Foldable crate

Abstract

Disclosed is a collapsible crate having a base and a plurality of walls. The base includes an upper surface and defines a cavity below the upper surface. The walls are removably attachable to one another and movable between a first configuration in which the walls extend substantially vertically above the upper surface of the base and a second configuration in which the walls are within the cavity of the base.

Description

Technical Field

[0001] <Cross - Reference to Related Applications> This application claims the benefit of U.S. Provisional Patent Application No. 63 / 109,098, filed on November 3, 2020, which is incorporated herein by reference in its entirety.

[0002] The present disclosure generally relates to crates for storage and transportation, and more particularly to foldable crates.

Background Art

[0003] Crates are used to transport and store articles and merchandise. When not in use, crates typically occupy the same amount of space as when they are full. Thus, when transporting or storing empty crates, they take up a lot of space in a transport vehicle or warehouse. Some crates have walls that are removable from the base. The walls can be removed and placed on top of the base of the crate or at other locations for transportation or storage. In another approach, the walls of the crate can be folded inwardly and disposed on top of the base of the crate.

[0004] However, in prior art approaches, the walls remain vulnerable to impact and damage. Further, the walls may still occupy additional space beyond the normal dimensions of the base. Additionally, many crates are transported using forklifts and similar tools. To accommodate such tools, the crates must be configured to have a base that accepts a lifting and transport structure. When the base is so configured, it can be particularly difficult to configure a crate such that one or more walls fold onto the base.

Summary of the Invention

[0005] There is a need for a crate that can be folded to a smaller size while preventing the walls from bending, buckling, or disengaging from the rest of the crate. [Brief explanation of the drawing]

[0006] [Figure 1A] This is a top-view perspective of the foldable crate in its assembled configuration. [Figure 1B] Figure 1A is a front elevation view of the foldable crate. [Figure 1C] Figure 1A is a rear elevation view of the foldable crate. [Figure 1D] Figure 1A is a left elevation view of the foldable crate. [Figure 1E] Figure 1A is a right-side elevation view of the foldable crate. [Figure 1F] Figure 1A is a top view of the foldable crate. [Figure 1G] Figure 1A is a bottom view of the foldable crate. [Figure 2] Figure 1A is a top perspective view of the foldable crate in its folded configuration. [Figure 3A] Figure 1A is a front perspective view of the lower portion of the foldable crate. [Figure 3B] Figure 1A is a front cross-sectional view of the lower portion of the foldable crate. [Figure 3C] Figure 1A is a cross-sectional perspective view of the right side of the lower portion of the foldable crate. [Figure 4A] Figure 1A is a top perspective view of the wall position locking mechanism of the foldable crate. [Figure 4B] Figure 1A is a left-side perspective view of the wall connection mechanism of the foldable crate. [Figure 4C] Figure 4B is a right-side perspective view of the wall connection mechanism. [Figure 5A] Figure 1A is a front perspective view of the corner of the foldable crate. [Figure 5B] Figure 1A is a right-hand perspective view of the corner of the foldable crate. [Figure 5C]This is a perspective view of the lower portion of the foldable crate shown in Figure 1A in a partially folded configuration. [Figure 5D] This is a perspective view of the lower portion of the foldable crate shown in Figure 1A in a partially folded configuration. [Figure 6A] Figure 1A shows a diagram illustrating the process of assembling the foldable crate. [Figure 6B] Figure 1A shows a diagram illustrating the process of assembling the foldable crate. [Figure 6C] Figure 1A shows a diagram illustrating the process of assembling the foldable crate. [Figure 6D] Figure 1A shows a diagram illustrating the process of assembling the foldable crate. [Figure 6E] Figure 1A shows a diagram illustrating the process of assembling the foldable crate. [Figure 6F] Figure 1A shows a diagram illustrating the process of assembling the foldable crate. [Figure 6G] Figure 1A shows a diagram illustrating the process of assembling the foldable crate. [Figure 7A] Figure 1A is a top perspective view of the collapsible crate, showing the wall partially inserted into the base of the collapsible crate. [Figure 7B] Figure 7A is a right-side cross-sectional view of the foldable crate shown in Figure 1A. [Figure 7C] Figure 1A is a right-side cross-sectional view of the foldable crate, showing the first wall fully inserted into the base of the foldable crate. [Figure 7D] Figure 1A is a right-side cross-section of the foldable crate, showing the two walls fully inserted into the base of the foldable crate. [Figure 8A] Figure 1A is a top perspective view of the corner of the foldable crate, showing how the two walls are inserted into the base of the foldable crate. [Figure 8B]FIG. 1A is a top perspective view of a corner of a foldable crate, showing two walls inserted into the base of the foldable crate.

