The recess 216 is large enough to receive the stacking projections 122A, 122B of the side frames 104, 106 when the extension member 200 is placed on the crate 100. In the illustrated form, the recess 216 is exposed and extends from the bottom and sides of the main body 212A, but in other embodiments, the main body 212A may enclose the recess 216 such that the recess 216 is accessible only from the bottom of the main body 212A.

[0048] Referring to FIG. 24A, the top of the side frames 104, 106 of the crate 100 is shown with one extension member 200 aligned for connection to the crate and the other extension member 200 coupled to the side frames 104, 106 of the crate 100. The recesses 216 of the first and second connecting portions 212, 214 align with and are lowered onto the stacking projections 122A, 122B of the crate 100, coupling the extension member 200 to the crate 100. Referring to FIGS. 24B-24D, a close-up view of section I of FIG. 24A is shown, showing how the second connecting portion 214 is connected to the crate 100 to secure the extension member 200 to the crate 100. Referring to FIG. 24B, the inner pin 220 is aligned with the opening 125A of the nesting projection 124A on the inside of the side frame 106. The support flange 218 is aligned with the cross member 140 of the side frame 106 and the outer locking pin 222 is aligned with the coupler 142 and / or the outer side of the cross member 140 of the side frame 106 .

[0049] 24C-24D , to connect the second connecting portion 214 to the side frame 106, the extension member 200 is lowered onto the coupler 142 and / or cross member 140 of the side frame 106 such that the inner pin 220 extends along the inner surface of the coupler 142 while the outer locking pin 222 extends along the outer surface of the coupler 142 and / or cross member 140. The inner pin 220 is inserted into the opening 125A in the lamination projection 124A of the side frame 106 while the lamination projection 122A of the side frame is inserted into the recess 216 in the second connecting portion 214. The extension member 200 can be lowered until the support flange 218 and / or the body 214A rests on the coupler 142 and / or cross member 140 of the side frame 106.

[0050] 25A-25B, there is shown a close-up view of section J of FIG. 24A showing how first connector 212 is connected to crate 100 to secure extension member 200 to crate 100. Referring to FIG. 25A, inner pin 220 is aligned with opening 125B formed by nesting protrusion 124B on the inside of side frame 104. Support flange 218 is aligned with cross member 140 of side frame 104 such that outer locking pin 222 is aligned with the outside of extension coupler 144 of side frame 104.

[0051] 25B, to connect the first connecting portion 212 to the side frame 104, the extension member 200 is lowered onto the extension coupler 144 of the side frame 104 so that the inner pin 220 extends along the inner surface of the extension coupler 144, while the outer locking pin 222 extends along the outer surface of the extension coupler 144. The inner pin 220 is inserted into the opening 125B of the nesting protrusion 124B of the side frame 104, similar to the connection of the second connecting portion 214 shown in FIGS. 24C-24D. The stacking protrusion 122B of the side frame 104 is inserted into the recess 216 of the first connecting portion 212. The extension member 200 may be lowered until the support flange 218 and / or the main body 212A rest on the extension coupler 144 of the side frame 104.

[0052] The inner pin 220 and outer pin 222 of the first and second connecting portions 212, 214 secure the extension member 200 to the side frames 104, 106. The inner pin 220 and outer pin 222 may be sized to securely receive the coupler 142 and / or extension coupler 144 therebetween, preventing the extension member 200 from rotating relative to the side frames 104, 106. The nesting protrusions 124A, 124B may further restrict movement of the inner locking pin 222 of the first and second connecting portions 212, 214. For example, the openings 125A, 125B of the nesting protrusions 124A, 124B may be sized to securely receive the inner locking pin 222 therebetween, preventing the extension member 200 from rotating relative to the side frames 104, 106.

[0053] 21, when the extension members 200 are secured to the crates across the side frames 104, 106, a crate 100 is stacked on the extension members 200 of that crate 100. The side frames 104, 106 and extension members 200 space the base 102 of the upper crate 100 from the support surface 108 of the lower crate 100, providing clearance for one or more items placed on the support surface 108 of the lower crate 100.

[0054] 26A-26B, a stackable pallet or folding crate 300 is provided, which is similar in many respects to the several embodiments of the folding crate 100 described above, with the differences emphasized. The folding crate 300 has a base 302 and side frames 304, 306 extending upwardly from the base 302. The side frames 304, 306 can be stored within the base 302, as described above. The base 302 includes corner portions 370 with foot members 314 for supporting the frame 312 of the base 302 above the surface on which the crate 300 rests. In this embodiment, the inner side 314A of the foot member 314 is angled to provide more clearance for the forks of a lifting device. This angled inner side 314A further reduces the material required for the foot members 314, thereby reducing the overall weight of the crate 300.

[0055] Each side frame 304, 306 includes a coupler 342 and an extension coupler 344. Referring to FIG. 27A , coupler 342 includes a stacking projection 322A and a nesting projection 324A. Coupler 342 is similar to coupler 142 of crate 100 described above, with the differences highlighted. In this embodiment, the thickness of the body of nesting projection 324A is increased relative to the thickness of coupler 142 to enhance the strength and rigidity of nesting projection 324A. Nesting projection 324A is smaller than coupler 142 and includes an opening 325A that corresponds in size and shape to the locking pin of an extension member inserted therein. The opening 325A in nesting projection 324A can aid in positioning and limiting the movement of an extension member attached thereto.

[0056] Referring to FIG. 27B , extension coupler 344 includes stacked projection 322B and nested projection 324B supported by extension 344B. Extension coupler 344 is similar to extension coupler 144 of crate 100 described above, with the differences highlighted. In this embodiment, the thickness of the body of nested projection 324B is increased relative to the thickness of extension coupler 144 to enhance the strength and rigidity of nested projection 324B. Nested projection 324B includes an opening 325B that is smaller than that of extension coupler 144 and corresponds in size and shape to the locking pin of an extension member inserted therein. Opening 325B in nested projection 324B can aid in positioning and limiting movement of an extension member attached thereto.

[0057] Referring to FIG. 28A, the second connecting portion 214 of the extension member 200 is shown with a locking pin 220, according to an embodiment. In this embodiment, the locking pin 220 has an increased thickness, and the length of the base 220A of the locking pin 220, which is attached to the body 214A of the second connecting portion 214, is increased, thereby improving the strength and rigidity of the locking pin 220. The locking pin 220 of the first connecting portion 212 can be similarly modified. Referring to FIGS. 28B-28C, the second connecting portion 214 of FIG. 28A is shown connected to the coupler 342 of FIG. 27A. As shown, the cross-section of the locking pin 220 corresponds to the cross-section of the opening 325A of the nesting protrusion 324A, thereby forming a stronger connection therebetween. The locking pin 220 of the first connecting portion 212 also forms a tight connection with the extension coupler 344.

