Field of the invention

The present invention relates to crates for handling goods. In particular, the present invention relates to crates in which non-self-supporting packages, such as liquid or solid dairy products, bread or other fast moving consumer goods, are transported, stored and displayed. More specifically, the present invention relates to a crate and a supply and merchandising method according to the preamble portions of claims 1 and 15, respective- ly.

Prior art

The current trend of streamlining supply chains reverberates directly to the spatial and functional efficiency of the tools used in transporting goods from manufacturers or re- packers to consumers. As a particular field of interest is to optimise the logistics of the supply chain to include as few handling steps as possible and to also rationalise reverse logistics, i.e. returning dollies, pallets and such back to the manufacturer or repacker. The tools used in present-day logistics of consumer products include cell trays, prismatic crates of different sorts, dollies, pallets, and such. Cell trays are mostly suited for transporting products, which can withstand external vertical loads so that products, such as beverage bottles, are loaded onto the trays, which can be then stacked on top of each other. Cell trays are a very advantageous way of transporting sturdy containers, since they take up very little space and enable handling by forklift.

However, certain consumer product packages are not designed to withstand external vertical loads but rather to act as a protective shell to the contents. In fact, the current envi- ronmentally conscious atmosphere tends to avoid excessive packing materials and secondary packaging. As a result, spatially very preferable cell trays cannot be used. Instead, such products are packed and transported in various kinds of crates that can be used in forming stacks. The crates are typically collapsible or they have a rigid frame. The rigid frame crates usually have a bottom piece, to which is fixed four opposing side walls that have handles of some sort. As said, crates having four foldable walls are also known, wherein the four walls are foldable for collapsing the crate so that the crate takes up minimal space during return logistics.

Disadvantages of the prior art

However, known crates for non-self-supporting packages feature considerable disadvan- tages. As stated earlier, cell trays are not suitable for transporting "non-self-supporting" containers. Rigid frame crates on the other hand are not very advantageous in terms of return logistics since they take up quite a lot space when stacked. Known collapsible crates provide remedy to the issue, but functionally speaking, known collapsible crates have been found rather labour intensive and lacking display value. In summary, none of the known transportation tools have been able to provide the combination of overall supply chain efficiency, display value and easy merchandising, user- friendliness, efficient in-store handling and consumer convenience.

Aim of the invention

The aim of the present invention is to solve at least some of the above identified prob- lems of the prior art and to provide an improved crate for transporting and handling non- self-supporting containers as well as a method for supplying and displaying products.

Summary

It has been noticed that a collapsible crate having two lateral walls and a supporting frame member engaged to support the walls is rigid enough for transporting most non- self-supporting products, such as liquid and solid consumer products, like dairy, bakery or beverage packages, or components, like individual parts or sub-assemblies, for other branches of industry. By having only two lateral walls and a supporting frame member in between, at least one side wall is left exposed, which makes it possible to exhibit the products directly in the crates without shelving or further handling steps. The invention is thus based on the concept of a novel collapsible transportation crate for the transportation and exhibition of particularly non-self-supporting containers. The crate comprises a quadrilateral tray, which forms the bottom of the crate, and at least two lateral walls connected pivotably to opposite edges of the tray. The walls are, on the one hand, pivotable into an erect position for operational mode of the crate, wherein the lateral walls are or- thogonal to the tray and define a space for the contents. The walls are, on the other hand, pivotable into a folded position for return mode of the crate, wherein the lateral walls are parallel to the tray. The crate further comprises at least one supporting frame member, which is adaptable to a laterally supporting position between the erected lateral walls on one lateral side of the crate so that at least one lateral side is left open. The supporting frame member is also adaptable to a folded position, wherein the supporting frame member is parallel the tray.

According to one preferred embodiment, the supporting frame member is a third lateral wall, wherein the crate comprises three foldable lateral walls adapted pivotably to corresponding three separate edges of the tray. One lateral side and the top side of the crate are therefore open when the lateral walls are in the erect position.

According to another embodiment, the supporting frame member is an open rectangular frame-like piece, which comprises two side portions connected pivotably to an edge piece of the tray and one top portion connecting the side portions. The top portion and the side portions define an open zone, whereby the side of the crate is left open. Accord- ing to a further embodiment, the crate comprises two suh frame members, which are adapted on opposite edge pieces of the tray.

More specifically, the crate according to the invention is characterized by what is stated in the characterizing portion of claim 1.

