RELATED APPLICATIONS This application claims priority benefit from U.S. Provisional Application No. 60/736,092, filed on Nov. 10, 2005, the entirety of which is hereby incorporated by reference herein.
BACKGROUND OF THE DISCLOSURE 1. Field of the Disclosure
The disclosure is generally related to a storage product and, more particularly, to a storage product comprising a rigid storage body and at least one flexible covering surface, wherein the rigid storage body is capable of being nestably stacked in a volume-efficient manner with another rigid storage body.
2. Brief Description of Related Technology
Traditionally, boxes designed to store and/or transport school supplies have been manufactured using rigid, substantially vertical walls. Such boxes have utility for the consumer in that they are durable, yet lightweight, being typically formed from plastic, wood, light metals, etc. Thus, when filled, they may be easily transported by the user without risking damage to or escape of the contents.
However, traditional school boxes have inherent limitations that are disadvantageous to the consumer. Specifically, it is difficult to provide the consumer with a variety of aesthetic designs on the box surface because of the manufacturing costs associated with printing designs on three-dimensional product surfaces. The result is that less expensive school boxes do not offer different design options other than, perhaps, a variable color thermoplastic used for the school box body.
Additionally, because the empty boxes have such a large void volume and substantially vertical sidewalls, their display on the shelves of retail stores is relatively volume-inefficient. Shipment to distibutors and retailers of these conventional empty boxes is also inefficient due to the cumulative empty space of the stacked boxes. Often, multiple units are simply stacked in horizontal rows or vertical columns, and much shelf space or shipping container space is wasted. This further limits the consumer's aesthetic options because, even if the manufacturer were willing to produce a large variety of designs, shelf-space constraints in the retail outlet limit the total number of units that can be displayed and successfully marketed.
Attempts at remedying the inefficient retail display and shipping of products have been made with respect to non-school products using the concept of nestability. When designed to be nestable, products that ordinarily displace a significant amount of volume as a single unit may be stacked such that the body of one product fits within the void volume defined by the body of a second product, thereby permitting efficient use of retail outlet shelves by increasing the shelf packing density on a per-product-unit basis.
Exemplary products with the trait of nestability include laundry baskets, waste baskets, and home organizational bins. Such products are typically open, one-piece products that do not securely contain their contents during extended transport, such as would be typical of a filled school box being transported from place to place in, for example, a backpack.
A food storage box with a lid is an example of a two-piece, nestable product that is capable of securely transporting its contents. In such a product, a group of food storage boxes may be nestably stacked. The lids, which are typically rigid and flat, do not pack inefficiently and may thus be simply stacked. However, there is some wasted volume in the retail packaging of a group of boxes and lids. Because the boxes and lids are necessarily used in a 1:1 ratio, they are sold as such. Therefore, there is typically some external packaging structure that holds the nestably-stacked boxes and the simply-stacked lids. This creates additional inefficient volume overhead in the retail packaging.
BRIEF DESCRIPTION OF THE PRESENT DISCLOSURE The school boxes of the present disclosure utilize a rigid storage body in connection with at least one flexible covering surface in order to create storage products that can securely hold their contained items, with school supplies being exemplary contents. The rigid storage body is comprised of at least one rigid storage frame. As illustrated in one embodiment of the following disclosure, the rigid storage frames are designed to permit efficient, nestable stacking arrangements of the rigid storage body, thereby facilitating volume-efficient packing of the rigid storage body either while on display in a retail store or while in transit during distribution. In another embodiment, the rigid storage frame is designed with open regions to promote material savings, while the flexible covering surface is used to contain the items in the storage product.
The flexible covering surface can serve as a way of incorporating various aesthetic designs into the storage product. Additionally (or optionally), the flexible covering surface can be used to seal the storage product in connection with the rigid storage body. Because the flexible covering surface is substantially flat in its natural state, various designs may be more easily imparted to the surface (as compared to the three-dimensional rigid surface of a conventional school box). This makes it less expensive for the manufacturer of the storage product to provide the consumer with a variety of aesthetic designs without having to vary the manufacture of the underlying rigid storage frame. Furthermore, in embodiments of the storage product that accept more than one flexible covering surface, the consumer is free to mix and match flexible covering surfaces with differing designs to suit personal tastes. Finally, because a consumer is encouraged to customize his or her own storage product by choosing from a selection of flexible covering surfaces and/or rigid storage bodies, there is no need for additional packaging, such as shrink wrap or twist ties, to group two or more associated elements into appropriate sets. The flexible covering can also serve to provide a soft exterior to the storage product.