BEST MODE FOR CARRYING OUT THE INVENTION

[0007] A crate is provided that is configured such that the walls of the crate are separable from each other and can be stored within the cavity of the base of the crate. When folding the crate from an assembled arrangement, the walls can be separated from adjacent walls. The upper portion of the wall can be rotated outwardly around the lower end of the wall that is attached to the base and engages the track of the base. When the wall is substantially parallel to the ground, the wall can be slid into the cavity below the base via a track within the base that receives the wall. The base can include a retaining mechanism to prevent the wall from slipping out of the cavity of the base unintentionally. Each wall can similarly be separated from adjacent walls and stored within the base.

[0008] Referring to FIGS. 1A through 1G, crate 100 is shown in an assembled arrangement and includes a base 102 and four walls 150A, B that extend upwardly from base 102. As shown in FIG. 2, the crate is in a folded arrangement with all four walls 150A, B within base 102. Referring also to FIGS. 3A through 3C, in one form, base 102 includes an upper platform 105A, a lower platform 105B, and four vertical posts 110 that extend between upper platform 105A and lower platform 105B. Thus, base 102 defines a space between upper platform 105A and lower platform 105B, and this space is cavity 112 of base 102. Upper platform 105A and lower platform 105B may be formed from a grid of support bars that extend above and below base 102. In other forms, upper platform 105A and lower platform 105B may be formed from a rigid, flat sheet such as sheet metal.

[0009] In one embodiment, the upper platform 105A includes a frame 114 formed from a grid of support members and a bottom wall 116 attached to the top of the frame 114. The bottom wall 116 provides a surface on which the contents of the crate 100 are placed. Since the walls 150A,B are moved into the base 102 to fold the crate 100 (and are not placed on the bottom wall 116), the crate 100 can be moved between an assembled configuration and a folded configuration without having to remove the contents placed on the bottom wall 116. This makes it possible to fold one or more walls 150A,B to access the contents of the crate 100, for example, when removing items from the crate. The crate 100 can also be used like a pallet when in the folded configuration to support the contents on the surface 116. The crates 100 may be stacked on top of each other in the folded configuration to save space. When the walls within the base 102 are in a folded position, the walls 105A,B are protected from damage when the crates 100 are stacked and transported. The bottom wall 116 can be formed of sheet metal to provide a sturdy, durable, flat surface. In other embodiments, the bottom wall 116 is a mesh or grid so as not to be a solid surface. In other forms, the bottom wall 116 may be formed of other materials such as wood, polymer, or a combination thereof. At least one of the upper platform 105A and the bottom wall 116 is provided with a hole 118 on the side facing the locking wall 150A for receiving a locking pin 164 of the wall orientation locking mechanism 106 of the locking wall 150A to lock the wall 150A in an upright position, as will be described in more detail below.

[0010] The lower platform 105B includes a frame 120 formed of a grid of support members. The lower platform 105B is provided with support blocks 122 extending downward from each corner of the lower platform 105B. The support blocks 122 abut the ground and lift the lower platform 105B off the ground, allowing the crate 100 to be picked up or moved by a moving device such as a forklift, pallet jack, or similar tool. The lower platform 105B is located below a cavity 112 into which walls 150A,B are moved in a folded configuration, so that the forks of the moving device can be positioned below the lower platform 105B whether the crate 100 is in an assembled or folded configuration.

[0011] Referring to Figures 3A to 3C, the base 102 further includes side walls 124A,B extending between the vertical posts 110 between the upper platform 105A and the lower platform 105B. Thus, the side walls 124A,B extend along the cavity 112 of the base 102. The side walls 124A,B include support structures that form tracks for housing the walls 150A,B within the base 102. In one embodiment, the left and right side walls 124A of the crate 100 are of the same height. In one embodiment, the front and rear side walls 124B of the crate 100 are of the same height as each other but are of different heights than side wall 124A. As shown, side wall 124A is lower than side wall 124B or closer to the lower platform 105B. Each of the side walls 124A,B is provided with upper and lower ledges 126 that extend horizontally inward from the side walls 124A,B and along the length of the side walls 124A,B. It should be recognized that other forms of support structures within the base 102 for guiding and / or accommodating the walls 150A,B may also be used. For example, the base 102 may include four solid sheets extending into the cavity 112 of the base 102, forming four levels for receiving the walls 120A,B. In another embodiment, the side walls 124A,B may include U-shaped members instead of ledges 126 to receive the sides of the walls 150A,B.

