REFERENCE TO RELATED APPLICATION

[0001] This application claims priority to Israeli Patent Application No. 277185, filed September 3, 2020, the content of which is hereby incorporated by reference in its entirety.

FIELD OF THE INVENTION

[0002] The invention is directed to crates for shipping products, particularly agricultural products, and more particularly to crates for long-distance shipping of fruit that need occasional inspection of their content.

BACKGROUND OF THE INVENTION

[0003] Crates for long-distance (e.g. international) shipping of products, particularly fruit and similar agricultural products, made of polymers, particularly of Polyolefins, are in general use. Their advantages over crates made of paper or cardboard (e.g. cartons) include greater sturdiness, aeration of the content and resistance to humidity. In some configurations, polymer crates may also be re-usable and therefore generally foldable for return shipping.

[0004] Polymer crates are generally constructed of five panels - four side panels and a base--- each formed as a lattice of ribs. Preferred fabrication method is injection molding. In some configurations, such as those of a so-called monobloc crate, they are fabricated directly in their final, erect form, that is - with the panels fixedly joined. In other configurations, mainly those of a so-called folding crate - mainly intended to be re-usable - the side panels are hingedly interconnected with the base and are erectable by joining their corresponding edges with fasteners or with integral interlocking devices; such a crate is fabricated in a flat form, with the panels either flexibly joined or disjoint; in the latter case the side panels are subsequently joined to the base - preferably by matching integral hinge members.

[0005] Crates, conveying products, are generally shipped in stacks, possibly placed on a pallet; they remain thus stacked throughout the journey - from the producer's (or packer's) plant to the point of retail distribution. There is often a need to inspect a sample of the product, especially fruit, in a given group of crates - for example, after shipping fruit over a long distance or after a period of its storage in a ripening chamber. This is especially pertinent to fruit with a relatively short usable life, such as avocado or banana. Typically, a sample of one unit, or a few' units, of the product need to be removed from a randomly selected crate and inspected or tested. When the crates are of conventional design, removing a sample of the product necessitates unstacking and then restacking some of the relevant crates - which is labor intensive - or destructively cutting off a part of a side panel of the selected crate - which also involves some extra labor and leaves the crate partly open and thus susceptible to spillage or to damage. Some prior-art crates (e.g. as disclosed in International publication WO 2018/104852 or US patent application 2019337677 - Fig. la) are designed so that a side panel is formed with a hinged door within a hatch opening, the door being joined to the frame of the opening by thin connectors; to remove a sample, the door is manually swung out of the panel, breaking the connectors. This, again, leaves the crate partly open and thus susceptible to spillage or to damage. Some other prior-art crates (e.g. as disclosed in US patent application 2016039598 - Fig. lb) are designed with an opening in a side panel and a door, which is formed as a separate part, joined to the panel by hinges and latchable thereto with a clip; the door normally blocks the opening, but may be swung open to retrieve a sample and then re-closed.

SUMMARY OF THE INVENTION

[0006] According to the present invention there is provided a crate of a novel design, for shipping products, such as fruit and other agricultural products, that enables easily removing a sample of the product from any randomly selected crate within a stack of crates and leaving the crate intact. According to the novel design, a side panel of the crate includes a flap, that may be reversibly deflected outwards, and a flexible member that may normally be set so as to retain the flap from bending outwards, but may also be reversibly flexed so as to clear the flap for opening. A crate of this novel design may be entirely fabricated in a single molding operation - particularly by injection molding. The design is applicable to crates of any configuration, e.g. such as listed hereabove. [0007] More specifically there is provided in example embodiments of the invention a crate for conveying products, the crate comprising four side panels and a base, wherein at least one of the side panels includes:

- a wall portion defining a hatch, a flap deployed to substantially obstruct the hatch, the flap configured to be reversibly deflectable outwards to enable removing a sample of the products via the hatch from inside the crate, and

- at least one flexible member, configured so that when it is in a first state, the flap is free to be deflected outwards and when the flexible member is in a second state, it retains the flap from being pushed outwards by contents of the crate; wherein at least one of the side panels is integrally formed from polymer material via injection molding.

[0008] In some embodiments the second state of the at least one flexible member is a stable state. In some embodiments each of the first state and second state of the at least one flexible member is a stable state.

[0009] In some embodiments the at least one flexible member is formed as part of the wall portion. In some of these embodiments, the flap includes a protrusion corresponding to each of the flexible members, located and formed so that the respective flexible member, when in the second state, can be engaged by the protrusion. Optionally, each of the flexible members is formed with a lug, configured to be engaged by the corresponding protrusion.

