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Stackable low depth bottle case Number:7,086,531 from the United States Patent and Trademark Office (PTO) owispatent

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Title: Stackable low depth bottle case

Abstract: A stackable case for retaining and transporting bottles including outer side walls forming an outer shell having a longitudinal axis and a horizontal axis, a case bottom disposed substantially within the outer shell, and a plurality of supports for supporting the outer surfaces of the bottles. The side walls include a lower wall portion and a plurality of spaced upwardly projecting pylons, where four corner pylons define the four corners of the case. A plurality of spaced upwardly projecting columns generally disposed within the outer shell define, in combination with the case bottom, the side walls and the end walls, a plurality of bottle retaining pockets. The columns and the pylons extend above the lower wall portions and below a top surface of the retained bottles. At least one of the side walls includes an integrally molded logo which identifies the source of the goods.

Patent Number: 7,086,531 Issued on 08/08/2006 to Apps,   et al.


Inventors: Apps; William P. (Alpharetta, GA), Koefelda; Gerald R. (Atlanta, GA)
Assignee: Rehrig Pacific Company (Los Angeles, CA)
Appl. No.: 09/844,822
Filed: April 26, 2001


Related U.S. Patent Documents

Application NumberFiling DatePatent NumberIssue Date
08854294May., 1997
08480927Jun., 1995
08421941Apr., 19955651461
08384331Feb., 19955660279
08268997Jun., 19945465843
29018317Feb., 1994D361431
07919376Jul., 19925529176

Current U.S. Class: 206/509
Current International Class: B65D 21/00 (20060101)
Field of Search: 220/506,516,517,518,519 206/139,201,203,427,509,511


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Other References

Product Brochure "Schoellerkasten" of Schoeller & Co. KG. cited by other .
Exhibit 1: Two photos of a prior art case of Rehrig Pacific fo 3 liter PET bottles. cited by other .
Exhibit 2: Two photos of a prior art case of D & W Plastics. cited by othe- r .
Exhibit 3: Two photos of a prior art case of ICS for 3 liter PET bottles. cited by other .
Exhibit 4: Two photos of a prior art case of ICS for 2 liter PET bottles. cited by other .
Exhibits A & B: Two photos of an embodiment of U.S. Pat. No. 4,773,554 to Warwick. cited by other .
Exhibits D-F: Three photos of a bottle neck resting type crate with projections above the outer side walls. cited by other .
Exhibits G-J: Four photos of a bottle neck resting type crate without projections above the outer side walls. cited by other .
Exhibit K: One photo of a bottle neck resting type with different height outer side walls. cited by other .
Exhibit L: Four photos of an embodiment of Great Britain Patent Publication No. 2,158,044 & U.S. Design Patent No. D289,938. cited by oth- er .
Exhibit M: Copy of a brochure illustrating an embodiment of GB No. 2,158,044/U.S. D289,938. cited by other .
Exhibit N: Copy of a brochure illustrating an embodiment of U.S. Patent No. 4,773,554 & an embodiment of GB No. 2,158,044/U.S. D289,938. cited by other .
Exhibit O: Four photos of an embodiment of U.S. Patent No. 4,344,530 to deLarosiere. cited by other .
Exhibit P: Two photos of an embodiment of U.S. Patent No. 4,700,837 to Hammett. cited by other .
Exhibit Q: Four photos of an embodiment of U.S. Patent No. 4,344,530 for 3-liter PET bottles. cited by other .
Exhibit R: Four photos of a modified embodiment of U.S. Patent No. 4,700,837 for 3-liter PET bottles. cited by other .
Exhibit S: Three photos of an embodiment of U.S. Patent No. 3,392,869 to Needt. cited by other .
Exhibit T: Four photos of a prior art crate of Rehrig-Pacific Company, Model No. PLBC-8-2L-HD. cited by other .
Exhibit U: Four photos of a prior art crate of Rehrig-Pacific Company Model No. PLBC-6-2L-HD. cited by other .
Exhibit V: Four photos of a prior art crate of Rehrig-Pacific Company, Model No. PLBC-8-2L-PET-QD. cited by other .
Exhibits W & X: Brochures including a PBC-6-2L (LO) crate for 2-liter bottles. cited by other .
Exhibit Y: Brochure and photo, "Interlocking bottom grid. Cross stackable". cited by other .
Exhibit Z: One-page brochure disclosing a prior art 2-liter PET case having a plurality of notches on the top wall. cited by other .
Exhibit AA: One-page brochure illustrating a prior art 2-liter PET case. cited by other.