[0012] In the illustrated embodiment, each ledge 126 of side walls 124A and B corresponds to the ledge 126 of the opposite side wall 124A and B on the base 102, forming tracks for receiving the walls 150A and B of the crate 100. For example, the lower ledge 126 of the left side wall 124A of the base 102 is at the same height as the lower ledge 126 of the right side wall 124A of the base 102. The upper ledge 126 of the left side wall 124A of the base 102 is at the same height as the upper ledge 126 of the right side wall 124A of the base 102. The ledges 126 of side wall 124B correspond to each other in a similar manner. This creates four levels (heights) of ledges 126 or tracks within the cavity 112 of the base 102 to accommodate the four walls 150A and B of the crate 100. For example, when crate 100 is in the folded configuration shown in Figure 2, wall 150A of crate 100 is located within the cavity 112 of base 102. The first sides of walls 150A and B abut against ledge 126, while the second sides of walls 150A and B abut against the corresponding opposite ledge 126 in base 102. In this way, each ledge 126 forms part of a track that receives wall 150.

[0013] The ledge 126 includes a fastener 128 at its end, which abuts against the wall 150A,B when it is inserted into the cavity 112 of the base 102. The fastener 128 prevents the wall 150A,B from being inserted too far into the cavity 112 and also prevents the wall 150A,B from coming out of the base 102 on the side of the crate 100 opposite to the side into which it was inserted. The base 102 is also provided with retaining members 130 and latches 140 used to hold the wall 150A,B inside the base 102 when the crate 100 is in a folded position. As will be described in more detail below, the retaining members 130 and latches 140 engage with portions of the wall 150A,B to prevent the wall 150A,B from unintentionally slipping out of the cavity 112 of the base 102.

[0014] Referring again to Figures 1A through 1G, the walls 150A and 150B may be formed from frames having a left-side member 152, a right-side member 154, an upper member 156, and a bottom member 158, respectively. The walls 150A and 150B include a number of vertical bars that extend spaced apart between the upper member 156 and the bottom member 158. In other embodiments, the walls 150A and 150B may include additional or alternative horizontally extending bars. In yet another embodiment, the walls 150A and 150B may be solid and not include any openings penetrating them. In the illustrated embodiment, there are two types of walls 150. The first type is a locking wall 150A, and the second type is a connecting wall 150B. In the assembled configuration, the locking wall 150A is on the opposing side of the crate 100, and the connecting wall 150B extends between the locking walls 150A along the remaining two sides of the crate 100. As shown in the illustration, the locking wall 150A includes a wall position locking mechanism 106 and two wall locking mechanisms 108. The bottom member 158 of the locking wall 150A includes a hole 158A used to lock the locking wall 150A in an upright position. The left member 152 and the right member 154 each include a slot 159A used to lock the locking wall 150A to an adjacent connecting wall 150B. The connecting wall 150B each has a slot 159B in the left member 152 and the right member 154, and the slot 159B is aligned with the slot 159A of the locking wall 150A and used to lock the locking wall 150A to the connecting wall 150B. Although the locking wall 150A is shown to include both the wall position locking mechanism 106 and the two wall locking mechanisms 108, it should be understood that in other embodiments, each wall of the crate 100 may also include a wall locking mechanism 108 for locking to an adjacent wall. In one configuration, each wall of the crate 100 includes a wall position locking mechanism 106. In another configuration, each locking wall 150A includes two wall position locking mechanisms 106. In other configurations, no wall includes a wall position locking mechanism 106.

[0015] The wall position locking mechanism 106 of the locking wall 150A includes a structure for locking the locking wall 150A in an upright position. In the embodiment shown in Figure 4A, the wall position locking mechanism 106 comprises a bracket 162 attached to the vertical member 160 of the locking wall 150A, and a locking pin 164 having a handle portion 164A and a shaft portion 164B. The bracket 162 includes an upper notch 166A and a lower notch 166B, which receive the handle portion 164A of the locking pin 164 when the locking pin 164 is in the unlocked position and the locked position, respectively. In the illustrated embodiment, the bracket 162 is substantially U-shaped. In other embodiments, the bracket for holding the locking pin 164 in the locked and unlocked positions may have a different shape, however it should be understood that it includes a structure for holding the locking pin 164 in which the handle portion 164A of the locking pin 164 engages when it is in the locked and unlocked positions.

[0016] During operation, the shaft portion 164B of the locking pin 164 penetrates the hole 158A in the bottom member 158 of the locking wall 150A and extends into the hole 118 in the bottom wall 116 of the base 102 in order to lock the locking wall 150A in an upright position. The handle portion 164A of the locking pin 164 can rotate and enter the lower notch 166B of the U-shaped bracket 162, thereby maintaining the state in which the locking pin 164 is inserted into the hole 118 of the base 102. The wall position locking mechanism 106 may also include a spring 168 that biases the locking pin 164 upward from the bottom member 158 of the locking wall 150A. The spring 168 biases the handle portion 164A when it is received in the lower notch 166B of the U-shaped bracket 162, engaging it with the upper portion of the lower notch 166B, thereby increasing the frictional engagement between the handle portion 164A and the lower notch 166B, and helping to prevent the handle portion 164A of the lock pin 164 from rotating outward from the notch 166B.

