S&F Ref: 812820 AUSTRALIA PATENTS ACT 1990 COMPLETE SPECIFICATION FOR A STANDARD PATENT Name and Address CHEP Technology Pty Limited, of Applicant: an Australian company, ACN 118 321 298, of Level 40 Gateway, 1 Macquarie Place, Sydney, New South Wales, 2000, Australia Actual Inventor(s): Michael David Lucas Address for Service: Spruson & Ferguson St Martins Tower Level 35 31 Market Street Sydney NSW 2000 (CCN 3710000177) Invention Title: A crate Associated Provisional Application Details: [33] Country: [31] Appl'n No(s): [32] Application Date: AU 2006904161 01 Aug 2006 The following statement is a full description of this invention, including the best method of performing it known to me/us: 5845c(891447_1) 1 A CRATE Field The present invention relates generally to a crate and more particularly to a crate for the transport and/or display of bottled beverages. The invention has been developed primarily for use as a crate for the transport and/or display of milk and juice bottles. However, it will be appreciated that the invention is not limited to this particular field and may also be used for the transport and/or display of other products in bottled, canned or carton form. Background Known beverage crates are typically formed from plastics and are of rigid, one-piece construction. The crates are typically returned to the beverage supplier when empty. A disadvantage of these known crates is that they occupy the same space when empty as when full, and thereby inefficiently occupy useful space during storage and during their return transport to the beverage supplier. Another disadvantage of known crates is that they have four closed sides, which prevents vision of, and access to, bottles carried in the crates when the crates are stacked. A further disadvantage of known crates is that they require a large tool to manufacture, due to their one-piece construction. Object It is the object of the present invention to substantially overcome or at least ameliorate one or more of the above disadvantages. Summary The present invention provides a crate comprising: a generally rectangular base having a pair of opposing ends and a pair of opposing sides; a first pair of opposing sidewalls adjacent the pair of opposing sides of said base, and having an upright position and a folded position with respect 2 to said base; a second pair of opposing sidewalls hingedly connected adjacent the pair of opposing ends of said base, and having an upright position and a folded position with respect to said base; said first and second pairs of opposing sidewalls defining an open top when in the upright position; and each sidewall of said second pair of opposing sidewalls including a window to allow a product to be accessed when in the upright position even if the open top is not accessible, and comprising a pair of spaced apart intermediate hinges on opposite sides of the window; wherein said first pair of opposing sidewalls in the folded position place the crate in a collapsed configuration, and in the upright position place the crate in an expanded configuration. Preferably, each sidewall of said first pair of opposing sidewalls is hingedly connected to said second pair of opposing sidewalls adjacent the open top. Preferably, each sidewall of said first pair of opposing sidewalls is generally parallel to said base when in the folded position. Preferably, each sidewall of said first pair of opposing sidewalls is hingedly connected to said second pair of opposing sidewalls adjacent said base. Preferably, each sidewall of said first pair of opposing sidewalls is snap-lockingly connectable with said base. Preferably, said base includes stop means to prevent rotation of said first pair of sidewalls outwardly with respect to an enclosed volume of said crate. Preferably, said stop means is a flange extending generally perpendicularly from said base toward the top. Preferably, each sidewall of said first pair of opposing sidewalls includes locating apertures and said base includes locating lugs engageable with said locating apertures for securing vertically adjacent said crates together when stacked. Preferably, said base is square. Preferably, said base is oblong.