On the other hand, the method according to the invention is based on the concept of sup- plying and merchandising products, where products are loaded into a crate having at least two foldable lateral walls and a laterally supporting frame member connecting the two walls, where after the crate is transported to a place of commerce, where the containers are exhibited to the customers at first hand in the crate. Emptied crates are collapsed by folding the walls to a folded position for benefiting return logistics. More specifically, the method according to the invention is characterized by what is stated in the characterizing portion of claim 15.

Advantages gained with aid of the invention

Considerable advantages are gained with the aid of the present invention. Because the novel structure comprises two foldable side walls and a supporting frame member sup- porting the two, one lateral side of the crate is open, whereby the contents are exhibited within the crate even when the crates are stacked. Since the contents are visible from the crate, the contents do not necessarily have to be shelved or further handled prior to exposure to end user. As a result, the crate stacks can be transported directly accessible to the end user. Indeed, the invention provides for reduced need for in-store handling and shelving from crates, high display value and consumer convenience compared to known structures. The novel foldable three wall structure also provides sufficiently secure, stabile, rigid and convenient handling and the contents of the crate can be loaded as well as unloaded by using both the lateral and upper opening in the crate. Furthermore, the folding walls significantly reduce the need of space for empty crates compared to rigid frame crates, for example. The collapsing feature of the crate results in high, about 3 to 1, nesting efficiency in return logistics and warehousing of empty crates.

Brief description of the drawings

In the following, some embodiments of the present invention are described with reference to the accompanying drawings, in which:

Fig. 1 presents an isometric view of a crate according to one embodiment of the present invention,

Fig. 2 presents an isometric view of the crate of Fig. 1 loaded with dairy product containers,

Fig. 3 presents an isometric view of the crate of Fig. 1 in a partially folded position, Fig. 4 presents an isometric view of the crate of Fig. 1 in a folded position, Fig. 5 presents a rear isometric view of the crate of Fig. 1,

Fig. 6 presents an isometric view of a plurality of crates of Fig. 4 stacked on top of each other,

Fig. 7 presents an isometric view of a stack of crates of Fig. 2 loaded onto a dolly, Fig. 8 presents an isometric view of a crate of Fig. 1 equipped with a cover sheet, Fig. 9 presents an isometric rear view of a crate according to another embodiment of the invention,

Fig. 10 presents an isometric rear view of a crate of Fig. 9 in a partially folded position, and Fig. 11 presents an isometric frontal view of a crate according to yet another embodiment of the invention.

Detailed description of preferred embodiments

The invention provides a novel collapsible crate, which features a quadrilateral tray forming the bottom of the crate. The crate also comprises at least two lateral walls, which are adapted pivotably to separate edges of the tray so that the lateral walls are pivotable into a folded position and into an erect position. When the walls are folded down to flank the tray, the crate assumes a return mode, whereby the crate is collapsed for minimizing space consumption in return logistics. When the walls are in the erect position, the crate assumes an operational mode, whereby the lateral walls define a space for the contents of the crate. When erected, the walls are essentially orthogonal in relation to the tray. The crate further comprises at least one supporting frame member other than the tray. The supporting frame member is adapted to be pivoted to a supporting position, wherein the supporting frame member provides lateral support between two erected opposing lateral walls. When the supporting frame member is arranged between the two erected lateral walls, at least one lateral side of the crate is left open. The at least one supporting frame member is also adapted to be pivoted to a folded position, wherein it flanks the lateral walls in a folded position. In other words, the supporting and folded positions of the supporting frame member contribute respectively to the operational and return modes of the crate. According to the present invention, there are several ways of providing a crate capable of establishing the technical effect of the novel concept. At least three alternative embodiments are described herein. One particularly preferable embodiment is illustrated in Figs. 1 - 7 and described in the immediate following. As illustrated in Fig. 1 and according to one preferred embodiment of the present invention, the crate 1 has four major pieces, which form a prismatic transportation and display platform. The crate 1 according to the invention can be designed to an arbitrary size, but the dimensions are preferably selected to optimize the occupation of local transportation pallets, dollies (Fig. 7) and such as well as to provide a suitable fit for a certain amount of the intended contents. Furthermore, the crate 1 can be manufactured from a vast number of materials using a wide selection of manufacturing techniques. However, catering for low manufacturing costs in high production volume, a preferable material would be an injection moulded polymer, such as polyethylene or polypropylene. According to another alternative embodiment, the crate 1 is manufactured from high tensile steel wire, which is braid to form mesh profiles that are assembled to form the crate 1.