[0017] To unlock the locking wall 150A and allow it to rotate from its upright position, the handle portion 164A of the locking pin 164 is rotated to disengage it from the lower notch 166B of the U-shaped bracket 162. The locking pin 164 can be moved upward to pull it out of the hole 118 in the bottom wall 116. The handle portion 164A can be rotated into the upper notch 166A to maintain the locking pin 164 in the unlocked position. The spring 168 can bias the locking pin 164 in the unlocked position, and when the handle portion 164A is inside the upper notch 166A, the spring 168 can press the handle portion 164A against the upper part of the upper notch 166A, thereby increasing the frictional engagement between the handle portion 164A and preventing the handle portion 164A from rotating outward from the notch 166A.

[0018] The wall locking mechanism 108 has a structure that connects two walls to each other in a removable manner. While a specific structure for the wall locking mechanism 108 is shown, it should be recognized that in other forms the wall locking mechanism 108 may be any structure that reversibly locks two adjacent walls to each other. Referring to Figures 5B to 5C, the illustrated wall locking mechanism 108 includes a support bracket 170 and a locking pin 172 having a handle portion 172A, a shaft portion 172B, and a hook portion 172C. The support bracket 170 includes a hole for passing the shaft portion 172B of the locking pin 172. The support bracket 170 guides the shaft portion 172B of the locking pin 172 as the locking pin 172 moves between a connected configuration and a disconnected configuration. In the connected configuration, the locking pin 172 moves toward the edge of the wall 150A, and in the disconnected configuration, the locking pin 172 moves toward the center of the wall 150A. The handle portion 172A of the lock pin 172 is attached to the shaft portion 172B of the lock pin 172, moving the lock pin 172 between a connected position and a disconnected position, and rotating the lock pin 172 around the shaft portion 172B between a locked position and an unlocked position. The hook portion 172C is attached to the end of the shaft portion 172B, which passes through a slot 159A in the lock wall 150A and a corresponding slot 159B in the adjacent connecting wall 150B when moving from the disconnected position to the connected position. The shape of the hook portion 172C is such that when the hook portion 172C is aligned with the slots 159A and 159B in the lock wall 150A and the connecting wall 150B, the hook portion 172C is in the unlocked position and can pass through the slots 159A and 159B. When the hook portion 172C is not aligned with slots 159A and B, the hook portion 172C is in the locked position and cannot pass through slots 159A and B. Thus, when the lock pin 172 is in the connected position (i.e., in the locked position) while the hook portion 172C is passing through slots 159A and B and is not aligned with slots 159A and B, the lock pin 172 cannot be removed from slots 159A and B without first aligning the hook portion 172C with slots 159A and B (i.e., moving the lock pin 172 to the unlocked position).

[0019] During operation, in order to lock the locking wall 150A to the adjacent connecting wall 150B, the locking pin 172 is rotated to the unlocked position, for example using the handle portion 172A, and the hook portion 172C is aligned with the slots 159A and 159B of the locking wall 150A and the connecting wall 150B. Next, the locking pin 172 is moved along the axis of the shaft portion 172B, and the hook portion 172C is passed through the slots 159A and 159B of the locking wall 150A and the connecting wall 150B, thereby moving the locking pin 172 from the disconnected position to the connected position. Next, the locking pin 172 is moved to the locked position by rotating the hook portion 172C, and as a result, the hook portion 172C is no longer aligned with the slots 159A and 159B, and therefore cannot be removed through the slots 159A and 159B.

[0020] To detach the locking wall 150A from the connecting wall 150B, for example, the locking pin 172 is moved to the unlocked position by rotating the handle portion 172A around the shaft portion 172A to align the hook portion 172C with the slots 159A and 159B of the locking wall 150A and the connecting wall 150B. Next, the locking pin 172 is moved to the detached position by moving the locking pin 172 along the axis of the shaft portion 172A of the locking pin 172, thereby pulling the hook portion 172C out of the slots 159A and 159B. When the hook portion 172C of the locking pin 172 no longer extends into the slot 159B of the connecting wall 150B, the connecting wall 150B is detached from the locking wall 150A. The locking pin 172 can then be rotated back to the locked position for storage.

[0021] In the embodiments shown in Figures 1A to 1G, when the handle portion 172B is rotated so that it extends substantially perpendicularly from the locking wall 150A, the hook portion 172C of the locking pin 172 is in the unlocked position or aligns with the slots 159A and 159B of the locking wall 150A and the connecting wall 150B. When the handle portion 172B is parallel to the locking wall 150A, the hook portion 172C is in the locked position or no longer aligns with the slots 159A and 159B. Due to gravity, when the locking wall 150A is in the upright position, the handle portion 172B is normally parallel to the locking wall 150A, so the hook portion 172C is normally not aligning with the slots 159A and 159B, and therefore normally the locking pin 172 is in the locked position.