Primary Examiner: Castellano; Stephen

Parent Case Text



CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of Ser. No. 08/854,294 filed May 12, 1997, now abandoned, which is a continuation of Ser. No. 08/480,927, filed Jun. 7, 1995, now abandoned, which is a continuation-in-part of U.S. application Ser. No. 08/421,941, filed Apr. 13, 1995 now Pat. No. 5,651,461; which is a continuation in part of 1) U.S. application Ser. No. 08/384,331, filed Feb. 1, 1995, now Pat. No. 5,660,279, which is a continuation-in-part of U.S. application Ser. No. 07/919,376, filed Jul. 29, 1992, now Pat. No. 5,529,176 and is a cip of U.S. application Ser. No. 08/268,997, filed Jun. 30, 1994, now Pat. No. 5,465,843 which is a continuation-in-part of U.S. application Ser. No. 29/018,317, filed Feb. 3, 1994, now U.S. Pat. No. D361,431, the entire contents of each hereby being incorporated by reference.
Claims



What is claimed is:

1. A stackable low depth case for retaining and transporting bottles, the case comprising opposing side walls and opposing end walls forming an outer shell, a case bottom disposed substantially within said outer shell, the case comprising: each of said side walls including a lower wall and a plurality of spaced upwardly projecting pylons, four corner pylons defining four corners of the case wherein the lower wall includes an upper edge and a lower edge, the upper edge having a curved shape substantially along the length thereof and the lower edge having a curved shape substantially along the length thereof, wherein the entire upper edge is spaced below the uppermost surface of the pylons; and a plurality of spaced upwardly projecting columns generally disposed within the outer shell defining, in combination with the case bottom, said side walls, and said end walls, a plurality of bottle retaining pockets, said columns and said pylons extending above the lower wall and below a top surface of the retained bottles.

2. The stackable case of claim 1 wherein the upper and lower edges of the lower wall substantially define an exterior surface of said lower wall.

3. The stackable case of claim 2 wherein said lower wall further includes a plurality of retaining tabs substantially defining an interior surface of said lower wall and extending upwards from said case bottom.

4. The case of claim 1 wherein a space between each adjacent pair of pylons along the side walls opens upwardly completely from the upper edge of the lower wall to a plane defined by uppermost surfaces of the adjacent pair of pylons to provide visibility of containers in the case.

5. The case of claim 1 wherein the side walls are longer than the end walls.

6. A stackable low depth bottle case comprising: a floor structure having an upper surface; a pair of side structural members and a pair of end walls attached to the floor structure and defining an inner compartment with the floor structure, the side structural members having a lower edge and an upper edge, wherein the side structural members are longer than the end walls; a plurality of pylons extending inwardly from the side structural members into the inner compartment, and a plurality of corner pylons defining corners of the case and extending into the inner compartment; and a plurality of longitudinally-spaced upwardly projecting columns generally disposed within the inner compartment defining, in combination with the floor structure and the side structural members, a plurality of bottle retaining pockets, each of the columns including at least one vertical, longitudinal recess opening upwardly and aligned with one another, each of the columns including a plurality of exterior surfaces each having an uppermost edge, each exterior surface partially defining one of the plurality of bottle retaining pockets, the uppermost edge of one of the exterior surfaces of one of the columns extending a first height above a first location along the upper edge of one of the pair of side structural members, wherein the first location is disposed between a pair of adjacent pylons, and the uppermost edge of one of the exterior surface of another of the columns extending a second height above a second location along the upper edge, wherein the second height is greater than the first height, wherein the second location is disposed between another pair of adjacent pylons, wherein at least one of the plurality of columns is located at the intersection of the case longitudinal axis and transverse axis and the uppermost edge of the exterior surface of the at least one of the plurality of columns is substantially co-planar with an uppermost edge of an exterior surface of of one of the plurality of pylons, the exterior surface of the one of the plurality of pylon partially defining one of the plurality of bottle retaining pockets.