[0058] 29A-29C, a stackable pallet or folding crate 400 is shown according to another embodiment. The folding crate 400 is similar to the folding crate embodiments described above, with the differences being highlighted. The folding crate 400 includes a base 402 and side frames 404 and 406. The side frames 404 and 406 are movable between an assembled configuration and a folded configuration. In the assembled configuration shown in FIGS. 29A-29C, the side frames 404 and 406 extend upwardly from the base 402. In the folded configuration (see FIG. 34), the side frames 404 and 406 are stored in tracks within the base 402, as described with respect to the other embodiments above. In the folded configuration, the folding crate 400 can be used similarly to a conventional pallet, supporting items on a support surface 408 of the base 402. In the illustrated embodiment, the support surface 408 is a mesh plate 410 extending above the base 402. In another embodiment, the support surface 408 may be a plate that provides a flat, solid surface. Items to be stored and / or transported may be placed on the support surface 408 of the collapsible crate 400. By removing the side frames 404, 406 from the base 402, the collapsible crate 400 may be moved to an assembled configuration, allowing another collapsible crate to be stacked on top of the collapsible crate 400. An upper collapsible crate may rest on the side frames 404, 406 of a lower collapsible crate 400, rather than on the items on the base 102 of the lower collapsible crate 400. Stacking the collapsible crates 400 using these rigid side frames 404, 406 allows for heavier crates to be stacked without damaging the items on the crates. Additionally, stacking the crate 400 allows multiple crates (e.g., five) to be stacked in one stack, allowing more crates to be stored in a single crate footprint, resulting in more efficient use of space and occupying less floor space on loading equipment (e.g., ships) or in warehouses.

[0059] 30A-30D, the foldable crate 400 includes support bars 412, 413 that provide support for the side frames 404, 406 when the foldable crate 400 is in the assembled configuration. The support bars 412, 413 extend from the side frames 404, 406 to the base 402 to support the side frames 404, 406 and prevent the side frames 404, 406 from substantially rotating relative to the base 402 when the foldable crate 400 is in the assembled configuration. The support bars 412, 413 thus increase the strength and rigidity of the side frames 404, 406 of the foldable crate 400, allowing more crates 400 to be stacked in a single stack. For simplicity, the following description will refer to the support bar 412 extending from the side frame 404 to the base 102, although the support bar 413 extending from the side frame 406 to the base 102 is similar in structure and function. It should be understood that the support bars 412, 413 may be used with any of the foldable crates described herein. The support bar 412 has a first end 414 that connects to a leg 418 of the side frame 404 and an opposite second end 416 that connects to the base 102.

[0060] The second end 416 of the support bar 412 can be removably connected to the base 102. The second end 416 of the support bar 412 can be connected to the base 102 to support the side frames 404 when the foldable crate 400 is in the assembled configuration. For example, the support bar 412 prevents the side frames 404 from pivoting outward from the base 402. When the foldable crate is in the collapsed configuration, the second end 416 can be detached from the base 102 and pivoted upward in direction 420 about the first end 414 to the storage configuration. In the storage configuration, the support bar 412 extends along the legs 418 of the side frames 404, allowing the side frames 404 to be inserted into the base 402 (see FIG. 30A ).

[0061] 30B, 35A, and 35C, the second end 416 of the support bar 412 has a hook configuration. The second end 416 may have an extension 422 extending generally parallel to the length of the support bar 412 and a protrusion or pin portion 424 extending laterally from the extension 422. The base 402 of the crate 400 may have a connector 426 to which the second end 416 of the support bar 412 can be removably attached. The connector 426 may be inserted into the frame 572 of the base 402 below the support surface 408. The connector 426 includes a connector body 428 having a side wall 430 and a guide surface 432 that forms a recess 434 for receiving a portion of the second end 416 of the support bar 412. The connector 426 includes a top wall 436 that extends into the recess 434 to form a mounting slot 438. The pin portion 424 has a width greater than the mounting slot 438.

[0062] To attach the second end 416 to the base 402, the pin portion 424 is inserted into the recess 434 and slid along the guide surface 432 until the extension portion 422 is in the mounting slot 438 and the pin portion 424 is positioned below the top wall 436. The side wall 430 prevents the second end 416 from moving laterally within the recess 434 to maintain the pin portion 424 below the top wall 436. The guide surface 432 may be sloped to bias or guide the pin portion 424 to be positioned below the top wall 436. When the pin portion 424 is positioned below the top wall 436, the top wall 436 limits the upward movement of the pin portion 424, thereby limiting the movement of the side frame 404. The extension portion 422 may have a narrow width relative to the main body 412A of the support bar 412 and the pin portion 424, which is sized to allow the extension portion 422 to slide within the mounting slot 438 of the base 402. The body 412A of the support bar 412 and / or the pin portion 424 may have a width that is too large to pass through the mounting slot 438. To remove the second end 416 from the base 402, the pin portion 424 can be slid upward along the guide surface 432 until the pin portion 424 is no longer below the top wall 436, at which point the second end 416 can be lifted off the connector 426.

[0063] 30C-30D, a first end 414 of the support bar 412 may be pivotally connected to a leg 418 of the side frame 404. The pivotal connection of the support bar 412 to the side frame 404 allows the support bar 412 to be moved to a storage configuration without being removed from the folding crate 400. The first end 414 of the support bar 412 has an opening 440 through which a pin 442 of the side frame 404 extends. The pin 442 is secured (e.g., by welding) to the leg 418 of the side frame 404. A clip 444 may extend through the end of the pin 442 to secure the first end 414 of the support bar 412 to the pin 442 and limit movement of the first end 414 along the pin 442. The support bar 412 is rotatable about its connection with the pin 442 to allow the support bar 412 to be moved from the assembled configuration to the stored configuration.

[0064] The first end 414 of the support bar 412 may further include a locking pin 446 for securing the support bar 412 in the assembled configuration and the stowed configuration. The legs 418 of the side frame 404 include a first locking opening 448 and a second locking opening 450. The locking pin 446 can be inserted into the first locking opening 448 to secure the support bar 412 in the assembled configuration and into the second locking opening 450 to secure the support bar 412 in the stowed configuration. The first end 414 of the support bar 412 can be shifted laterally in a direction 454 relative to the legs 418 to insert the locking pin 446 into the first locking opening 448 or the second locking opening 450. To enable the support bar 412 to be transitioned between a storage configuration or an assembled configuration, the first end 414 of the support bar 412 can be shifted laterally relative to the leg 418 in a direction opposite to the direction 454 to remove the locking pin 446 from the first locking opening 448 or the second locking opening 450.