[0022] The support bracket 170 further includes a handle retaining bracket 171, which receives the handle portion 172B of the locking pin 172 when the locking pin 172 is in the locked position and in either the connected or disconnected position. Referring to Figures 4B to 4C, the handle retaining bracket 171 includes an arm 171A extending from the support bracket 170. Each arm 171A includes a projection 171B extending inward toward the support bracket 170 from a portion of the arm 171A. The handle portion 172B of the locking pin 172 includes a portion sized to fit between the projection 171B of the arm 171A and the support bracket 170. The projection 171B restricts the space between the arm 171A and the support bracket 170, thereby requiring the handle portion 172B to be forcibly inserted into or forcibly removed from the handle retaining bracket 171. The handle portion 172B may be held by the handle retaining bracket 171 in both the disconnected and connected configurations. Thus, the handle retaining bracket 171 prevents the handle portion 172B from rotating around the shaft portion 172A, thereby fixing the locking pin 172 in the locked position and preventing, for example, the locking wall 150A and the connecting wall 150B from unintentionally disconnecting from each other when they are in the connected configuration.

[0023] As shown in Figures 1B and 1D, one locking wall 150A and one connecting wall 150B include a latch engaging member 190. The latch engaging member 190 may be a plate extending below the bottom member 158 of the walls 150A and B. As will be described in more detail below, when the locking wall 150A or the connecting wall 150B slides into the cavity 112 along their respective tracks in the base 102, the latch engaging member 190 engages with a latch 140 in the base 102, thereby rotating the latch 140 and extending it into the path of the wall track directly above the walls 150A and B, thus holding the walls 150A and B upward within the base 102.

[0024] Each wall 150A and B includes a crossbar 174. The crossbar 174 engages with the corresponding retaining member 130 or latch 140 of the base 102 when the crate 100 is in the folded position as shown in Figure 2, preventing the walls 150A and B from sliding out of the cavity 112 of the base 102. In the illustrated embodiment, the crate 100 includes a retaining member 130 for one locking wall 150A and one connecting wall 150B, and a latch 140 for one locking wall 150A and one connecting wall 150B. In another embodiment, the crate 100 may include retaining members 130 for all walls 150. Also in the illustrated embodiment, one retaining member 130 or latch 140 is used for each wall 150A and B in the left portion of the track for housing the walls 150A and B within the base 102. In other embodiments, the crate 100 may include a retaining member 130 or latch 140 on each side of each wall 140. For example, each wall 150A,B may include a retaining member 130 or latch 140 on the left side of the track that houses the walls 150A,B within the base 102, and a retaining member 130 or latch 140 on the right side of the track.

[0025] Referring to Figures 5A and 8A, a retaining member 130 is shown extending from the side wall 124A. The retaining member 130 includes a bar 132 that rotates around the shaft 134. The retaining member 130 includes a torsion spring coupled to the shaft 134 and the bar 132, which biases the end 132A of the bar 132 downward and toward the path of the track formed by the two corresponding ledges 126. When the walls 150A,B are housed in the cavity 112 of the base 102, the end 132A of the bar 132 extends downward and engages with the upper surface 174A of the crossbar 174 of the wall 150 (see Figure 8A). In this way, the bar 132 of the retaining member 130 prevents the walls 150A,B from exiting the cavity 112. To remove walls 150A,B from the cavity, end 132A of bar 132 is rotated upward around shaft 132. This can be done by pushing down the opposite end 132B of bar 132A to overcome the biasing force of the torsion spring. Once bar 132 is no longer in the track and / or engaged with the crossbar 174 of walls 150A,B, walls 150A,B can be removed from the cavity 112.