7. The case of claim 6, wherein each of the pair of side structural members is contoured along its length.

8. The case of claim 6, wherein the upper edge of each of the pair of side structural members is contoured along its respective length.

9. The case of claim 6, wherein the lower edge of each side structural member is wave-shaped along its respective length.

10. The case of claim 6, wherein the side structural members are attached to the floor structure by a plurality of retaining tabs which define an interior surface of the inner compartment between adjacent pylon.

11. The case of claim 6, wherein the plurality of columns are substantially the same height.

12. The case of claim 6, further comprising a pair of integrally molded handle structures directly connecting a pair of corner pylons and having an exterior surface and a generally open area being defined below the exterior surface.

13. The case of claim 6, wherein the floor structure has a substantially flat upper surface.

14. The case of claim 6, wherein the floor structure has a lower surface which includes plurality of bottle closure acceptance areas defined by generally conically shaped, concave portions.

15. The case of claim 6, wherein the floor structure includes resting and guiding means for resting the floor structure on the closures of bottles on which the case is stacked, the resting and guiding means including a rib formation having a longitudinal centerline offset from the centerline of the bottle retaining pockets to guide closures of bottles into a central region of the bottle retaining pockets.

16. The case of claim 15, wherein the rib formation comprises a cloverleaf shape.

17. The case of claim 6, wherein at least one of the columns has a vertically extending portion disposed below the lower edge of the side structural members.

18. The ease of claim 6, wherein at least one of the columns has a vertically extending portion which is substantially co-planar with the lower surface of the floor structure.

19. The ease of claim 6, wherein the plurality of pylons extend above the upper edge of the side structural members.

20. The case of claim 6, wherein the plurality of pylons have upper surfaces which are generally co-planar.

21. The case of claim 6, wherein the plurality of pylons and the plurality of columns have generally co-planar upper surfaces.

22. A low depth crate for storing and transporting bottles, the crate comprising: a floor including a floor top surface having thereon a plurality of support areas for supporting an array of bottles; a pair of side structural members and a pair of end walls attached to the floor and defining an inner compartment with the floor structure, the side structural members having a lower edge and an upper edge, wherein the side structural members are longer than the end walls; a plurality of pylons extending inwardly from the side structural members into the inner compartment; and a plurality of spaced upwardly projecting columns generally disposed within the inner compartment defining, in combination with the floor structure and the side structural members, a plurality of bottle retaining pockets, wherein each of a pair of the columns is of substantially the same height, and extends to an uppermost surface that is a first height above a first location along the lower edge of one of the pair of side structural members, and wherein another one of the columns has an uppermost surface that is a second height above a second location along the lower edge, wherein the second height is different from the first height, wherein the uppermost surface of the another one of the columns is substantially co-planar with an uppermost surface of one of the plurality of pylons.

23. The crate of claim 22, wherein the side structural members are contoured along their respective lengths.

24. The crate of claim 22, wherein the upper edge of the one of the pair of side structural members is contoured along its respective length.

25. The crate of claim 22, wherein the lower edge of each side structural member is wave-shaped along its respective length.

26. The crate of claim 22, wherein the side structural members are attached to the floor structure by a plurality of retaining tabs which define an interior surface of the inner compartment between adjacent pylons.

27. The crate of claim 22, wherein the another one of the columns is located at the intersection of the case longitudinal axis and transverse axis.

28. The crate of claim 22, wherein the plurality of columns are substantially the same height.

29. The crate of claim 22, further comprising a plurality of corner pylons defining corners of the case and extending into the inner compartment.