[0010] In some embodiments the at least one flexible member is part of the flap. Preferably the wall portion includes a protrusion corresponding to each of the flexible members, located and formed so that the respective flexible member, when in the second state, can be engaged by the protrusion.

[0011] In some embodiments the at least one flexible members is formed as a ribbon, whose width is at least twice its thickness.

[0012] In some embodiments a lower edge of the flap is joined with the wall portion or with the base of the crate at an integral flexible hinge. In other embodiments a lower edge of the flap is rigidly joined with the wall portion or with the base of the crate and the flap is flexible so as to be deflectable.

[0013] In some embodiments the four side panels and the base are integrally formed from polymer material via injection molding as a monoblock crate. In some other embodiments the four side panels are hingedly interconnected with the base to form a folding crate.

LIST OF DRAWINGS

[0014] Figures la and lb are front views of two inspectable shipping crates of prior art.

[0015] Figures 2a-2d show a shipping crate according to a first example embodiment of the invention, including a deflectable flap; Figs. 2a and 2c are each a front view and Figs. 2b and 2d are each a detail in trimetric view; Figs. 2a and 2b show tire crate in its normal, closed state, while Figs. 2c and 2d show the crate in its open state with the flap deflected.

[0016] Figure 3 shows, in trimetric view, a detail of an example variation of the embodiment of figs 2a-2d, the crate being in its normal state.

[0017] Figure 4 shows, in trimetric view, a detail of another example variation of the embodiment of figs 2a-2d, the crate being in an open state with the flap deflected.

[0018] Figures 5a-5b show an inspectable shipping crate according to a second example embodiment of the invention - each as a detail in trimetric view; Fig. 5a shows the crate in its normal, closed state, while Fig. 5b shows the crate in an open state with the flap deflected.

[0019] Figures 6a-6d show an inspectable shipping crate according to a third example embodiment of the invention, including a flap; Figs. 6a and 6c are each a front view and Figs. 6b and 6d are each a detail in trimetric view; Figs. 6a and 6b show the crate in its normal, closed state, while Figs. 6c and 6d show the crate with the flap in an open state with the flap deflected.

[0020] Figures 7a-7b show, in a front view and as a detail in trimetric view, respectively, an inspectable shipping crate according to a fourth example embodiment of the invention, including a flap; Fig. 7a shows the crate in its normal state; Fig 7b shows the crate in an open state with the flap deflected.

DESCRIPTION OF EXAMPLE EMBODIMENTS

[0021] Figures 2a-2d illustrate a first example embodiment of a shipping crate 10 according to the invention. As seen in the front view of Fig. 2a, side panel 20 (preferably one or both of the narrow side panels, to be also termed end panels) of the crate is formed as a wall portion surrounding, and thus defining, a rectangular window 21, to be termed hatch (also referred to as a sampling hatch). The wall portion of the panel is largely formed with a lattice of ribs, similarly to conventional side panels of shipping crates. Set within the hatch 21 is a generally rectangular flap 30, somewhat smaller in both dimensions than the hatch. The flap 30 is generally formed with a lattice of ribs and is disjoint from the wall portion along its left, top and right edges; however its lower edge is joined with the base of the side panel or of the crate - e.g. along a horizontal line 31. This joint is preferably flexible and may be formed as an integral hinge (e.g. a thin strip formed as part of the flap in the same molding operation as the panel or the crate), also referred to as a living hinge. Thus the flap may be manually and reversibly swung, or deflected, about the line 31 between a closed state (as shown in Figs. 2a and 2b) and an open state (such as shown, for example, in Figs. 2c and 2d). In other embodiments, such as of light thin-walled crates intended for single use, the flap 30 may be joined to the base more rigidly but may be flexible over its entire height, making it possible to bend, or deflect, it outwards and thus clear the hatch 21 for retrieving a sample of the contents.

[0022] The panel 20 is additionally formed with an integral elastically flexible member 22 (to be termed flexible member for short). The flexible member 22 may be more clearly perceived in Fig. 2b, which is a trimetric detail drawing of the panel 20. As shown in Figs 2a and 2b, the flexible member is in its normal state, which will be referred to hereunder as a locking state. In this state the flexible member overlaps a top portion of the hatch and of the flap 30 (when in a closed state). Clearly, when the flexible member 22 is in a locking state, it prevents the flap 30, when in a closed state, from swinging, or tilting, to an open state, thus enabling the crate to contain products, such as fruit, during shipping. The flexible member 22 may be manually pulled (or guided) to assume a so-called unlocking state - as shown in the elevation view of Fig. 2c and the trimetric detail view of Fig. 2d. Clearly, when the flexible member 22 is in an unlocking state, it allows the flap 30 to be swung, or deflected, to an open state, as seen, for example, in Fig. 2d.