[0026] Referring to Figures 5B and 8B, a latch 140 extending from ledge 126 is shown. The latch 140 includes a support 140A extending from side wall 124B and a bracket 140B configured to rotate around the axis of support 140A. As shown in Figures 5B and 8B, the latch 140 is in a retaining orientation that engages with and / or holds the walls 150A,B along the associated tracks of base 120. The bracket 140B includes a vertically extending member 140C that can rotate to extend within the path of the tracks formed by the two corresponding ledges 126. The latch 140 is in the retaining orientation when the two opposing walls 150A,B are inside the cavity 112 when crate 100 is in the folded position. When in the holding position, the vertically extending member 140C of the latch 140 engages with the upper surface 174A of the crossbar 174 of the walls 150A,B, preventing the walls 150A,B from coming out of the cavity 112 as they slide along the ledge 126 that forms the track (see Figures 7D and 8B). Thus, the vertically extending member 140C acts as a stopper to prevent the walls 150A,B from coming out of the cavity 112 unintentionally. As shown in Figures 7A to 7C, the rotatable hook 140 rotates around the support 140A or hangs in the non-holding position, thereby preventing the vertically extending member 140C from being in the path of the walls 150A,B, thereby allowing the walls 150A,B held by the latch 140 to slide into the cavity 112 of the base 102. When opposing walls 150A and B are inserted into the cavity 112 of the base 102 along the track, the latch engaging member 190 engages with the bracket 140B, rotating the bracket 140B around the axis of the support 140A, and bringing the vertically extending member 140C into the track of the walls 150A and B above the walls 150A and B together with the latch engaging member 190 (i.e., the retaining position). In the illustrated embodiment, the latch engaging member 190 slides along the bottom side of the bracket 140B of the latch 140, thereby aligning the bottom side of the bracket 140B with the latch engaging member 190, thereby rotating the latch 140 into the retaining position (see Figures 7D and 8B).With the vertically extending member 140C in the path of walls 150A and B, walls 150A and B cannot slide out of the base 102 along their tracks. To prevent walls 150A and B from accidentally leaving the base 102, the vertically extending member 140C can engage with the crossbar 174 of walls 150A and B. When opposing walls 150A and B are removed from the base 102, the latch engaging member 190 no longer pushes the latch 140 into the retaining position, the latch returns to the non-retaining position, and walls 150A and B are removed from the base 102.

[0027] With respect to Figures 5A to 5D, each of the walls 150A and B further includes a leg 180 that extends from the bottom member 158 and engages with the ledge 126 of the base 102. The legs 180 of the walls 150A and B are sized such that when the walls 150A and B are in an upright position (for example, when the crate is in an assembled position), the legs 180 extend to the corresponding ledge 126 of the base 102, which forms a track that receives the walls 150A and B within the cavity 112 of the base 102. Since the ledge 126 for each wall 150A and B is at a different distance from the bottom wall 116 of the base 102 (for example, the track is at a different level), the legs 180 for each wall 150A and B are of different lengths. For example, the walls 150A and 150B that slide into the lowest track have the longest legs 180, as their legs must extend from the bottom member 158 to the ledge 126 of the lowest track. The walls 150A and 150B that slide into the uppermost track of the base 102 have the shortest legs 180, as their legs only extend from the bottom member 158 of the walls 150A and 150B to the ledge 126 of the uppermost track. Each leg 180 includes a pin 182 located at the end of the leg 180 opposite the top of the wall 150. The pin 182 may include a rounded surface, which helps the walls 150A and 150B pivot or rotate between a horizontal position and an upright position when assembling and folding the crate 100. The pin 182 extends laterally outward from the leg portion 180 and engages with the fastener 184 when the walls 150A,B are removed from the cavity 112 of the base 102. The fastener 184 prevents the walls 150A,B from coming loose or detaching from the base 102 when the walls 150A,B are removed from the base 102 when assembling the crate 100. The fastener 184 has an upper portion that extends over the top of the pin 182 as the pin 182 slides to the end of the track when the wall is removed, which can prevent the pin 182 from moving substantially upward away from the ledge 126 on which the pin 182 slides. Once the walls 150A,B are removed and the pin 182 is engaged with the fastener 184, the walls 150A,B can then be rotated around the base 102 to an upright position.

[0028] In another embodiment, the walls 150A,B do not include legs 180 that extend to or remain in contact with the tracks corresponding to each wall 150A,B. Instead, the walls 150A,B are not pivoted around legs 180 that rest on ledges 126 forming the tracks, but are removed and manually aligned for insertion into the tracks of the base 102.

[0029] As shown in Figures 1A to 1G, the connecting wall 150B includes a projection 186 extending from the upper member 156. The support block 122 of the base 102 includes a complementary recess 188 sized to receive the projection 186. These projections 186 and recesses 188 allow the crates 100 to be stacked on top of each other by positioning the projection 186 of the first crate 100 within the recess 188 of the second crate 100.

[0030] To assemble the crate 100 from the folded configuration shown in Figure 2, the bar 132 of the retaining member 130 that engages with the crossbar 174 of the locking wall 150A is rotated, and the end 132A of the bar 132 is moved upward to move the first locking wall 150A out of the track path. As shown in Figure 6A, this may also be done by pushing the end 132B downward. The locking wall 150A is slid along the ledge 126 of the track on which the locking wall 150A rests until the pin 182 of the leg 180 of the locking wall 150A engages with the fastener 184 of the base 102. Referring to Figure 6B, the upper end of the locking wall 150A is then rotated around the pin 182 toward an upright position until the bottom member 158 rests on the bottom wall 116 of the base 102. Next, the handle portion 164A of the locking pin 164 of the wall position locking mechanism 106 is rotated outward from the upper notch 166A of the U-shaped bracket 162. Then, the locking pin 164 is pushed downward toward the base 102, and the shaft 164B of the locking pin 164 extends into the hole 158A of the bottom member 158 and into the hole 118 of the bottom wall 116. Referring again to Figure 4A, the handle portion 164A of the locking pin 164 is then rotated toward the U-shaped bracket 162 until the handle portion 164A of the locking pin 164 enters the lower notch 166B of the U-shaped bracket 162, thereby locking the locking wall 150A in the upright position.