The tray 10 acts as a chassis to which the other components are attached. The tray 10 has a quadrilateral, preferably rectangular, plate-like mesh 11, which is flanked by four interconnected edge pieces 6, 7, 8, 9 (Figs. 1 and 5). The mesh 11 is a bottom piece, onto which the non-self-supporting containers are loaded. In this context the term non-self- supporting refers to structures that have sufficient rigidity for only supporting their own weight and contents, i.e. non-self-supporting bodies cannot withstand significant external forces and are therefore not intended to be stacked on top of each other. For this reason cell trays cannot be applied to non-self-supporting bodies, which is the case in, for exam- pie, dairy product packages (Fig. 2), tea bag boxes, packets of crisps and such. While the crate 1 according to the invention is naturally applicable also to other kinds of pieces, i.e. supporting containers such bottles, the invention is especially suitable for non-self- supporting containers.

As said, the mesh 11 is flanked by edge pieces 6, 7, 8, 9 which are interconnected at the corners of the quadrilateral tray 10. The corners of the tray 10 are preferably rounded or chamfered to avoid sharp external edges. The edge pieces 6, 7, 8, 9 can be provided in several alternative ways. According to one embodiment, the edge pieces 6, 7, 8, 9 are made to form an enclosure-like structure, which has been provided with vertical through holes. The pieces are open from the top and bottom and have inner and outer partitions, to the middle of which has been provided lathing for improved rigidity. This embodiment is advantageous for manufacturing reasons. According to another embodiment, the edge pieces 6, 7, 8, 9 have a sandwich structure for superior rigidity in other applications requiring such robust endurance. According to yet another embodiment, the structure can be hollow with assisting gas within the cavity.

As can be seen from Figs. 1 and 5, the front edge piece 6 and the rear edge piece 8 have a thicker structure than the first and second lateral edge pieces 7, 9 that connect the former two. The edge pieces 6, 7, 8, 9 are preferably equipped with means for positioning and securing neighbouring crates 1 to each other. According to one embodiment, the outer faces of the edge pieces 6, 7, 8, 9 of the crate 1 are provided with groove sets 12, 13, 14, 15. As illustrated in Figs. 1 and 5, front edge piece 6 and the rear edge piece 8 have a female side locking groove set 12 and a male side locking groove set 13. The groove sets 12, 13, 14, 15 are a plurality banded protrusions, which form grooves between them. The groove sets 12, 13 are mirrored between the front and the rear edge piece 6, 8 so that when a plurality of crates 1 are aligned sequentially, the female groove set 12 of the front edge piece 6 of the latter crate 1 engages with the male groove set 13 of the rear edge piece 8 of the former crate, and vice versa. The lateral edge pieces 7, 9 are provided with equivalent groove sets 14, 15, in which the female groove set 14 has two nested protrusions, between which is a groove for receiving a corresponding male groove set 15, which is a rectangular protrusion. The means for positioning and securing neighbouring crates 1 to each other may also have other manifestations according to the invention.

The crate 1 according to the preferred embodiment of the invention comprises three fold- able lateral walls 20, 30, 40, which define a space there between for the contents 50 of the crate 1 (Figs. 1 and 2). In this context the two opposing walls are referred to as the first and second side wall 20, 40, respectively. The wall connecting the first and second side wall 20, 40 is referred to as the rear wall 30. The rear wall 30, therefore, forms the pivotable supporting frame member, which provides lateral support for the first and second side wall 20, 40 and is foldable for return mode. To be precise, the rear wall 30 engages with the first and second wall 20, 40 with the purpose of preventing the walls 20, 40 from folding in. The fourth side, which is referred to as the frontal side, is therefore exposed. However, according to one embodiment of the invention, the fast front edge piece 6 of the tray 10 is elevated from the mesh 11 so that the front edge piece 6 supports the contents of the crate 1 from the front. The front edge 6 is lower than any of the walls 20, 30, 40. According to a further embodiment, the front edge piece 6 has a height at most 50 per cent of that of any of the walls 20, 30, 40. On the other hand, the front edge piece 6 preferably has a height matching at least the height of the lateral walls 20, 30, 40 when they are folded on top of each other, i.e. the crate 1 is collapsed. A front edge piece 6 of described height therefore provides protection for the folded walls 20, 30, 40 when, for example, empty crates 1 are stacked on top of each other. While the front side of the crate 1 is not completely exposed from the mesh 11 up, it is, in this context, considered to be open because it is not covered by a wall but rather by a edge piece of the tray at the bottom, whereby the contents of the crate 1 is exposed so that the contents can be re- moved from the crate 1 through the side in question. Likewise, the side opposing the mesh 11 of the tray 10, i.e. the top side, is also open.

