Drop box container

• US 6,416,271 B1
• Filed: 04/07/2000
• Issued: 07/09/2002
• Est. Priority Date: 04/07/2000
• Status: Expired due to Fees

• Current Assignee: Nucon Corporation (Menasha Corporation)
• Original Assignee: Nucon Corporation (Menasha Corporation)
• Inventors: Pigott, Schuyler F., Pigott, Maurice J., Pigott, Peter S., Pigott, Brandon L., Trapp, Michel
• Primary Examiner(s): Ellis, Christopher P.
• Assistant Examiner(s): Bower, Kenneth W
• Application Number:
  US09/545,797
• Time in Patent Office: 823 Days
• Field of Search: 414/422
• US Class Current: 414/422
• CPC Class Codes: B65D 11/10 of polygonal cross-section and all parts being permanently connected to each other B65D11/18 takes precedence
• CPC Class Codes: B65D 19/18 made wholly or mainly of plastics material
• CPC Class Codes: B65D 2519/00034 Plastic
• CPC Class Codes: B65D 2519/00069 Plastic
• CPC Class Codes: B65D 2519/00174 Plastic
• CPC Class Codes: B65D 2519/00208 Plastic
• CPC Class Codes: B65D 2519/00273 made of more than one piece
• CPC Class Codes: B65D 2519/00288 made of one piece
• CPC Class Codes: B65D 2519/00318 made of one piece
• CPC Class Codes: B65D 2519/00333 contact surface having a stringer-like shape
• CPC Class Codes: B65D 2519/00407 on the load supporting surface
• CPC Class Codes: B65D 2519/00427 on the lid or cover
• CPC Class Codes: B65D 2519/00497 whereby at least one side wall is made of one piece
• CPC Class Codes: B65D 2519/00567 mechanical connection, e.g. snap-fitted
• CPC Class Codes: B65D 2519/00587 side walls directly connected to each other
• CPC Class Codes: B65D 2519/00597 integrally formed
• CPC Class Codes: B65D 2519/00621 sidewalls directly connected to each other
• CPC Class Codes: B65D 2519/00641 Structures intended to be disassembled
• CPC Class Codes: B65D 2519/00711 removable lid or covers
• CPC Class Codes: B65D 2519/00805 Means for facilitating the removal of the load
• CPC Class Codes: B65D 2519/0091 : whereby all side walls are hingedly connected to each other
• CPC Class Codes: B65D 2519/0099 : single dismountable pallet element, e.g. for replacement

Abstract

A new drop box assembly or container having a base frame, a pair of runners to elevate the base frame from a surface, a first pair of door panels attached along one edge to the base frame, a sleeve having a plurality of sidewalls, and a top frame is disclosed. The base frame is preferably designed with a plurality of side members configured to define an opening, and a channel seated within the side members and circumjacent the opening—an upper surface of each side member being sloped away from the channel and toward the opening. Engagement of the disclosed container by a forklift or the like from four directions is permissible. A first means for securing the sleeve within the channel of the base frame includes a plurality of connecting members on one of either the base frame or the sleeve. Such connecting members include a plurality of male connecting members on the sleeve and a plurality of corresponding female connecting members on the base frame. An optional pair of short door panels may be included to assist flow direction of the discharging material. Compaction of the preferred container allows space efficiencies during shipping and storage of the empty container to be realized.

Claims

1. A modular drop box container for bulk items comprising:

a base frame having a plurality of side members configured to define an opening, a channel seated within the side members and circumjacent the opening, and wherein an upper surface of each side member is sloped away from the channel and toward the opening;

at least one runner to elevate the base frame from a surface and thereby allow engagement of the container by a forklift or the like;

at least one door panel attached along one edge to the base frame for opening and closing across the opening; and

a sleeve having a plurality of sidewalls and two outer edges defining opposed open ends with one outer edge configured to be seated within the channel of the side members of the base frame to cover the open end.

2. The modular drop box container of claim 1, wherein the sleeve comprises a plurality of fold lines allowing the sleeve to be folded and stored within the base frame when compacted.

3. The modular drop box container of claim 1, wherein the sleeve comprises a plurality of connecting members for securing to the base frame.

4. The modular drop box container of claim 1, wherein the base frame and the at least one first door panel are made from an injection molded plastic.

5. The modular drop box container of claim 1, further comprising a top frame for covering the other open end of the sleeve and thereby forming a closed container.