BRIEF DESCRIPTION OF THE DRAWINGS Exemplary aspects and features of a storage product in accordance with the present disclosure are described and explained in greater detail below with the aid of the drawing figures in which:
FIG. 1 is an exploded perspective view of a storage product in a half-body embodiment in accordance with the present disclosure;
FIG. 2 is an enlarged, fragmented perspective view of an alternate embodiment of the flexible covering surface fromFIG. 1;
FIG. 3 is a perspective view of the assembled storage product shown inFIG. 1;
FIG. 4 is a front view of the rigid storage body fromFIG. 1;
FIG. 5 is a side view of the rigid storage body fromFIG. 1;
FIG. 6 is an exploded perspective view of a storage product in a full-body embodiment in accordance with the present disclosure;
FIG. 7 is a perspective view of the assembled storage product shown inFIG. 6;
FIG. 8 is a side view of the rigid storage body fromFIG. 6;
FIG. 9 is a front view of the rigid storage body fromFIG. 6;
FIG. 10A is a perspective view of a storage product in an alternate full-body embodiment in accordance with the present disclosure;
FIG. 10B is a perspective view of a plurality of the storage product ofFIG. 10A in an open position;
FIG. 11 is an exploded perspective view of a storage product in an alternate full-body embodiment in accordance with the present disclosure;
FIG. 12 is an exploded perspective view of a storage product in an alternate half-body embodiment in accordance with the present disclosure;
FIG. 13A is a perspective view of a storage product in an alternate full-body embodiment in accordance with the present disclosure;
FIG. 13B is a perspective view of a plurality of storage products ofFIG. 13A in a stacked, nested arrangement in accordance with the present disclosure;
FIG. 14A is a perspective view of a storage product in an alternate full-body embodiment in accordance with the present disclosure;
FIG. 14B is a perspective view of a plurality of storage products ofFIG. 14A in a stacked, nested arrangement in accordance with the present disclosure;
FIG. 15 is a side view of multiple rigid storage bodies in a stacked, nested arrangement in accordance with the present disclosure; and,
FIG. 16 is a side view of multiple interlocking rigid storage frames in a stacked, nested arrangement in accordance with the present disclosure.
DETAILED DESCRIPTION One embodiment of the disclosure provides a rigid storage body and a single flexible covering surface, wherein the rigid storage body further comprises a single rigid storage frame. In this embodiment, the rigid storage frame is a solid body and the affixation of the flexible covering surface to the rigid storage frame creates a sealed storage product that can protect its contents either during stationary storage or during transport.
Another embodiment of the disclosure comprises a rigid storage body and two flexible covering surfaces, wherein the rigid storage body further comprises two rigid storage frames. In this embodiment, the rigid storage frames may be either solid bodies or partially-open frames. When the rigid storage frames are partially open, the affixation of the flexible covering surfaces to the rigid storage frames not only serves a decorative purpose, but also creates a sealed storage product that can protect its contents either during stationary storage or during transport by covering any open portions of the rigid storage frame. When the rigid storage frames are solid bodies, the flexible covering surfaces are not required to create a sealed storage product, but still serve aesthetic functions.
Another embodiment of the disclosure comprises a rigid storage body and two flexible covering surfaces, wherein the rigid storage body further comprises two rigid storage frames. However, this embodiment illustrates an alternate rigid body frame structure that provides an alternate means of affixation for the flexible covering surface.
Yet another embodiment of the disclosure comprises a rigid storage body and two flexible covering surfaces, wherein the rigid storage body further comprises a single rigid storage frame. In this embodiment, the rigid storage frame has a plurality of open regions that are covered by the first flexible covering surface. The affixation of the second flexible covering surface to the rigid storage frame creates a sealed storage product that can protect its contents either during stationary storage or during transport.