The walls 20, 30, 40 can be constructed in several ways. According to the embodiment illustrated in the accompanying drawings, the walls 20, 30, 40 are plates made of an undulated profile, which provides outstanding structural rigidity. The walls 20, 30, 40 are pivotably connected to the tray 10, in particular to the corresponding edge piece 6, 7, 8,

9, through hinges 19 (Fig. 3). According to one preferred embodiment, the hinges 19 are integrated hinges, which consist of a thin film of the same material as the tray 10 and walls 20, 30, 40. The integrated hinges therefore provide a continuous pivoting connection between the walls 20, 30, 40 and the tray 10. The hinged connection can also be ac- complished in an alternative suitable manner. Due to said hinged connection, the walls 20, 30, 40 are foldable to a folded position and to an erect position in respect to the tray

10. In other words the walls 20, 30, 40 can be folded down parallel to the mesh 11, wherein the crate 1 is collapsed, or the walls 20, 30, 40 can be pivoted to an erect position, wherein the crate 1 is assembled. As is further apparent from Fig. 3, the edge pieces 7, 8, 9 are designed to be of different height so that hinges 19 are on different heights, whereby both side walls 20, 40, for example, fit under the folded rear wall 30. Respectively, the first lateral edge piece 7 connected to the first side wall 20 is elevated at a distance from the mesh 11 corresponding to the thickness of the second side wall 40.

As is apparent from Fig. 5, the walls 20, 30, 40 of the crate 1 are provided with apertures 21, 31 for accommodating engagement with an external gripper or suchlike. The apertures 21, 31 are designed so that, they conform to the local material handling equipment, such as a specific type of grippers used for automatic handling. Apertures are preferably also provided to enable easy grabbing by hand (see horizontal apertures in side walls 20, 40).

According to a preferred embodiment, the free ends of the lateral walls 20, 30, 40 are further equipped with locking pieces 16, which are adapted to engage to corresponding recesses (not shown) in the bottom face of the tray 10. The locking pieces 16 have two functions. The first function is to position and secure crates 1 to each other when crates 1 are stacked on top of each other (Fig. 7). The second function is to provide rigidity to the crate 1, when crates 1 are stacked on top of each other. In fact, with the aid of the locking pieces, it is possible to provide a quadrilateral support for a trilateral crate, when the crates 1 are stacked. In a stacked position, the tray 10 of the upper crate 1 acts as an additional stiffening ceiling piece for the lower crate 1. For further making the structure more rigid, the side walls 20, 40 are preferably equipped with brackets (not shown), which are adapted to lock into corresponding receptive openings (not shown) in the rear wall 30. The locking piece arrangement further provides for a possibility of stacking crates 1 according to the invention as well as other cargo handling equipment, such as cell trays, having appropriate locking pieces and recesses in the bottom surface. This possibility significantly improves the flexibility and efficiency of transport systems.

According to a further embodiment, the crate 1 is equipped with an external cover sheet 70 (Fig. 8) for protecting the contents and sealing the crate 1. For example, the cover sheet 70 can be made of card board and applied to the cage 1 upon loading it. It is preferably provided with holes for easy removal. When the crate 1 is supplied to the place of commerce, the cover sheet 70 is removed for displaying the contents and for providing access to the crate 1. The cover sheet 70 is preferably adapted to engage with a shape of the crate 1 so that the cover sheet 70 seals the crate 1 for indicating the integrity of the contents. Such a shape could be vertical grooves on the inner front surfaces of the first and second lateral wall 20, 40, into which grooves the cover sheet can be slid. Furthermore, the applied cover sheet 70 can be used to protect the contents from external influences such as dust or dirt. Alternatively or additionally, edged cover sheet 70 can be used for forming multiple layers within the crate in a case, where the contents are short enough. The cover sheets 70 can be attached to the crate 1 by shape joints, by gluing or by other attachment methods.