[0023] Hie flexible member 22 in the embodiment of Figs. 2a--2d, as well as in many other embodiments, may have any one of two configurations - a first one with a single stable state and a second one with dual stable states. A stable state is defined in this context as a state (or shape) that the flexible member can retain without any external force acting on it. In the first configuration either the locking state or the unlocking state may be the stable state - meaning that when the flexible member is in the alternative (i.e. unstable) state, it must be held so by some force. In the second configuration both the locking- and the unlocking states are stable. As depicted In the Figs. 2a-2d the flexible member 22 may be of either of the two configurations, wherein in any case the unlocking state (illustrated in Figs. 2c and 2d) is a stable state. In the case of dual stable states configuration, also the locking state (illustrated in Figs. 2a and 2b) is stable and the locking function is carried out as described above; switching the flexible member between the two states requires a mere momentary manual pressure up or down. In the case of a single stable state configuration, holding the flexible member in a locking state, against its internal reactive elastic force, requires a continuous counter force. Such a force may be provided in the illustrated example embodiment by an optional protrusion (e.g. pin) 33, formed at the top of the flap 30 so that it may engage the flexible member 22 while in its locking state. It is noted that in variations of this embodiment (not i llustrated), the flexible member may have a single stable state configuration wherein the locking state is the stable one; in this case, the flexible member may need a similar protrusion, as part of the panel 20, to engage it in the unlocking state. It is noted that a protrusion, such as pin 33, may be deployed also when the Locking state of the flexible member is a stable state. Optionally the protrusion 33 may have any suitable shape, such as including a hook or a recess, so as to securely engage the flexible member.

[0024] It is noted that, according to the invention in all of its embodiments, the design of the panel 20 and its components - the flexible member 22 and the flap 30 - is such that the whole panel, with these components, may be fabricated integrally, i.e. in a single molding operation, particularly in a single injection molding operation. This operation may apply to the panel alone, if the crate is constructed of a plurality' of joinable panels (as, for example, in the case of a folding crate), or it may apply to the fabrication of tire entire crate, if it is fabricated as a monobloc, i.e. a single solid entity (which is the case for all the example embodiments depicted in the drawings, but should not be construed as limiting). In some embodiments (including some described below) the design calls for overlap between some parts of a panel (e.g. between tire flap, in a closed state, and a flexible member, in a locking state); such design forms so-called undercuts, but is still amenable to fabrication by injection molding in a single operation, using means known in the art, such as sideways movable parts of a mold; some embodiments are amenable to fabrication by injection molding in a single operation, wherein the flap is fabricated in a partly open state.

[0025] Generally the flexible member 22 as fabricated is in a stable state. Since the flexible member is perforce fabricated of the same material as the panel or the whole crate, its shape and dimensions must be designed so as to achieve the desired mechanical characteristics, such as elasticity, flexibility and strength. Typically, as seen in the illustrations, the flexible member has the shape of a ribbon, relatively thin in the vertical dimension (e.g. up to 3 mm) and relatively wide in a horizontal dimension (normal to the face of the panel) (e.g. 6 mm or more), the ratio between these two dimensions being at least 2. The width dimension is aimed at resistance to bending along the dimension nonnal to the face of the panel (when the flexible member is in the locking state), so as to retain the flap 30, when closed, against any pressure exerted on it by the contents of the crate. It is also noted that also any hinge formation at the bottom of the flap is designed to be fabricated integrally, i.e. in the same single molding operation.

[0026] Operation of the crate 10 in the example embodiment of Figs 2a - 2d is as follows: Each end panel 20 designed according to the invention is normally closed, i.e. its flap 30 is closed, blocking the hatch 21, and its flexible member 22 is in a locking state - as depicted in Figs. 2a and 2b. As such the crate may be filled with products, such as fruit, stacked with similar crates and shipped. When an inspection of the product in a particular crate is desired, the flexible member 22 is manually flipped to its unlocking state and the flap 30 is deflected outwards and generally downwards to clear enough area of the hatch 21 in the panel 20 to permit access to the contents of the crate - resulting in the situation depicted, for example, in Figs. 2c and 2d. A sample of the products in the crate (e.g. one or more units of fruit) may then be withdrawn for inspection. Thereafter the flap 30 is returned to its closed state and the flexible member 22 is flipped, or flexed, back to its locking state. When the design includes a protrusion 33, the operation of flipping the flexible member 22 from its locking state to its unlocking state, or the reverse operation, includes disengaging the flexible member from the protrusion or reengaging them, respectively. It is noted that, following such an inspection operation, the crate reverts to its original, normal state - ready for further shipping.