The embodiments disclosed herein thus satisfy a need for a versatile storage product that securely holds its contents while simultaneously providing manufacturing and merchandising advantages to both the producer and the consumer. In each of the disclosed embodiments, the sidewalls of the rigid storage frames which form the rigid storage body are slanted, arced, or bowed away from opposing sidewalls, instead of being vertical. As a result, a plurality of the disclosed rigid storage frames are nestable with one another. The rigid storage frames may be nested as connected pairs of open storage frames, each pair of storage frames forming a rigid storage body of a storage product. Alternately, the rigid storage frames may be nested individually, as explained further below.
Storage Product of a First Embodiment A representative embodiment of the disclosed storage product is shown in FIGS.1 to5.
FIG. 1 illustrates astorage product100 that comprises arigid storage body120 and aflexible covering surface140. In this embodiment, therigid storage body120 comprises a singlerigid storage frame122. Therigid storage frame122 is generally defined by a base124 from whichlongitudinal sidewalls126 andlateral sidewalls128 upwardly extend. The upper edges of thesidewalls126 and128 define a continuousupper sidewall edge130, which further defines anesting surface132. The upwardly projected area of thebase124 defines a projectedbase surface125. To facilitate nestability of therigid storage frame122, each of thesidewalls126 is slanted, arced, or bowed away from an opposingsidewall126. Thenesting plane132 circumscribes the projectedbase surface125, thus allowing multiplerigid storage bodies120 to be nestably stacked.
A plurality ofcatches134 is disposed circumferentially on the outer surfaces ofsidewalls126 and128.FIG. 1 illustrates an embodiment with fourcatches134, one on each corner of therigid storage frame122, although more orfewer catches134 are possible depending on such factors as, for instance, whether it is desirable to enable quick attachment and detachment of the flexible covering surface140 (in which casefewer catches134 would be used) or whether it is desirable to more securely attach the flexible covering surface140 (in which casemore catches134 would be used).
Theflexible covering surface140 comprises awrap142, the outer edge of which defines awrap edge146. A plurality ofloops144 is disposed circumferentially on thewrap edge146. As shown inFIG. 1, theloops144 may be provided at the corners of theflexible covering surface140, so as to be located at positions complementary to thecatches134 provided on therigid storage frame122. The number ofloops144 need not be fixed at four (as illustrated inFIG. 1), and the locations of theloops144 need not be at the corners. Rather, the number and locations of theloops144 provided on theflexible covering surface140 would generally be selected to correspond to the number and locations of thecatches134 disposed on therigid storage frame122.
FIG. 2 illustrates an alternate embodiment of aflexible covering surface160 comprising awrap162 which defines awrap edge168. The means for attaching theflexible covering surface160 to therigid storage frame122 in this embodiment is shown bymultiple draw strings164 disposed along thewrap edge168. The draw strings164 may be held in place when attaching to therigid storage frame122 via acord stop166 mounted around the draw strings164. Thecord stop166, once adjusted by a user, remains in a fixed location along the length of the draw strings164 by, for example, frictional means. Alternatively, thecord stop166 may incorporate a clamp (not shown) or other mechanical devices to keep itself fixed in place.
FIG. 3 illustrates thestorage body100 once it has been assembled by attaching theflexible covering surface140 to therigid storage frame122. In the embodiment illustrated, theloops144 are elastically stretched over thecatches134 to generate a circumferentially distributed spring tension that holds theflexible covering surface140 securely in place. Alternatively (or additionally), thewrap142 may be fabricated from material having sufficient elasticity so that it may be stretched to hold theflexible covering surface140 in place. In the embodiment shown, thewrap142 is of sufficient size so thatwrap edge146 completely envelops theupper sidewall edge130 and thereby securely holds any items (not shown) contained in therigid storage body120.
In an alternate embodiment (not shown), thebase124, instead of comprising a solid surface (as shown inFIG. 4), may be partially solid and partially open. There must be enough solid material to impart rigidity and shape to therigid storage frame122, while the presence of open areas reduces the weight of thestorage product100 and lessens the cost of total raw material used to fabricate therigid storage frame122. With such an embodiment, the size of theflexible covering surface140 and the location of thecatches134 may be altered such that theflexible covering surface140 envelops therigid storage frame122, thereby covering both thenesting surface132 and thebase124. Alternatively, two flexible covering surfaces140 may be employed: one to cover thenesting surface132 and one to cover thebase124.