[0031] Next, the second locking wall 150A, located opposite the first locking wall 150A in the crate 100, is removed from the base 102 as shown in Figure 6C. Once the first locking wall 150A is removed, the latch 140 is pivoted to a non-retaining position where the vertically extending member 140C is not in the path of the track of the second locking wall 150A (similar to that shown for the connecting wall 150B in Figures 7B and 7C). The second locking wall 150A is slid out of the base 102 along the ledge 126 of the track on which the locking wall 150A rests. The locking wall 150A is slid out of the base 102 along the ledge 126 until the pin 182 of the leg 180 of the locking wall 150A engages with the fastener 184 of the base 102. Next, the locking wall 150A is pivoted toward the upright position and locked using the same wall position locking mechanism 106 as the first locking wall 150A.

[0032] As shown in Figure 6D, the first connecting wall 150B is removed from the base 102. To do this, the retaining member 130 can be detached from the crossbar 174 of the connecting wall 150B, as described above. Next, the wall 150B can be removed from the base 102 until the pins 182 of the legs 180 of the first connecting wall 150B engage with the fasteners 184 of the base 102. The first connecting wall 150B is then pivoted to an upright position, the bottom member 158 rests on the bottom wall 116 of the base 102, and the slot 159B aligns with the slot 159A of the adjacent locking wall 150A.

[0033] Next, the handle portion 172A of the lock pin 172 of the wall lock mechanism 108 of the lock wall 150A is rotated upward so that the hook portion 172C of the lock pin 172 is aligned with the slots 159A and B. Next, the lock pin 172 is slid along the axis of its shaft so that the hook portion 172C passes through the slots 159A and B. Next, the handle portion 172A is rotated downward so that the hook portion 172C is not aligned with the slots 159A and B. The handle portion 172A is pushed between the retaining arm 171A of the handle retaining bracket 171 and the support bracket 172, locking the handle portion 172A in the locked position, thereby locking the lock wall 150A to the connecting wall 150B. The other lock wall 150A is similarly connected to the first connecting wall 150B using the wall lock mechanism 108. As shown in Figure 6E, the three walls of crate 100 are then assembled in an upright position.

[0034] Next, the second connecting wall 150B, which is on the opposite side from the first connecting wall 150B, is removed from the base 102. As shown in Figures 7B to 7C, when the first connecting wall 150B is removed from the base 102, the latch 140 is in a non-retaining position and does not prevent the second wall 150B from moving away from the base 102. The second connecting wall 150B slides outward from the base 102 along the ledge 126 of the track on which the second connecting wall 150B rests. As the second connecting wall 150B slides outward from the base 102 along the ledge 126, the pin 182 of the leg 180 of the second connecting wall 150B engages with the fastener 184 of the base 102, as shown in Figure 6F. The connecting wall 150B is then pivoted around the pin 182 toward an upright position similar to that of the first connecting wall 150B. The wall locking mechanism 108 is used to secure the connecting wall 150B to the adjacent locking wall 150A, similar to the method described for the first connecting wall 150B. Then, as shown in Figure 6G, the crate 100 is assembled into its configuration.

[0035] To fold the crate 100, the steps for assembling the crate 100 are performed in reverse order. Separating the second connecting wall 150B from the adjacent locking wall 150A is done by moving the wall locking mechanism 108 to the unlocked position and aligning the hook portion 172C of the locking pin 172 with the slots 159A,B. Next, the locking pin 172 is slid along the axis of the shaft portion 172B to the detached position and the locking pin 172 is pulled out from the slots 159A,B. Next, the locking pin 172 is rotated to the locked position and the locking pin 172 is attached to the handle retaining bracket 171 so that the handle portion 172A does not unintentionally rotate around the shaft portion 172B of the locking pin 172. Next, the second connecting wall 150B can be separated from the adjacent locking wall 150A, and the upper portion of the connecting wall 150B can be rotated around the pin 182 of the leg 180 until the second connecting wall 150B is substantially aligned with the track of the base 102 formed by the ledge 126 of the side wall 124B. The connecting wall 150B can then be slid along the ledge 126 into the cavity 112 of the base 102. The connecting wall 150B can be inserted until the leg 180 abuts against the fastener 128 of the ledge 126.