[0027] Turning now to Fig. 3, there is shown, in a trimetric detail view and by way of example, a variation of the embodiment of Figs. 2a-2d. Here the flexible member 22 is provided with a lug 23 that is pierced with a hole so as to be engaged by the pin-shaped protrusion 33. In this illustration the lug is shown engaged by the protrusion, keeping the flexible member in its locking state. Other states of the components and the operation are similar to those described above.

[0028] Turning now to Fig. 4, there is shown, in a trimetric detail view and by way of example, another variation of the embodiment of Figs. 2a-2d. Here the flexible member 22 is provided with a T-shaped lug 24 and the flap 30 is provided with a pair of pins 34, configured to engage the lug 24 and to thus enable holding the flexible member in its locking state. Other states of the components and the operation are, again, similar to those described above.

[0029] Figs. 5a-5b illustrate a second example embodiment of a shipping crate 10 according to the invention. It is generally similar to the first example embodiment (of Figs. 2a~2d), except that, instead of a single flexible member, there are two flexible members 26, located respectively at the upper two comers of the hatch 21. Each is similar in function to the flexible member 22 of the first embodiment. Corresponding to the two flexible members 26 there are optionally two protiusions 35, configured to engage the respective flexible members 26 when in locking states. Fig. 5a depicts the flap 30 in its closed position and the flexible members 26 in their locking states, while Fig. 5b depicts the flap 30 in an open position and the flexible members 26 in their unlocking states. Operation is, again, similar to that described above with respect to the first embodiment.

[0030] Figs. 6a-6d illustrate a third example embodiment of a shipping crate 10 according to the invention. It is similar to the first example embodiment (of Figs. 2a~2d), in that the panel 20 includes a flap 30, accommodated within a hatch 21 and deflectable about a base line 31 . It differs, though, from the first example embodiment in that it has a flexible member 36 as part of the flap 30 (instead of the flexible member being part of the panel, as in the first embodiment) and a corresponding protrusion 27 that is an integral part of the panel 20. Figs. 6a and 6b show, in a front view and a trimetric detail view respectively, the flap 30 in a closed position and its flexible member 36 in a locking state, engaged by the protrusion 27. Figs. 6c and 6d show, in a front view and a trimetric detail view respectively, the flexible member 36 in an unlocking state, disengaged from the protrusion 27, thus enabling the flap 30 to be swung open. Operation is generally similar to that described above with respect to the first embodiment. [0031] F»gs. 7a-7b illustrate a fourth example embodiment of a shipping crate 10 according to the invention. It is similar to the third example embodiment (of Figs 6a-6c), but differs from it in that the flap includes two flexible members 37 (rather than a single one), located respectively at its upper two comers. Each is similar in function to the flexible member 36 of the third embodiment. Corresponding to the two flexible members 37 there are two protrusions 28, configured to engage the respective flexible members 37 when in locking states. Operation of this embodiment is similar to that of the other embodiments, described above. Fig. 7a shows, in a front view, the flexible members 37 engaged by the respective protrusions 28 and thus in a stretched locking state, holding the flap 30 in a closed position. Fig. 7b shows, in a trimetric detail view, the flap 30 in an open position, with the flexible members 37 disengaged and in an unlocking state. Re-closing of the crate may be carried out by swinging the flap 30 up and stretching the flexible members 37 so as to be engaged by the protrusions 28.

[0032] It is noted that, while the above descriptions and the accompanying illustrations deal with a single side panel, the invention, in any of its embodiments, is equally applicable to any of the other side panels of the crate 10 and to any combination of such side panels. A particularly usefill, but not limiting, example of such a combination is that of the two opposing narrow panels (also referred to as a front- and back panel). It is further noted that when all the panels of a crate 10 are fabricated in a single molding operation, all the parts of each panel, including in particular the flap and tire flexible members, are fabricated in the same single operation.

[0033] It will be appreciated that the above descriptions are intended only to serve as examples and that many other embodiments are possible within the scope of the present invention as defined in the appended claims.

[0034] To the extent that the appended claims have been drafted without multiple dependencies, this has been done only to accommodate formal requirements in jurisdictions which do not allow such multiple dependencies. It should be noted that all possible combinations of features which would be implied by rendering the claims multiply dependent are explicitly envisaged and should be considered part of the invention.