30. The crate of claim 29, further comprising a pair of integrally molded handle structures extending between a pair of corner pylons and having an exterior surface and a generally open area being defined below the exterior surface.

31. The crate of claim 22, wherein the floor has a substantially flat upper surface.

32. The crate of claim 22, wherein the floor has a lower surface which includes plurality of bottle closure acceptance areas defined by generally conically shaped, concave portions.

33. The crate of claim 22, wherein at least one of the columns has a vertically extending portion disposed below the lower edge of the side structural members.

34. The crate of claim 22, wherein at least one of the columns has a vertically extending portion which is substantially co-planar with a lower surface of the floor.

35. The crate of claim 22, wherein the plurality of pylons extend above the upper edge of the side structural members.

36. The crate of claim 22, wherein the plurality of pylons have upper surfaces which are generally co-planar.

37. The crate of claim 22, wherein the plurality of pylons and the plurality of columns have generally co-planar upper surfaces.

38. The crate of claim 22, wherein at least some of pylons and at least some of the plurality of columns have generally co-planar upper surfaces.

39. A stackable low depth bottle case comprising: a floor structure having an upper surface; a pair of side structural members attached to the floor structure and defining an inner compartment with the floor structure, the side structural members having a lower edge and an upper edge; a plurality of pylons extending inwardly from the side structural members into the inner compartment, and a plurality of corner pylons defining corners of the case and extending into the inner compartment; and a plurality of spaced upwardly projecting columns generally disposed within the inner compartment defining, in combination with the floor structure and the side structural members, a plurality of bottle retaining pockets, wherein a first column and second column each extend a first height above a predetermined first location along the upper edge of one of the pair of side structural members, wherein the predetermined first location is disposed between a pair of adjacent pylons, and wherein a third column is located at the intersection of the case longitudinal axis and transverse axis and extends a second height above a predetermined second location along the upper edge of the one of the pair of side structural members, wherein the second height is greater than the first height and wherein the second height to which the third columns extends is substantially co-planar with an uppermost surface of one of the plurality of pylons.

40. The case of claim 39, wherein the plurality of columns are substantially the same height.

41. The ease of claim 39, wherein the plurality of pylons extend above the upper edge of the side structural members.

42. The case of claim 39, wherein the plurality of pylons and the plurality of columns are generally co-planar.

43. The case of claim 42, wherein each of the upper and lower edges of the side structural members is wave-shaped along its length.

44. The case of claim 42 wherein the first location is different from the second location.

45. A low depth crate for storing and transporting bottles, the crate comprising: a floor including a floor top surface having thereon a plurality of support areas for supporting an array of bottles; a pair of side structural members and a pair of end walls attached to the floor and defining an inner compartment with the floor structure, at least one of the pair of side structural members having a lower edge and an upper edge; a plurality of corner pylons defining corners of the case and extending into the inner compartment; a plurality of pylons extending inwardly from the aide structural members into the inner compartment between each pair of corner pylons on each side structural member; and a plurality of spaced upwardly projecting columns generally disposed within the inner compartment defining, in combination with the floor structure and the side structural members, a plurality of bottle retaining pockets, wherein each of a pair of the columns is of substantially the same height, and extends to an uppermost surface that is a first height above a first location along the lower edge, and wherein another one of the columns has an uppermost surface that is a second height above a second location along the lower edge, wherein the second height is different from the first height, wherein the uppermost surface of the another one of the columns is substantially co-planar with an uppermost surface of one of the plurality of pylons.

46. A low depth crate for storing and transporting bottles, the crate comprising: a floor including a floor top surface having thereon a plurality of support areas for supporting an array of bottles; a pair of side structural members and a pair of end walls attached to the floor and defining an inner compartment with the floor structure, one of the side structural members having a lower edge and an upper edge, the end walls each including a handle; a plurality of pylons extending inwardly from the side structural members into the inner compartment; and a plurality of spaced upwardly projecting columns generally disposed within the inner compartment defining, in combination with the floor structure and the side structural members, a plurality of bottle retaining pockets, wherein each of a pair of the columns is of substantially the same height, and extends to an uppermost surface that is a first height above a first location along the lower edge, and wherein another one of the columns has an uppermost surface that is a second height above a second location along the lower edge, wherein the second height is different from the first height, wherein the uppermost surface of the another one of the columns is substantially co-planar with an uppermost surface of one of the plurality of pylons.