FIGS. 4 and 5 present a front view and a side view (respectively) of therigid storage body120. They illustrate the outward and upward slope or extension, i.e. slant, of thelongitudinal sidewalls126 and thelateral sidewalls128 from thebase124. This sloped geometric feature facilitates the nestability of multiplerigid storage bodies120, inasmuch as it results in thenesting surface132 that circumscribes the projectedbase surface125.
Storage Product of a Second Embodiment A representative second embodiment of the disclosed storage product is shown in FIGS.6 to9.
FIG. 6 illustrates astorage product200 that comprises arigid storage body220, aflexible covering surface240, and a secondflexible covering surface260. In this embodiment, therigid storage body220 comprises arigid storage frame222 and a secondrigid storage frame236. Ahinge238 joins the two rigid storage frames222 and236 as illustrated inFIG. 6. When in the closed configuration, twolatches239 securely seal thestorage product200. In the illustrated embodiment, the rigid storage frames222 and236 are identical; therefore, only the detailed structure with respect to therigid storage frame222 is described. However, the two may be separately designed to accommodate different bases, base elements, catches, etc.
Therigid storage frame222 is generally defined by a base224 from whichlongitudinal sidewalls226 andlateral sidewalls228 upwardly extend. In the illustrated embodiment, the base comprises a plurality ofbase elements223 that defineopen regions227 in thebase224. This structure provides rigidity and shape while simultaneously reducing the weight and material consumption of therigid storage body200. However, an alternate embodiment (not shown) could use a solid base without open regions (analogous tobase124 in the first embodiment).
The upper edges of thesidewalls226 and228 define a continuousupper sidewall edge230, which further defines anesting surface232. The upwardly projected area of thebase224 defines a projectedbase surface225. Thenesting surface232 circumscribes the projectedbase surface225, thus allowing multiplerigid storage bodies220 to be nestably stacked.
A plurality ofcatches234 is disposed on the inner surfaces oflongitudinal sidewalls226.FIG. 6 illustrates an embodiment with eight catches234 (of which four are visible), although more or fewer are possible depending on such factors as, for instance, whether it is desirable to enable quick attachment and detachment of the flexible covering surfaces240 and260, or whether it is desirable to more securely attach the flexible covering surfaces240 and260.
In this embodiment, the two flexible covering surfaces240 and260 are identical; therefore, only the detailed structure with respect to theflexible covering surface240 is described. However, the two may be separately designed to accommodate different designs, coverage areas, attachment means, etc. Theflexible covering surface240 comprises awrap242, the outer edge of which defines awrap edge246. Thewrap242 comprises three regions corresponding to the particular element of therigid storage frame222 that they contact when attached: abase region248, anouter sidewall region250, and aninner sidewall region252. A plurality ofholes244 is disposed on theinner sidewall region252 of thewrap242. Theholes244 may be reinforced with grommets or the like (not shown) to extend the life of theflexible covering surface240. The number ofholes244 need not be fixed at two per inner sidewall region252 (as illustrated inFIG. 6), and would generally be selected to correspond to the number ofcatches234 disposed on therigid structure frame222.
FIG. 7 illustrates thestorage body200 once it has been assembled and closed. In the embodiment illustrated, theflexible covering surface240 has been attached to therigid storage frame222 by elastically stretching thewrap242 so that theholes244 are held by thecatches234. This generates a longitudinally distributed spring tension that holds theflexible covering surface240 securely in place. Similarly, the secondflexible covering surface260 has been attached to the secondrigid storage frame236.
FIGS. 8 and 9 present a side view and a front view (respectively) of therigid storage body220. They illustrate the outward and upward slope or extension, i.e. slant, of thelongitudinal sidewalls226 and thelateral sidewalls228 from thebase224. This geometric feature facilitates the nestability of multiplerigid storage bodies220 inasmuch as it results in thenesting surface232 that circumscribes the projectedbase surface225.
FIGS. 10A and 10B present a perspective view of therigid storage body220 in an alternate configuration in which therigid storage body220 is a solid structure as opposed to having a plurality ofopen regions227. Thus, in this embodiment, theflexible wrap242 is provided as a means for customization and personalization of the storage body by a user.
Storage Product of a Third Embodiment A third embodiment of the disclosed storage product is shown inFIG. 11.