As said, the crate 1 according to above-described embodiment of the present invention is especially suitable for transporting and displaying non-self-supporting containers 50, such as dairy products, e.g. milk cartons. Crates 1 are preferably stored in a collapsed position before they are loaded with the intended contents (Figs. 4 and 6). Prior to loading, the walls 20, 30, 40 are pivoted to an erect position, whereupon they are locked to each other through the engagement of the locking brackets of the side walls 20, 40 and the openings of the rear wall 30 (Fig. 3). When the crate 1 is assembled (Fig. 1), the con- tents can be inserted by descending the containers 50 vertically into the crate 1 or capitalizing the open frontal side of the crate 1 (Fig. 2). Loaded crates 1 can be conveyed onto pallets, dollies 60 (Fig. 7) or other transportation platforms with suitable means. According to one embodiment the loaded crates 1 are transported by using a gripper, which engages with the apertures 21, 31 of the walls 20, 30, 40. Once the crates 1 are loaded onto dollies 60 or alike, they are transported to be displayed and ultimately sold, whereby the crates 1 do not have to be unloaded. Thanks to the open frontal side of the crate 1, the products 50 can be sold straight off the crate 1. When the crates 1 are stacked on top of each other (Fig. 7), the consumer is able to select any one of the containers 50 without having to dismantle the stack. As a result, the first stack of crates 1 may be sold out, where after the first stack is removed or the dolly 60 is turned around, thus exposing a new stack of full crates 1 , providing the stacks are built back-to- back. Once a crate 1 is empty, it is easily collapsed by pivoting the walls 20, 30, 40 into a folded position, as illustrated in Fig. 6. Because the crates 1 are collapsible on top of the tray 10, they require very little space and, on the other hand, can be loaded onto a similar dolly 60 for the return route. This is particularly advantageous, since the collapsed crates 1 leave a similar foot print as the assembled crates 1 , while requiring less height.

As said, the above-described embodiment featuring two opposing lateral walls 20, 40 and a rear wall 30 acting as a supporting frame member is one advantageous way of implementing the invention. According to another embodiment illustrated in Figs. 9 and 10, the supporting frame member 30 can be provided with an open rectangular frame-like piece made, for example, from a single bent high-tensile steel wire. The supporting frame member 30 according to the embodiment is considered open because, while in an erect position, the lateral side in question is left open. In other words, the frame-like member 30 features only the edges of a wall, whereby the portions define an open zone within. The supporting frame member 30 according to the embodiment has two side portions, which are connected pivotably to the tray 10, and one top portion, which connects the side portions. The supporting frame member 30 is pivotable to a folded position, wherein it is folded down to flank the tray 10, and to a supporting position, wherein it is erected to an essentially 90 degree angle to the tray 10. The supporting position, therefore, corresponds to the erected position of the lateral walls 20, 40. When the two opposing lateral walls 20, 40 are in an erect position and the supporting frame member 30 is in a supporting position (Fig. 9), the corners between the side portions and the top portion of the supporting frame member 30 engage with the rear faces of the opposing first and second lateral wall 20, 40. These faces are preferably equipped with a receiving groove for accommodating the pieces of the member 30. When in a supporting position, the support- ing frame member 30 provides lateral support for the lateral walls 20, 40, wherein the member 30 prevents the walls 20, 40 from folding down, while leaving two lateral sides of the crate 1 open.

When collapsing the crate 1 (Fig. 10), the lateral walls 20, 40 are folded down normally, after or before which the supporting frame member 30 is folded down to flank the tray 10 or a folded wall 20, 40. The bottom ends of the vertical portions of the member are preferably bent in a 90 degree angle and adapted to corresponding receiving holes in the tray 10 (Figs. 9 and 10). This insertion fit provides a joint, about which the member 30 is pivotable to the folded and supporting position. A similar joint structure may also be constructed in an alternative way without departing from the scope of the present invention. The member 30 can alternatively be pivotably adapted either of the lateral walls 20, 40, whereby the member 30 would comprise only the horizontal top portion. The top portion of the member 30 can be pivotably attached to the terminal end of either lateral wall 20, 40. The other lateral wall 20, 40 would correspondingly have a receiving slot for accommodating the terminal end of the top portion of the member 30. The supporting frame member 30 can also have other embodiments within the scope of the present invention. According to yet another embodiment of the present invention and as illustrated in Fig. 11, the crate 1 comprises two supporting frame members 30 illustrated in Figs. 9 and 10. Because the frame members 30 do not cover the sides of the crate 1, on which they are adapted, two sides of the crate 1 are left open. The supporting frame members 30 are provided as described above and are adapted to be pivoted on the one hand to a folded position and on the other hand to a supporting position, wherein the lateral walls 20, 40 are supported laterally from two sides.

In this context the term comprise is used to indicate inclusion instead of limitation, i.e. in addition to the stated elements, other elements may also be present. Furthermore, the above description is only to exemplify the invention and is not intended to limit the scope of protection defined by the claims. Indeed, it will be appreciated by persons skilled in the art that numerous variations and/or modifications may be made to the invention as shown in the specific embodiments without departing from the scope of the invention as broadly described. The present embodiments are, therefore, to be considered in all respects as illustrative and not restrictive.

able 1: List of reference numbers.