47. A low depth crate for storing and transporting bottles, the crate comprising: a bottom portion having a top surface having thereon a plurality of support areas for supporting an array of bottles; at least one side structural member attached to the bottom member and defining an inner compartment with the bottom member, the at least one side structural member having a lower edge and an upper edge; a plurality of corner pylons defining corners of the case and extending into the inner compartment; a plurality of pylons extending inwardly from the side structural members into the inner compartment between each pair of corner pylons on each side of the at least one structural member; and a plurality of spaced upwardly projecting columns generally disposed within the inner compartment defining, in combination with the bottom member and the at least one side structural member, a plurality of bottle retaining pockets, wherein each of a pair of the columns is of substantially the same height and extends to an uppermost surface that is a first height above a first location along the lower edge, and wherein another one of the columns has an uppermost surface that is a second height above a second location along the lower edge, wherein the first height is different from the second height, and wherein the uppermost surface of the another one of the columns is generally co-planar with an uppermost surface of at least one of the plurality of pylons.
Description



TECHNICAL FIELD

The present invention relates to low depth stackable bottle cases for use in retaining and transporting bottles. More particularly, the present invention relates to beverage bottle cases that combine low depth with high stability for stored bottles, full label visibility for display purposes, and an integrally formed logo for easy identification of the bottle or product supplier.

BACKGROUND OF THE INVENTION

Plastic bottles are widely used as containers for retailing soft drinks and other beverages. One type of plastic, polyethylene terephthalate (PET), has become particularly popular because of its transparency, light weight, and low cost. In addition to being flexible, the walls of PET bottles are strong in tension and thus can safely contain the pressure of a carbonated beverage. Moreover, conventional PET bottles can bear surprisingly high compressive loads, provided that the load is directed substantially along an axially symmetric axis of the bottle. A single PET bottle can support the weight of many bottles of the same size filled with beverage if the bottle is standing upright on a flat, horizontal surface and the weight of the other bottles is applied to the closure of the single bottle and is directed substantially vertically along the symmetric axis. However, if a compressive load is applied to a conventional PET beverage bottle along a direction other than the symmetry axis of the bottle, the bottle tends to buckle. This tendency of conventional PET bottles to give way under off-axis compressive loads is particularly pronounced for large capacity bottles, such as the two-liter bottle widely used for marketing soft drinks.

Soft drink bottles are ordinarily packaged by bottlers in cases or other containers, several bottles to the case, for shipment to retailers or for storage. The term "case", "crate" or "tray" is used interchangeably herein to include all cases, crates, trays and similar containers having a bottom and peripheral side wall structure. Cases of bottles are customarily stacked on top of each other. In storage warehouses, columns of cases are frequently stacked on pallets which can be lifted and moved about by fork-lift trucks. The stacks of cases on the pallets must therefore be particularly stable in order to remain standing in the face of the jostling inherent in being moved about. A technique for interconnecting stacks of empty cases, called "cross-stacking," is often used to improve the stability of empty cases loaded on a warehouse pallet. Cross-stacking generally involves stacking rectangular bottle cases to build up a layered structure, with each layer having cases oriented parallel to each other and with the adjacent layers being oriented at right angles to each other. Thus, since the adjacent layers are perpendicular, each case in the cross-stacked layer rests on at least two cases in the layer below. As a result, the cases of the cross-stacked layer tend to keep the cases on which they rest from moving apart from each other. The cross-stacked layers therefore stabilize the stacked structure.

Because of the tendency of conventional PET beverage bottles to buckle under off-axis loads, attempts to stack cases of these bottles give rise to serious problems. Bottles can tilt away from vertical alignment upon stacking if conventional partitioned cases having low side walls are used to contain the bottles. Tilted bottles in the lower cases of a stack can


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