FIG. 11 illustrates astorage product300 that comprises arigid storage body320, aflexible covering surface340, and a secondflexible covering surface360. In this embodiment, therigid storage body320 comprises a firstrigid storage frame322 and a secondrigid storage frame336. The firstrigid storage frame322 and the secondrigid storage frame336 may be hingedly connected to one another, as shown inFIG. 10. The primary difference between this embodiment and the disclosedstorage product200 is the means used to attach the firstrigid storage frame322 to theflexible covering surface340; as such, only the structure pertinent to this feature is described.
A plurality ofcatches344 is disposed circumferentially on theupper sidewall edge330 of the firstrigid storage frame322. Eachcatch344 is defined by a pair ofgrooves335 in thesidewalls326 and328 projecting downward from theupper sidewall edge330, as shown inFIG. 10.
Theflexible covering surface340 comprises awrap342, the outer edge of which defines awrap edge346. Thewrap342 comprises three regions corresponding to the particular element of the firstrigid storage frame322 that they contact when attached: abase region348, anouter sidewall region350, and acorner region252. A plurality ofholes344 is disposed on thecomer region352 of thewrap342. The number ofholes344 is generally selected to correspond to the number ofcatches334 disposed on the firstrigid structure frame322.
Storage Product of a Fourth Embodiment A fourth embodiment of the disclosed storage product is shown inFIG. 12.
FIG. 12 illustrates astorage product400 that comprises arigid storage frame422, aflexible covering surface440, and a secondflexible covering surface460. Therigid storage frame422 is generally defined by a base424 from whichlongitudinal sidewalls426 andlateral sidewalls428 upwardly extend. In the illustrated embodiment, the base comprises a plurality ofbase elements423 that defineopen regions427 in thebase424. This structure provides rigidity and shape while simultaneously reducing the weight and material consumption of therigid storage body400.
The upper edges of thesidewalls426 and428 define a continuousupper sidewall edge430, which further defines asurface432. The upwardly projected area of thebase424 defines a projectedbase surface425. In the illustrated embodiment ofFIG. 11, thesurface432 circumscribes the projectedbase surface425, thus allowing multiple rigid storage frames422 to be nestably stacked. However, therigid storage frame422 of this embodiment need not be nestable, in which case (not shown) thesurface432 would not circumscribe the projectedbase surface425.
A plurality ofcatches434 that allows attachment of a firstflexible covering surface440 to therigid storage frame422 is disposed on the inner surfaces oflongitudinal sidewalls426. The structure and manner of attachment of the firstflexible covering surface440 are analogous to those described above in relation toFIG. 6 andflexible covering surface240.
A plurality ofcatches468 that allows attachment of a secondflexible covering surface460 to therigid storage frame422 is also disposed circumferentially on the outer surfaces ofsidewalls426 and428. The structure and manner of attachment of the secondflexible covering surface460 are analogous to those described above in relation toFIG. 1 andflexible covering surface140.
Storage Product of a Fifth EmbodimentFIGS. 13A and 13B and14A and14B illustrate astorage product500 that comprises arigid storage body520 and aflexible covering surface540. In this embodiment, therigid storage body520 comprises a singlerigid storage frame522. Therigid storage frame522 is generally defined by a base524 from whichlongitudinal sidewalls526 andlateral sidewalls528 upwardly extend. The upper edges of thesidewalls526 and528 define a continuousupper sidewall edge530. To facilitate nestability of therigid storage frame522, each of thesidewalls526 is slanted, arced, or bowed away from an opposingsidewall526.
The embodiments shown inFIGS. 13A-14B differ from earlier embodiments in that thestorage products500 have a sidewall height that is greater that either a sidewall width or a sidewall depth. In other words, thestorage products500 are tall, narrow storage products as opposed to short wide storage products. Thus, the dimensions of thestorage products500 may be adjusted to contain certain products or to fit in certain spaces depending on user needs. In this case, theflexible covering540 provides a means of customization and personalization by a user.
Multiple Storage Products in a Nested Configuration
The efficient packing of a plurality of the disclosed storage products is shown inFIGS. 15 and 16.
FIG. 15 illustrates a nestedstack610 of a plurality ofrigid storage bodies220. As discussed above, because eachrigid storage frame222 has sidewalls226 and228 that extend upward and outward from thebase224, slanting, arcing, or bowing away from opposing sidewalls, successiverigid storage bodies220 may be nestably stacked as shown inFIG. 15.