[0036] The first connecting wall 150B can be detached from the adjacent locking wall 150A in the same manner as the steps relating to the second connecting wall 150B described above. The first connecting wall 150B can be rotated around the pin 182 of the leg 180 until the connecting wall 150B is substantially aligned with the track of the base 102 formed by the ledge 126 of the side wall 124B. The first connecting wall 150B can then be slid along the ledge 126 into the cavity 112 of the base 102. The crossbar 174 contacts the retaining member 130 and can bend the end 132A of the retaining member 130 upward so that the wall 150B can enter the cavity 112. As the crossbar 174 passes under the retaining member 130, the retaining member 130 is spring-loaded into the path of the connecting wall 150B along the track, preventing the wall 150B from unintentionally coming out of the cavity 112 of the base 102. As the first connecting wall 150B is inserted along the track, the latch engaging member 190 contacts the latch 140 of the second connecting wall 150B, rotating the latch 140 into a retaining position. The vertically extending member 140C of the latch 140 may then extend into the track path of the second connecting wall 150B (as shown in Figure 7D) and contact the crossbar 174 of the second connecting wall 150B, preventing the second connecting wall 150B from sliding out of the base 102. The connecting wall 150B can slide along the ledge 126 until its leg portion 180 abuts against the fastener 128 of the ledge 126.

[0037] Next, the locking pin 164 of the wall position locking mechanism 106 of the second locking wall 150A can be pulled out from the hole 118 in the bottom wall 116, moving the handle portion 164A to the unlocked position within the upper notch 166A of the U-shaped bracket 162. Then, the second locking wall can be rotated around the leg portion 180 and inserted into the cavity 112 of the base 112 along the track formed by the ledge 126 along the side wall 124A, in the same manner as described above with respect to the second connecting wall 150B.

[0038] Next, the first locking wall 150A can be detached from the base 102 in the same manner as described above with respect to the second locking wall 150A. Then, the first locking wall 150A can be rotated around the leg 180 and inserted into the cavity 112 of the base 112 along the track formed by the ledge 126 along the side wall 124A, in the same manner as described above with respect to the first connecting wall 150B. With all four walls 150A,B inside the cavity 112 of the base 102, the crate 100 is in the folded position as shown in Figure 2.

[0039] The use of singular terms such as "a" and "an" is intended to cover both singular and plural forms unless otherwise specifically indicated herein or unless the context clearly indicates otherwise. The terms "equip," "have," "include," and "contain" are interpreted as open-ended terms. The phrase "at least one" as used herein is intended to be interpreted as a disjunctive term. For example, the phrase "at least one of A and B" is intended to include A only, B only, or both A and B.

[0040] While specific embodiments of the present invention have been illustrated and described, those skilled in the art will recognize that various modifications, alterations, and combinations can be made with respect to the above embodiments without departing from the scope of the invention, and such modifications, alterations, and combinations should be considered to be within the scope of the concept of the present invention.

Claims

1. A base that includes the upper surface and defines a cavity below the upper surface, It comprises multiple walls that can be attached to each other in a removable manner, The plurality of walls are movable between a first arrangement in which they extend substantially vertically above the upper surface of the base and a second arrangement in which the plurality of walls are located within the cavity of the base. A collapsible crate, wherein the upper surface of the base is configured to support articles on the upper surface when the collapsible crate is in the first and second configurations.

2. The base includes a plurality of tracks within the cavity, The collapsible crate according to claim 1, wherein each of the plurality of tracks is configured to receive a wall from the plurality of walls and to guide the wall as it slides in or out of the cavity.

3. The collapsible crate according to claim 2, wherein each of the plurality of tracks is substantially parallel to the upper surface of the base and is in a different vertical position relative to the other tracks of the plurality of tracks.

4. The collapsible crate according to claim 2 or 3, wherein each of the plurality of tracks comprises a first portion for receiving a first side of one of the plurality of walls and a second portion for receiving a second side of the wall.

5. The collapsible crate according to any one of claims 1 to 4, wherein each of the plurality of walls includes a mounting arm that engages with the base, and the wall is rotatable around the mounting arm when the wall is detached from the other walls of the plurality of walls.

6. The folding crate according to claim 5, wherein the mounting arm includes a rounded end that engages with the track of the base, and the wall rotates around the rounded end.

7. The first wall of the plurality of walls includes a locking mechanism for locking the first wall to the second wall of the plurality of walls. The foldable crate according to any one of claims 1 to 6, wherein the locking mechanism is provided with a pin that extends into a complementary hole in the second wall and attaches the first wall to the second wall.

8. The first wall of the plurality of walls includes a locking mechanism for locking the first wall in a position substantially perpendicular to the upper surface of the base, The collapsible crate according to any one of claims 1 to 7, wherein the locking mechanism is provided with a pin configured to extend into a complementary hole in the base such that the first wall does not substantially rotate relative to the base.

9. The base includes a lower frame below the cavity, The collapsible crate according to any one of claims 1 to 8, wherein the lower frame is positioned away from the surface on which the base is mounted, thereby allowing forks of a mobile device to extend below the lower frame for transporting the collapsible crate.

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