6. The modular drop box container of claim 5, further comprising a second means for securing the sleeve within the top frame.

7. The modular drop box container of claim 6, wherein the second means for securing comprises a plurality of connecting members on one of either the top frame or the sleeve.

8. The modular drop box container of claim 6, wherein the second means for securing comprises a plurality of male connecting members on the sleeve and a plurality of corresponding female connecting members on the top frame.

9. The modular drop box container of claim 5, wherein the top frame comprises a channel configured to engage the edge of the sleeve.

10. The modular drop box container of claim 5, wherein the top frame comprises an opening defined in a surface of the frame.

11. The modular drop box container of claim 10, wherein the top frame further comprises a detachable lid for covering the opening of the top frame.

12. The modular drop box container of claim 11, wherein the top frame comprises means for locking the detachable lid to the top frame.

13. The modular drop box container of claim 5, further comprising alignment members between the base frame and the top frame.

14. The modular drop box container of claim 13, wherein the alignment members comprise tabs and slots on the base frame and the top frame, with the tabs fitting into the slots during compaction of the container.

15. The modular drop box container of claim 1, further comprising a first means for securing the sleeve within the channel of the base frame.

16. The modular drop box container of claim 15, wherein the first means for securing comprises a plurality of connecting members on one of either the base frame or the sleeve.

17. The modular drop box container of claim 16, wherein the first means for securing comprises a plurality of male connecting members on the sleeve and a plurality of corresponding female connecting members on the base frame.

18. The modular drop box container of claim 17, further comprising a second means for securing the sleeve within a top frame used for covering the other open end of the sleeve, and wherein the second means for securing comprises a plurality of male connecting members on the sleeve and a plurality of corresponding female connecting members on the top frame such that either open end of the sleeve may be secured within either the top frame or the base frame.

19. The modular drop box container of claim 1, wherein the sleeve comprises at least one integral side support between adjacent sidewalls.

20. The modular drop box container of claim 19, wherein the at least one integral side support comprises double-bend comers between adjacent sidewalls.

21. The modular drop box container of claim 19, wherein the at least one integral side support comprises a T-fold running from one outer edge to the other in at least one sleeve sidewall.

22. The modular drop box container of claim 21, wherein the at least one integral side support comprises a T-fold running from one outer edge to the other in two sleeve sidewalls.

23. The modular drop box container of claim 21, wherein the at least one integral side support comprises a T-fold running from one outer edge to the other in each sleeve sidewall.

24. The modular drop box container of claim 21, wherein the at least one integral side support further comprises double-bend comers between adjacent sidewalls.

25. The modular drop box container of claim 1, further comprising an integral support along an edge of the first pair of door panels distal to the edge of attachment and below a plane defined by the first pair of door panels.

26. The modular drop box container of claim 25, wherein the integral support comprises a means for increasing the container volume.

27. The modular drop box container of claim 26, wherein the means for increasing the container volume comprises a cavity defined within the integral support and being open to the container interior.

28. The modular drop box container of claim 27, wherein the cavity has a volume within the range of from about 0.5 ft³ to about 20 ft³.

29. The modular drop box container of claim 1, further comprising at least one second door panel attached to the base frame for opening and closing across the opening, wherein the at least one second door panel comprises means for preventing the second door panels from binding with the at least one first door panel during closing.

30. The modular drop box container of claim 29, wherein the means for preventing comprises only a single contact point between the each of the second door panels and each of the first door panels.

31. The modular drop box container of claim 30, wherein the means for preventing comprises a protrusion along an edge of each second door panel contacting a first door panel.

32. The modular drop box container of claim 31, wherein each second door panel has a protrusion on each of two edges.

33. The modular drop box container of claim 1, wherein the sleeve is collapsible.

34. The modular drop box container of claim 33, wherein the collapsible sleeve is made from a plastic sheet material.

35. The modular drop box container of claim 34, wherein the plastic sheet material is corrugated.

36. The modular drop box container of claim 33, wherein the collapsible sleeve comprises a plurality of panels joined together.

37. The modular drop box container of claim 1, further comprising an inner liner having an opening at two opposing ends and positioned within the sleeve.

38. The modular drop box container of claim 37, wherein the inner liner is attached to at least one sidewall of the sleeve to prevent discharge of the liner.

39. The modular drop box container of claim 37, wherein one open end of the inner liner attaches to an open end of the sleeve.

40. The modular drop box container of claim 37, wherein one open end of the inner liner folds up adjacent the at least one door panel.