FIG. 16 illustrates two separate nestedstacks620,630 of pluralities of rigid storage frames622,636. Eachrigid storage frame622,636 has a structure similar to either rigid storage frame122 (e.g., when the structure is a solid body) or rigid storage frames222,236 (e.g., when the structure has partially open regions (not shown) in, for example, its base), and, therefore, may be nestably stacked as shown inFIG. 16. Eachrigid storage frame622,636 also accommodates the attachment of a flexible covering surface (not shown) in the manner illustrated inFIG. 6.
Eachrigid storage frame622,636 also may have acorresponding hinge element638a,638b.Thehinge elements638a,638bmay be releasably attached to form a single hinge (not shown) similar to hinge238. This allows a consumer to design and assemble a customized storage product by individually selecting rigid storage frame components (e.g., where the top and bottom may be of the same or different structure) and flexible covering surfaces (e.g., where the top and bottom may be of the same or different decorative design and/or material).
The volume displacement of a singlerigid storage body220 or arigid storage frame622,636 is proportional to its height h. The volume displacement of each additionalrigid storage body220 orrigid storage frame622,636 in a nestedstack610,620,630 is proportional to its incremental height Δh. The volume efficiency, defined as the actual volume displaced by the nestedstack610,620,630 relative to the volume which would otherwise be occupied by an un-stacked group of storage bodies, approaches Δh/h as the number of storage bodies in the nestedstacks610,620,630 increases. The value of Δh/h in typical applications is about 1/20 to ⅓, but may be larger or smaller depending on a variety of geometric factors, such as (by way of example only) the clearance height required by hinges, latches, and lips; the thickness of the sidewalls; and the slope of the sidewalls, etc.
The volume efficiency of the nestedstacks610,620,630 allows retailers to display approximately 3 to 20 times more product on a fixed amount of retail shelf space. This results in the retailer being able to present the consumer with more product choices, both in terms of the size, shape, and material of the rigid product body, as well as the design and material of the flexible covering surface. Similarly, manufacturers and distributors may transport more product in a fixed volume.
Storage Product Material Composition
The rigid storage frame may be fabricated from any material that is strong enough to impart rigidity and shape to the storage product and that is also durable enough to withstand continuous transport and use. It is also desirable for the rigid storage frame to be lightweight. Typically, an injection-molded thermoplastic resin is used for the rigid storage frame, as it satisfies all of these desired qualities. Additionally, the use of a thermoplastic facilitates other design choices, such as the inclusion of open areas in the rigid storage frame to reduce the storage product weight. Other suitable materials for the rigid storage frame include, for example, wood, metal, mesh, glass, and wire.
The flexible covering surface should meet the functional object of securely attaching to the rigid storage frame and sealing (where appropriate) the storage product. It should also meet the aesthetic object of being able to accommodate various different designs. Typically, the wrap of the flexible covering surface is made from fabric, which may or may not have some inherent elasticity. Other materials for the wrap are possible, including, for example, rubber and plastic. The materials may be used alone or in combination. For instance, a two-layer wrap may have a bottom layer of rubber to provide secure frictional gripping to the rigid storage frame and may have a fabric outer layer to impart visual and textural designs to the storage product. The wrap designs may be printed, embroidered, or may be inherent to the wrap itself (e.g., a patchwork of multi-colored fabric, knits or wovens comprising multicolored yarns, etc.). When the flexible covering surface includes loops or draw strings, these may be made from elastic material (e.g., rubber) or relatively inelastic material (e.g., string, nylon, plastic, etc.) and serve as a way to enhance the attachment force of the flexible covering surface to the rigid storage frame.
Other means of attaching the flexible covering surface to the rigid storage frame are possible. For instance, buttons, snaps, zippers, glue, hook-and-loop type fasteners, other synthetic fastening material having complementary parts which adhere to each other when pressed together, etc., may all be used within the scope of the present disclosure. Additionally, these alternate means may be used in connection with the flexible covering surface and/or the rigid storage frame.
Although numerous different embodiments of storage products in various configurations using rigid and flexible components are disclosed herein, the detailed description is to be construed as exemplary only, and does not describe every possible embodiment in accordance with the disclosure. Thus, it should be recognized that variations may be made that are within the scope of the appended claims.