[0065] Referring again to FIGS. 29A-29C, the base 402 of the foldable crate 400 can include a plurality of runners 456 extending between the plurality of corners 458 of the base 402. The runners 456 can extend along and rest on a surface (e.g., the ground or floor) on which the foldable crate 400 rests. The runners 456 provide a surface for supporting the foldable crate 400 on a conveyor, such as a roller or chain conveyor, which can contact the runners 456 to move the foldable crate 400 along the conveyor system. The runners 456 provide the base 402 with increased rigidity. The runners 456 connect the corners 458 to support members 460 positioned along the sides of the base 402 between the plurality of corners 458. The support members 460 can include mounting brackets 462 to which an RFID tag can be attached. The radio frequency identification (RFID) tag can be used to track the collapsible crate 400 or the contents carried by the collapsible crate 400. For example, the RFID tag can store information about the items carried by the collapsible crate 400. During transportation, the RFID tag can be scanned at various times (e.g., when loaded onto a carrier or when stored in a warehouse) to allow tracking of the items and / or the collapsible crate 400. The support member 460 can form multiple walls around the mounting bracket 462 to protect the RFID tag and prevent inadvertent contact that could cause damage to the RFID tag.

[0066] Referring to FIG. 31 , a cross section of leg 418 of side frame 404 is shown. The other legs of side frames 404, 406 can have a similar configuration. Leg 418 is composed of a first support column 464 and a second support column 466 welded together. First support column 464 has a wall portion 468 extending around an interior perimeter 470. Wall portion 468 has a rectangular portion 472 and a folded portion 474 extending from the corner of rectangular portion 472. Second support column 466 similarly has a wall 476 forming a rectangular portion 478 and a folded portion 480. First support column 464 and second support column 466 are joined in an opposing but generally cooperating configuration such that folded portion 474 of first support column 464 is opposite folded portion 480 of second support column 466. The folded portion 474 of the first support column 464 extends along a portion of the rectangular portion 478 of the second support column, and the folded portion 480 of the second support column 466 extends along the rectangular portion 472 of the first support column 464 to provide increased support and rigidity for the leg 418. The folded configuration of the first support column 464 and the second support column 466 provides increased strength for the leg while minimizing weight with hollow interiors.

[0067] Referring to FIG. 32 , the side frame 404 includes couplers 482 at the corners of the legs 418 and an upper cross member 484. The couplers 482 have a configuration similar to that of the couplers in the previous embodiments. The couplers 482 include openings 486 extending into a body 490 of the coupler 482 and openings 488 in the mounting projections 492. The openings 486 and 488 allow the coupler 482 to reduce material and weight while maintaining sufficient strength to support other folding crates 400. The side frame 404 also includes a plate 494 attached to the upper cross member 484 adjacent the coupler 482. The plate 494 contacts the base 402 when the side frame 404 is in the folded configuration. The plate 494 adds strength to the cross member 484 of the side frame 404. An extension coupler 496 (see FIG. 29A) may similarly include an opening in the body and a mounting projection of the extension coupler 496. The side frame 404 may also include a plate 494 attached to the cross member 48 adjacent the extension coupler (see FIG. 29A).

[0068] 33, the connection between multiple foldable crates 400 is shown when stacking crates 400 on top of one another in an assembled crate 400. The corners 458 of the bases 402 of the crates 400 have recesses 498 sized to receive the mounting protrusions 492 of the couplers 482. The mounting protrusions 492 align with corresponding recesses 498 in the corners 458 of the bases 402. An upper crate 400 can be lowered onto a lower crate 400 so that the mounting protrusions 492 insert into the recesses 498. The other corners 458 of the bases 402 similarly have recesses that align with and receive the mounting protrusions of the other couplers 482 and extension couplers 496 of the lower crates 400 as the upper crate 400 is lowered onto the lower crate 400. The upper crate 400 is lowered until it rests on the side frames 404, 406 of the lower crate 400. The connections between the mounting lugs of the lower crate 400 and the corners 458 of the upper crate 400 prevent the crates from moving laterally relative to each other.

[0069] Referring to FIG. 34, similar to the foldable crates 400 described above, connections between foldable crates 400 are shown when one crate 400 is stacked on top of a folded crate 400A. Corner portions 458 of the bases 402 of the crates 400 have recesses 502 sized to receive the nesting protrusions 504 of the extension couplers 496. The nesting protrusions 504 align with corresponding recesses 502 in the corners 458 of the bases 402. The upper crate 400 is lowered onto the lower crate 400A, allowing the nesting protrusions 504 to be inserted into the recesses 502. The other corners 458 of the bases 402 similarly have recesses aligning with and receiving the nesting protrusions of the couplers 482 and other extension couplers 496 of the lower crate 400A when the upper crate 400 is lowered onto the lower crate 400A. The upper crate 400 is lowered until it rests on the lower crate 400A. The connections between the nesting projections of the lower crate 400A and the corners 458 of the upper crate 400 prevent the crates from moving laterally relative to each other when stacked on top of the folded crate 400.

[0070] As shown in FIGS. 35A-35C , the side frames 404 can be connected to the base 402 of the foldable crate 400 in the assembled and folded configurations. Additionally, portions of the side frames 404 can be connected to and / or remain within the base 402 during movement between the assembled and folded configurations. The legs 418 of the side frames 404 have ends 506 at their lower ends. While the following description will refer to the legs 418 and their corresponding corners 458 for simplicity, the other corners 458 and legs of the side frames 404, 406 of the foldable crate 400 can have similar structures and functions. The ends 506 of the legs 418 are sized to connect with locking recesses 508 in the corners 458 of the base 402 to secure the legs 418 in an upright position. The ends 506 have a base 510 and an insert 512. The base 510 is coupled to the main member 418A of the leg 418. The base 510 may be secured to the main member 418A of the leg 418 by welding or by a friction or snap-fit ​​connection. The base 510 may include a locking opening 518 for receiving a locking pin 520 on the base 402 of the crate 400 to lock the leg 418 to the base 402 in an assembled configuration as described below.

[0071] The insert 512 extends from the base 510. The insert 512 is sized to be inserted into the locking recess 508. The insert 512 narrows relative to the base 510, forming a step 514. The step 514 limits insertion of the end 506 into the locking recess 508, and when the end 506 is inserted into the locking recess 508, it rests against support surfaces 522, 524 of the base 402 around the locking recess. The insert 512 may include tapered sides 516 to facilitate insertion into the locking recess 508 of the base 402. Providing the tapered sides 516 on the insert 512 may also reduce the force required to withdraw the end 506 from the locking recess 508 (e.g., when transitioning to the folded configuration). This is because the surface area of ​​the insert 512 that is in frictional contact with the locking recess 508 decreases when the side frame 404 is lifted from the base 402 of the crate 400 .

[0072] Corner portions 458 of base 402 include guide slots 526 formed by lower guide portions 528 and upper guide portions 530. Guide slots 526 guide the movement of guide pins 536 (see FIGS. 36A-36E) of side frames 404 as they transition between the assembled and folded configurations, as described below. Thus, guide slots 526 guide the movement of ends 506 of legs 418 between locking recesses 508 and tracks 542 on which legs 418 rest during the folded configuration.

[0073] The corner portion 458 includes a receiver body 532 having sidewalls 534 that form a locking recess 508 for receiving the insert 512 of the leg 418 of the side frame 404. The inner surface of the sidewall 534 has a taper that corresponds to the taper of the insert 512 of the leg 418, thereby allowing the insert 512 to be received therein (see FIG. 35C). The height of the inner sidewall 534A (see FIG. 35C) is lower than the other sidewalls 534, allowing the end 506 of the leg 418 to pivot during transition between the assembled and folded configurations, as described below. The receiver body 532 is positioned adjacent to the guide slot 526. The receiver body 532 opens to the guide slot 526 to allow the guide pin 536 of the side frame 104 to extend into the guide slot 526 when the leg 418 is inserted into the locking recess 508. For example, the receiver body 532 may not have a sidewall 534 on the side of the receiver body 532 adjacent the guide slot 526. As another example, the receiver body 532 may have a slot or opening in the sidewall 534 adjacent the guide slot 526 so that the guide pin 536 can extend through to the guide slot 526.

[0074] The process of transitioning the crate 400 between the assembled and folded configurations will be described with reference to FIGS. 36A-36E. As shown in these figures, at least a portion of the leg remains connected to and / or retained within a portion of the base 402 when transitioning between the assembled and folded configurations. FIG. 36A shows a side view of the crate 400 in the assembled configuration, with a side panel of the base 402 removed to reveal the end 506 of the leg 418 and the guide slot 526. The following description will discuss the leg 418 of the side frame 404, but the other legs of the crate 400 can be similarly transitioned between the assembled and folded configurations. As shown in FIG. 36A, the side frame 404 extends upright relative to the support surface 408 of the base 402. The end 506 of the leg 418 is fully inserted into the locking recess 508, with the guide pin 536 extending into the guide slot 526. The side walls 534 , 534 A of the locking recess 508 prevent the legs 418 of the side frame 404 from rotating relative to the base 402 .

[0075] 36B , the side frame 404 can be lifted in direction 538 to lift the ends 506 of the legs 418 of the side frame 404 upward relative to the receiver body 532 and above the inner sidewall 534A. For example, a user can grasp the side frame 404 and lift the side frame 404 in direction 538. As the side frame 404 is lifted, the guide pins 536 can come into contact with the upper guide portions 530 of the guide slots 526, limiting the distance the side frame 404 can move in direction 538. The upper guide portions 530 can be sloped or angled so that when the guide pins 536 contact the upper guide portions 530, the upper guide portions 530 guide the guide pins 536 along the guide slots 526 at a predetermined angle. The lower guide portion 528 may also be sloped or angled so that when the guide pin 536 contacts the lower guide portion 528, it guides the guide pin 536 at an angle along the lower guide portion 528. Referring to FIGS. 36C-36D , when the side frame 404 is lifted from the locking recess 508, the top of the side frame 404 can be gradually rotated outward and downward in direction 540 to align the legs 418 of the side frame 404 with the tracks 542 of the base 402. As shown, as the side frame 404 is rotated, the guide pin 536 of the side frame 404 slides along the guide slot 526 from the locking recess 508 toward the tracks 542. As the side frame 404 rotates, the guide pin 154 can contact the upper guide portion 530 and / or the lower guide portion 528 of the guide slot 526 to guide the end 506 of the side frame 404 along the guide slot 526 toward the tracks 542.

[0076] 36E, once the side frame 404 is rotated outward until the legs 418 are substantially parallel to the tracks 542, the side frame 404 can slide inward in direction 544 along the tracks 542 of the base 102, thereby storing the side frame 404 in the base 402. A second side frame 406, similar to the first side frame 404 described above, can be inserted into the base 402 to place the crate 400 in a folded configuration.

[0077] The crate 400 can be transitioned from the folded configuration to the assembled configuration by reversing the steps described above with reference to FIGS. 36A-36E. The support frame 404 is transitioned between the folded and assembled configurations while at least a portion of it (e.g., the ends of the legs 418) remains within the base 402. For example, with reference to FIG. 36E, to move the support frame 404 from the folded configuration to the assembled configuration, the support frame 404 can be slid along the tracks 542 in a direction opposite to the direction 544 until the guide pins 536 are aligned with the guide slots 526. Once the guide pins 536 are aligned with the guide slots 526, the weight of the side frames 404 causes the pins 536 to drop into the guide slots 526 and slide along the lower guide portions 528 to the locking recesses 508. Users can also slightly lift the cross members 484 of the side frames 404 as they remove the side frames 404 from the base 402. Lifting the cross member 484 increases the weight of the side frame 404 supported by the pins 536 and causes the guide pins 536 to enter the guide slots 526 when they are aligned with the guide slots 526 .

[0078] The side frame 404 can also be removed from the base 402, for example, to replace a damaged side frame 404. Referring to FIG. 36E , to remove the side frame 404, the support frame 404 is moved in a direction opposite to direction 544. The side frame 404 is held approximately horizontal or aligned with the track 542 so that the pins 536 pass through the entrances of the guide slots 526 without entering them. The side frame 404 can continue to be removed from the base 402 until the side frame 404 is no longer within the base 402.

[0079] 37A, the base 402 of the foldable crate 400 may include a locking mechanism 546. The locking mechanism 546 may be attached to a corner 458 of the base 402 adjacent the locking recess 508. The foldable crate 400 may include a locking mechanism 546 at each corner 458 of the crate 400. In some forms, the foldable crate 400 includes one locking mechanism 546 for each side frame 404, 406. The locking mechanisms 546 are movable between locked and unlocked configurations to selectively secure the side frames 404 to the base 402 during the assembled configuration.

[0080] 37B, locking mechanism 546 includes a housing 548, a locking pin 550, a biasing member 552, a lever 554, and a lock actuator 556. Housing 548 may include a mounting tab 558 having a mounting opening 560 for securing locking mechanism 546 to base 402 of crate 400. Locking pin 550 is movable relative to housing 548 between a retracted position and an extended position. When locking pin 550 is in the retracted position, locking mechanism 546 is in an unlocked configuration. When locking pin 550 is in the extended position, locking mechanism 546 is in a locked configuration. Biasing member 552 is connected to housing 548 and locking pin 550 and biases locking pin 550 toward the extended position.

[0081] Lever 554 is coupled to locking pin 550 and is accessible to the user. Locking pin 550 may include a pin portion 550A and a sliding portion 550B. Pin portion 550A is rigidly coupled to sliding portion 550B and extends from housing 548 when locking pin 550 is in the extended position. Sliding portion 550B has a width greater than pin portion 550A and includes an opening 551 in housing 548 through which pin portion 550A passes. Thus, sliding portion 550B cannot pass through opening 551, limiting outward movement of locking pin 550. Sliding portion 550B is slidable on base 502 of crate 400 between an extended position and a retracted position.

[0082] A user can move lever 554 in direction 553 to overcome the biasing force of biasing member 552 and move lock pin 550 toward the retracted position. Lock pin 550 can include a protrusion 555 coupled to and moving with lock pin 550. As shown in FIGS. 37C-37D , protrusion 555 can be disposed on slide 550B. Protrusion 555 is biased outward by a biasing member such as spring 557. Spring 557 can extend between adjustment base 559 and protrusion 555. Adjustment base 559 can be screwed to slide 550B to adjust the biasing force of spring 557 on protrusion 555 (e.g., by adjusting the screw on adjustment base 559 to move adjustment base 559 closer to or farther from protrusion 555). 37C, when locking pin 550 is in the extended position, protrusion 555 is biased against housing 548 which holds protrusion 555 in the removed configuration. Referring to FIG. 37D, when locking pin 550 is moved to the retracted position, protrusion 555 becomes aligned with opening 562 in housing 548, where spring 557 biases protrusion 555 to extend into opening 562. With protrusion 555 at least partially extending into opening 562 in housing 548, locking pin 550 is retained in the retracted position, thereby maintaining locking mechanism 546 in the unlocked position.

[0083] The lock actuator 556 has an arm 564 having a first end attached to the housing 548 and a second end supporting a head 566. The head 566 is disposed in an opening 562 in the housing 548. A force can be applied to the head 566 to bend the arm 564 and urge the head 566 from its rest position into the opening 562. The arm 564 is resiliently flexible so that the head 566 returns to its rest position when the force is removed from the head 566. When the protrusion 555 of the lock pin 550 is within the opening 562, the head 566 contacts the protrusion 555 and can push the protrusion 555 out of the opening 562 against the biasing force of the spring 557. When the protrusion 555 is not within the opening 562 and holds the lock pin 550 in the retracted position, the biasing member 552 biases the lock pin 550 to the extended position, thereby locking the lock mechanism 546. While the lock actuator 556 and lever 554 are shown as being located on the side of the housing 548 that faces outward from the crate 400, in other configurations such as those shown in Figures 40-41B, the lock actuator 556 and lever 554 can be located on the side of the housing 548 that faces inward. Locating the lock actuator 556 and lever 554 inside the housing 548 prevents damage to the locking mechanism due to unintentional contact and prevents unintentional movement of the lock actuator 556 and / or lever 554.

[0084] In some forms, the locking mechanism 546 includes a lock actuator 556 on either side of the housing 548. The lock pin 550 can include two protrusions 555 that extend away from each other so as to protrude into corresponding openings 562 when the lock pin 550 is in the retracted position. The lock actuators 556 can be pinched or pushed against each other from either side of the housing 548 to simultaneously activate both lock actuators 556 to move the lock pin 550 toward the extended position.

[0085] In use, while the side frame 104 is transitioned to the assembled configuration, the locking mechanism 546 is in the unlocked configuration. A user can move the locking mechanism 546 to the locked configuration by pressing the head 566 of the lock actuator 556. Pressing the head 566 of the lock actuator 556 moves the locking pin 550 to the extended position and into the locking opening 518 (see FIG. 35A ) in the leg 418 of the side frame 404. In some forms, when the locking mechanism 546 is not in the unlocked configuration and the side frame 404 is transitioned to the assembled configuration, the biasing member 552 biases the locking pin 550 against the leg 418 of the side frame 404. When the locking pin 550 is aligned with the locking opening 518 in the leg 418, the biasing member 552 pushes the locking pin 550 into the locking opening 518. With the locking pin 550 in the locking opening 518 , the leg 418 cannot be lifted out of the locking recess 508 , thereby securing the side frame 404 to the base 402 .

[0086] To transition the side frame 404 to the folded configuration, a user can apply force to the lever 554 to move the locking mechanism 546 to the unlocked configuration. Moving the lever 554 retracts the locking pin 550 into the housing 548 and out of the locking opening 518 in the leg 418 of the side frame 404. The side frame 404 can then be moved to the folded configuration, as described above with respect to Figures 36A-36E. The side frame 406 on the opposite side of the base 402 can similarly include a locking mechanism 546 to lock the side frame 406 in the assembled configuration.

[0087] As shown in FIGS. 29A, 35C, and 38, the foldable crate 400 can include connector bars 570 to which multiple hooks or straps can be attached. For example, straps can be used to secure items on the support surface 408 of the crate 400. The straps can be attached to the connector bars 570 to secure the items to the crate 400. The base 402 of the crate 400 can include recesses 574 in a frame 572 of the base 402 of the crate 400. The connector bars 570 span the recesses 574. As shown in FIG. 35C, the connector bars 570 are longer than the recesses 574, and the ends of the connector bars 570 contact the inner surface of the frame 572. The connector bars 570 can be secured to the frame 572 of the base by, for example, welding the ends of the connector bars 570 to the frame 572.

[0088] Referring to FIG. 39 , another embodiment of a foldable crate 600 is shown. The foldable crate 600 is similar to the previously described embodiments, with the differences being highlighted. The foldable crate 600 includes a base 602, a first support frame 604, and a second support frame 606. The foldable crate 600 further includes a first support bar 608 and a second support bar 610 that extend from legs 612 of the first support frame 604 to the base 602. The first support bar 608 and the second support bar 610 extend in different directions from the legs 612 to support the support frame 604 when the first support frame 604 is in an assembled configuration. Specifically, the first support bar 608 extends from the legs 612 toward the second support frame 606, and the second support bar 610 extends from the legs 612 toward the other leg 614 of the first support frame 604. When the support frame 604 is moved to the folded configuration, the first support bar 608 can be detached from the base 602 and rotated about its connection with the legs 612 to extend substantially parallel to the legs 612, and the second support bar 610 can be detached from the legs 612 and rotated about its connection with the base 602 to extend substantially parallel to the support surface 616 of the base 602. The structure of the second support frame 606 is similar to the structure of the first support frame.

[0089] Referring to FIG. 40 , another embodiment of a collapsible crate 700 is shown. The collapsible crate 700 is similar in many respects to the previously described embodiments, with the differences being emphasized. The collapsible crate 700 includes mounting brackets 702, 704 on a base 706 of the crate 700. An RFID tag 708 is attached to the mounting bracket 702. The RFID tag 708 stores information related to the contents associated with and / or supported by the collapsible crate 700 that can be read by an RFID reader to enable tracking of the collapsible crate 700 and / or their contents during transport or storage and / or to facilitate automated sorting of the collapsible crate 700, for example, on a conveyor system. A scannable code 708 can be attached to the mounting bracket 704. The scannable code 708 can be a barcode, QR code, or the like, that can be scanned with a code reader (e.g., a barcode scanner) to obtain information associated with the scannable code 708. For example, scannable code 708 may include information that identifies crate 700. When scannable code 708 on crate 700 is scanned, the obtained information may be used to search a database to obtain additional information associated with crate 700, such as the destination and / or contents of crate 700.

[0090] 41A-41B, the foldable crate 700 can include stoppers 710 for preventing side frames 712 of the foldable crate 700 from sliding out of the base 706 when in the folded configuration. As shown in FIG. 41B, when the foldable crate 700 is in the folded configuration, the stoppers 710 can contact a portion of the side frames 712, such as couplers 714 of the side frames 712, to prevent the side frames 712 from sliding out of the base 706. To remove the side frames 712 from the base 706, the side frames 712 are lifted slightly above the stops 710 and then pulled outward so that the side frames 712 pass over the stops 710.

[0091] 42A-42B, the foldable crate 700 includes a support bar 716 extending from the side frame 712 to the base 706 and supporting the side frame 712 in an upright, assembled configuration. The support bar 716 includes a first end 718 pivotally attached to the side frame 712 and a second end 720 removably attached to a connector 722 on the base 706 of the crate 700, as described with respect to the previous embodiment. The support bar 716 is pivotable about the first end 718 from the assembled configuration (see FIG. 42A) to a stowed configuration (see FIG. 42B). In the illustrated embodiment, the first end 718 of the support bar 716 is pivotally secured to the side frame 712 by a bolt 724. The side frame 712 includes a clip 726 (e.g., a C-clip) that releasably secures the support bar 716 in the stowed configuration. For example, the support bar 716 can be secured in the storage configuration by pivoting the support bar 716 generally parallel to the side frames 712 and then applying force to press the support bar 716 into the clips 726. When the support bar 716 is in the storage configuration, the side frames 712 can be moved to the collapsed configuration and stored in the base 706 of the crate 700. To move the support bar 716 from the storage configuration to the assembled configuration, referring to the above-described embodiment, force can be applied to pull the support bar 716 out of the clips 726 and then the support bar 716 can be pivoted downward and inserted into the connectors 722 of the base 706.

[0092] The singular forms "a" and "an" are intended to encompass both the singular and the plural unless otherwise stated herein or clearly contradicted by context. The terms "comprising," "having," "including," and "containing" are to be construed as open-ended terms. As used herein, the phrase "at least one" is intended to be construed in a disjunctive sense. For example, the phrase "at least one of A and B" is intended to encompass A, B, or both A and B.

[0093] Thus, while the present invention has been described in connection with particular embodiments and examples, it is not necessarily so limited, and many other embodiments, examples, uses, and variations, and variations from these embodiments, examples, and uses, are intended to be encompassed within the scope of the claims appended hereto. The entire disclosures of each patent document and publication cited herein are each incorporated herein by reference.

Claims

1. a first side frame having an end portion and an upper portion extending from the end portion; a base comprising a support surface and a receptacle below the support surface for positioning the first side frame, the base comprising one or more locking recesses located below the support surface to receive the end of the first side frame; Including, The first side frame is a first configuration in which the end of the first side frame is received within one or more locking recesses of the base such that at least a portion of the first side frame extends above the support surface of the base; a second configuration in which the end and at least a portion of the top of the first side frame are within the receptacle of the base; A foldable crate that can be moved between

2. the first side frame includes a first leg and a second leg; the end of the first side frame includes an end of the first leg and an end of the second leg; In the first configuration, the end of the first leg and the end of the second leg are received within the one or more locking recesses. The collapsible crate of claim 1.

3. 3. The foldable crate of claim 2, wherein the one or more locking recesses of the base comprise support walls that engage the ends of the first legs and the second legs to prevent the first side frame from rotating relative to the base in the first configuration.

4. 4. The foldable crate of claim 3, wherein the base has a sloped surface extending from the locking recess to the receptacle to guide the end of the first leg and the end of the second leg during transition between the first and second configurations.

5. The end of the first side frame has a guide pin, the base has a guide slot for receiving the guide pin; the guide slot guides movement of the end of the first side frame between the first configuration and the second configuration. The collapsible crate of claim 1.

6. 6. The foldable crate of claim 5, wherein the guide slot has a cam surface positioned above the guide pin when the first side frame is in the first configuration, thereby limiting vertical movement of the first side frame when the first side frame is disengaged from the locking recess and guiding the first side frame to the second configuration.

7. the first side frame includes a first leg and a second leg; the receptacle of the base includes a first set of tracks for receiving the first leg and the second leg of the first side frame; the collapsible crate further comprises a second side frame having a first leg and a second leg; the receptacle of the base includes the second leg of the second side frame and a second set of tracks for receiving the second leg; the first set of tracks being substantially coplanar with the second set of tracks; The collapsible crate of claim 1.

8. 10. The foldable crate of claim 1, wherein the top of the first side frame includes stacking projections for insertion into recesses in the base of another foldable crate when in the first configuration.

9. 2. The foldable crate of claim 1, wherein the top of the first side frame includes a nesting projection for insertion into a recess in the base of another foldable crate when in the second configuration.

10. 2. The foldable crate of claim 1, wherein the base includes a recess for receiving a protrusion of the second foldable crate when the base is placed on the second foldable crate.

11. 2. The foldable crate of claim 1, wherein the base includes at least one stop projection that limits movement of the first side frame when in the second configuration.

12. the base comprises a frame underlying the support surface; the frame is spaced from a surface on which the base rests to allow forks of a moving device to extend below the frame to carry the crate; The collapsible crate of claim 1.

13. 13. The foldable crate of claim 12, wherein the base comprises a plurality of foot members that space the frame from the surface on which the base rests.

14. the first side frame includes a first leg, a second leg, and a cross member extending between the first leg and the second leg; the cross member, in the second configuration, extends from a first leg member of the plurality of leg members to a second leg member of the plurality of leg members; the base includes one or more protection bars positioned below the cross member; 14. The collapsible crate of claim 13.

15. a support bar supporting the first side frame in the first configuration; The support bar has a first end attached to the top of the first side frame and a second end removably attached to the base. The collapsible crate of claim 1.

16. the base includes a slotted connector; the second end of the support bar has a hook configured to be inserted into the slotted connector to attach the second end of the support bar to the base.

16. The collapsible crate of claim 15.

17. 16. The foldable crate of claim 15, wherein the first end of the support bar is pivotally attached to the top of the first side frame such that the support bar can be pivoted between a storage configuration and an assembled configuration.

18. The collapsible crate of claim 1 , further comprising a locking mechanism operable to reversibly secure the first side frame in the first configuration and / or the second configuration.

19. 20. The foldable crate of claim 18, wherein the locking mechanism includes a retractable locking pin that is inserted into a locking opening in the first side frame to secure the end of the first side frame to the one or more locking recesses in the base.

20. 20. The foldable crate of claim 18, wherein the locking mechanism includes a retractable locking pin extendable into the path of the first side frame to prevent the first side frame from moving from the second configuration.

21. the first side frame includes a first leg, a second leg, and a cross member extending between the first leg and the second leg; the first leg includes first and second support columns, each having a rectangular cross-section and a folded cross-section extending from the rectangular cross-section; the first support column and the second support column meet in an opposed but generally cooperating configuration such that the folded cross section of the first support column faces the folded cross section of the second support column; The collapsible crate of claim 1.

22. a support surface; a receptacle including first and second tracks below the support surface, each of the first and second tracks including a locking recess and a first and second track surface extending from the locking recess; a first side frame having a first leg slidable along the first track surface of the first track and a second leg slidable along the second track surface of the second track, The first side frame has the first leg and the second leg, and is removably received in the first track surface and the second track surface of the receptacle; a first side frame, the first and second legs having ends removably insertable into locking recesses of the first and second tracks to secure the first side frame in an upright position against the support surface when removed from the first and second track surfaces of the first and second tracks; Includes a collapsible crate.

23. 23. The foldable crate of claim 22, wherein the locking recesses of the first and second tracks include support walls that engage the ends of the first and second legs when inserted into the locking recesses to prevent the first side frame from pivoting.

24. 24. The foldable crate of claim 23, wherein the first and second tracks include sloped surfaces extending from the locking recesses to the first and second track surfaces of the receptacle to guide the ends of the first and second legs between the locking recesses and the first and second track surfaces.

25. 23. The foldable crate of claim 22, wherein the end of the first leg and the end of the second leg remain below the support surface during transition between the locking recess and the first and second tracks.

26. The end of the first side frame includes a guide pin, the first track and the second track include guide slots that receive the guide pins; the guide slot guides movement of the end of the first side frame between the locking recess and the first and second track surfaces; 23. The collapsible crate of claim 22.

27. 27. The foldable crate of claim 26, wherein the guide slots have cam surfaces positioned above the guide pins to limit vertical movement of the first side frame when the ends of the first and second legs are received in the locking recesses, and to guide the ends of the first and second legs toward the first and second track surfaces, respectively, when the first and second legs are disengaged from the locking recesses.

28. the receptacle further includes a third track and a fourth track below the support surface, the third track and the fourth track each having a locking recess and a third track surface and a fourth track surface extending from the locking recess; the collapsible crate further includes a second side frame having a third leg slidable along the third track surface of the third track and a fourth leg slidable along the fourth track surface of the fourth track to receive the second side frame on the third and fourth track surfaces of the receptacle, the third and fourth legs having ends removably insertable into the locking recesses of the third and fourth tracks to secure the second side frame in an upright position against the support surface when removed from the third track surface of the third track and the fourth track surface of the fourth track.

23. The collapsible crate of claim 22.

29. 23. The foldable crate of claim 22, wherein the top of the first side frame includes stacking projections for insertion into recesses in the base of another foldable crate when the first side frame is secured in the upright position against the support surface.

30. 23. The foldable crate of claim 22, wherein an upper portion of the first side frame includes a nesting protrusion for insertion into a recess in a base of another foldable crate when the first side frame is stored on the first and second track surfaces of the receptacle.

31. 23. The foldable crate of claim 22, wherein the underside of the receptacle comprises a recess for receiving a protrusion of the second foldable crate when the foldable crate is placed on the second foldable crate.

32. the receptacle has a frame below the support surface; 23. The foldable crate of claim 22, wherein the frame is spaced apart from a surface on which the foldable crate rests, thereby allowing forks of a moving device to extend below the frame to carry the foldable crate.

33. a base having the support surface and the receptacle; a support bar supporting the first side frame in the upright position and having a first end attached to the first side frame and a second end removably attached to the base; 23. The collapsible crate of claim 22, further comprising:

34. the base includes a slotted connector; 34. The foldable crate of claim 33, wherein the second end of the support bar has a hook configuration adapted to be inserted into the slotted connector to attach the second end of the support bar to the base.

35. 34. The collapsible crate of claim 33, wherein the first end of the support bar is pivotally attached to the first side frame such that the support bar is pivotable between the storage configuration and the erected configuration.

36. 23. The foldable crate of claim 22, further comprising a locking mechanism operable to reversibly secure the first side frame in the upright position and / or when stored within the first and second track surfaces of the receptacle.

37. 37. The foldable crate of claim 36, wherein the locking mechanism comprises a retractable locking pin inserted into a locking opening in the first side frame to secure the end of the first side frame within the locking recess.

38. 37. The foldable crate of claim 36, wherein the locking mechanism comprises a retractable locking pin extendable into the path of the first side frame to prevent movement of the first and second legs along the first and second track surfaces, respectively.

39. a base having a support surface with an outer edge and defining a receptacle below said support surface; a first side frame on a first end of the base having first and second legs removably insertable along a plurality of tracks of the receptacle; a second side frame on the second end of the base, the second side frame having third and fourth legs removably insertable along the plurality of tracks of the receptacle, wherein the outer edge of the support surface extends from the first end to the second end, and one leg of the first and second side frames is at a different distance from the outer edge than the other leg of the first and second side frames.

40. 40. The foldable crate of claim 39, wherein the third leg is farther from the outer edge than the first leg, the fourth leg is farther from the outer edge than the second leg, and the second leg is farther from the outer edge than the first leg.

41. 40. The foldable crate of claim 39, wherein the receptacles of the base include four tracks along which the legs of the first and second side frames are inserted into the base.

42. 42. The foldable crate of claim 41, wherein each of the four tracks extends parallel to one another along the same plane.

43. the first side frame includes a first protrusion and a second protrusion, the second side frame includes a third protrusion and a fourth protrusion, the first protrusion and the third protrusion are at the same distance from the outer edge; the second protrusion and the fourth protrusion are the same distance from the outer edge; 40. The collapsible crate of claim 39.

44. 44. The foldable crate of claim 43, wherein the first side frame includes a top member extending between the first leg and the second leg, the top member extending beyond the second leg to align and support the second protrusion with the fourth protrusion.

45. 45. The foldable crate of claim 44, wherein the second side frame includes an upper member extending between the third leg and the fourth leg, the upper member of the second side frame extending beyond the third leg to support and align the third protrusion with the first protrusion.

46. 44. The foldable crate of claim 43, wherein the first and second protrusions extend upwardly beyond the first side frame and beyond the support surface when the first side frame is inserted into the receptacle, and the third and fourth protrusions extend upwardly beyond the second side frame and beyond the support surface when the second side frame is inserted into the receptacle.

47. the first side frame and the second side frame are removable from the receptacles of the base and are capable of being secured in an upright position relative to the support surface; When the first side frame is fixed in the upright position, the first protrusion and the second protrusion extend upward from the first side frame; When the second side frame is fixed in the upright position, the third protrusion and the fourth protrusion extend upward from the second side frame.

44. The collapsible crate of claim 43.

48. a base having a support surface; a first side frame coupled to a first end of the base and extending above the support surface; a second side frame connected to a second end of the base opposite the first end and extending above the support surface; an extension portion having a first connecting portion and a second connecting portion, the extension portion extending between the first side frame and the second side frame, the first connecting portion being attachable to the first side frame and the second connecting portion being attachable to the second side frame such that the extension portion extends upward beyond the first side frame and the second side frame; Crate containing.

49. the first side frame includes a stacking protrusion, the second side frame includes a stacking protrusion, the first connecting portion of the extension portion includes a recess for receiving the stacking protrusion of the first side frame; the second connecting portion includes a recess for receiving the stacking protrusion of the second side frame; 49. The crate of claim 48.

50. the first side frame includes an attachment opening; the second side frame includes an attachment opening; the first connecting portion of the extension portion includes a lock pin that can be inserted into the mounting opening of the first side frame; the second connecting portion of the extension portion includes a lock pin that can be inserted into the mounting opening of the second side frame; 49. The crate of claim 48.

51. The first connecting portion of the extension portion further includes a guide pin; The second connecting portion of the extension portion further includes a guide pin, the guide pin and the lock pin of the first coupling portion are sized to receive a portion of the first side frame therebetween; the guide pin and the lock pin of the second coupling portion are sized to receive a portion of the second side frame therebetween; 51. The crate of claim 50.

52. 49. The crate of claim 48, wherein the extensions include stacking projections for insertion into recesses in the base of other crates.

53. further comprising a second extension portion having a first connecting portion and a second connecting portion; the first connecting portion is attachable to the first side frame and the second connecting portion is attachable to the second side frame so that the second extending portion extends between the first side frame and the second side frame and the second extending portion extends upward beyond the first side frame and the second side frame; 49. The crate of claim 48.

54. a base having a first end, a second end, a left side, and a right side, the left side and the right side extending from the first end to the second end; a first side frame having an upper portion and a lower portion, the lower portion including a first side portion extending toward the upper portion, the upper portion including a first stacking projection; a second side frame having an upper portion and a lower portion, the lower portion of the second side frame including a second side portion extending toward the upper portion of the second side frame, the upper portion of the second side frame including a second stacking projection; Including, the first side is adjacent to and spaced a first distance from a plane extending upward from the left side of the base; the second side is adjacent to the plane and is spaced a second distance from the plane; the first distance is different from the second distance; The crate, wherein each of the first stacking projection and the second stacking projection is positioned substantially a third distance from the plane.

55. the first stacking projection has a fourth distance from the first side; the second stacking projection has a fifth distance from the second side; the fourth distance is different from the fifth distance; 55. The crate of claim 54.

56. 55. The crate of claim 54, wherein the third distance is different from the first distance and the second distance.

57. the first side of the first side frame has a first leg, the lower portion of the first side frame further has a third leg, the first leg and the third leg extend from the upper portion of the first side frame to the first side of the base; the second side of the second side frame has a second leg, the lower portion of the second side frame further has a third leg, the second leg and the fourth leg extend from the upper portion of the second side frame to the second side of the base; each leg of the first side frame and the second side frame is different in distance from the left side surface from the other legs of the first side frame and the second side frame; 55. The crate of claim 54.

58. 58. The crate of claim 57, wherein the upper portion of the first side frame supports the first stacking projection laterally from the first leg toward the left side.

59. 59. The crate of claim 58, wherein the second stacking projection of the first side frame is substantially aligned with the second leg.

60. 59. The crate of claim 58, wherein the upper portion of the second side frame supports a third stacking projection laterally from the third leg away from the left side surface.

61. a lower portion of the first side frame having a third side portion extending toward an upper portion of the first side frame, and the upper portion of the first side frame having a third stacking protrusion; a lower portion of the second side frame having a fourth side portion extending toward an upper portion of the second side frame, the upper portion of the second side frame having a fourth stacking protrusion; the third side portion is adjacent to a right side surface extending upward from the right side portion of the base and is positioned a fourth distance away from the right side surface, the fourth side portion is adjacent to the right side surface and is positioned a fifth distance away from the right side surface, the fourth distance is different from the fifth distance, and each of the third stacking protrusion portion and the fourth stacking protrusion portion is positioned substantially a sixth distance away from the plane; 55. The crate of claim 54.

62. a width of the upper portion of the first side frame is greater than a width of the lower portion of the first side frame, the width of the upper portion of the first side frame is the distance from the first stacking protrusion to the third stacking protrusion of the first side frame; 55. The crate of claim 54.

63. the width of the upper portion of the first side frame is the same as the width of the upper portion of the second side frame, the width of the upper portion of the second side frame is the distance from the second stacking protrusion to the fourth stacking protrusion of the second side frame; 63. The crate of claim 62.

64. the base includes a plurality of locking recesses; 55. The crate of claim 54, wherein ends of the first side frame are insertable into the locking recesses to connect the first side frame to the base.

65. the base further comprises a track; the lower portion of the first side frame is slidable along the track to removably store the first side frame within the base.

65. The crate of claim 64.

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