3 Preferably, the second pair of opposing sidewalls is longer than the first pair of opposing sidewalls. Preferably, said base and said pair of first and second opposing sidewalls are adapted for separate manufacture and subsequent connection to form the crate. Preferably, said crate is adapted for transporting bottled beverages. The present invention further provides a method for making a crate comprising: forming a generally rectangular base having a pair of opposite opposing ends and a pair of opposing sides; forming a first pair of opposing sidewalls adjacent the pair of opposing sides of the base, and having an upright position and a folded position with respect to the base; forming a second pair of opposing sidewalls hingedly connected adjacent the pair of opposing ends of the base, and having an upright position and a folded position with respect to the base; the first and second pairs of opposing sidewalls defining an open top when in the upright position; and each sidewall of the second pair of opposing sidewalls including a window to allow a product to be accessed in the upright position even if the open top is not accessible, and comprising a pair of spaced apart intermediate hinges on opposite sides of the window; wherein the first pair of opposing sidewalls in the folded position place the crate in a collapsed configuration, and in the upright position place the crate in expanded configuration. Preferably, each sidewall of said first pair of opposing sidewalls is hingedly connected to the second pair of opposing sidewalls adjacent the open top. Preferably, each sidewall of the first pair of opposing sidewalls is hingedly connected to the second pair of opposing sidewalls adjacent the top. Preferably, each sidewall of the first pair of opposing sidewalls is snap-locked connected with the base. Brief Description of the Drawings A preferred embodiment of the present invention will now be described, by way of an example only, with reference to the accompanying drawings, in which: 4 Fig. I is a perspective view of a preferred embodiment of a crate according to the present invention; Fig. 2 is a perspective view of the crate of Fig. 1, shown rotated by 90' about a vertical axis; Figs. 3A, 3B, 3C, 3D and 3E are views showing the progressive collapsing of the crate of Fig. 1; [The next page is page 9.] -5 with said base. Even more preferably, said base includes stop means to prevent rotation of said second pair of sidewalls outwardly with respect to an enclosed volume of said crate. In a preferred form, said stop means is a flange extending generally perpendicularly from said base toward said top. 5 Preferably, each one of said second pair of sidewalls includes locating apertures and said base includes locating lugs engageable with said locating apertures for securing vertically adjacent said crates together when stacked. 10 Preferably, at least one of said sidewalls has an opening to allow product carried in said crate to be accessed and removed therethrough. More preferably, a said opening is provided in each one of an opposite said pair of sidewalls. Even more preferably, a said opening is provided in one or both of said first pair of sidewalls. is The crate may be square or oblong depending on the intended use of the crate. In embodiments where the crate is oblong, the first pair of sidewalls is preferably longer than the second pair of sidewalls. Preferably, said base, top and sidewalls are separately manufactured and subsequently 20 connected to form the crate. Preferably, the crate is adapted for transporting bottled beverages. In a fourth aspect, the present invention provides a crate comprising: 25 a generally rectangular base having a pair of opposite ends and a pair of opposite sides; an open and generally rectangular top; and four sidewalls extending between said base and said top; wherein at least one of said sidewalls includes an opening to allow product 30 carried in said crate to be accessed and removed therethrough. Preferably, said four sidewalls include: a first pair of sidewalls, each of which is located at a respective one of said pair of opposite ends of said base, wherein each of said first pair of sidewalls is connected to one -6 of said base and said top and is at least connectable to the other of said base and said top; and a second pair of sidewalls, each of which is located at a respective one of said pair of opposite sides of said base, wherein each of said second pair of sidewalls is S connected to one of said base and said top and is at least connectable to the other of said base and said top. Preferably, a said opening is provided in each one of an opposite said pair of sidewalls. 10 Preferably, each one of said first pair of sidewalls is hingedly connected to one of said base or said top and rotatable between a first position in which said first pair of sidewalls are connected with the other of said base and said top and a second position in which said first pair of sidewalls are disconnected from the other of said base and said top. In a preferred form, each one of said first pair of sidewalls is generally parallel to said base is when in said second position. More preferably, each one of said first pair of sidewalls is hingedly connected to said top. Even more preferably, each one of said first pair of sidewalls is snap-lockingly connectable with said base. Preferably, each one of said first pair of sidewalls includes locating apertures and said 20 base includes locating lugs engageable with said locating apertures for securing vertically adjacent said crates together when stacked. Preferably, said base includes stop means to prevent rotation of said first pair of sidewalls outwardly with respect to an enclosed volume of said crate. In a preferred form, said stop 25 means is a flange extending generally perpendicularly from said base toward said top. Preferably, each one of said second pair of sidewalls is hingedly connectable at one end to said base and at the other end to said top. More preferably, each one of said second pair of sidewalls has at least one intermediate hinge to allow said second pair of sidewalls to 30 fold. Preferably, a said opening is provided in one or both of said second pair of sidewalls.
-7 The crate may be square or oblong depending on the intended use of the crate. In embodiments where the crate is oblong, the second pair of sidewalls is preferably longer than the first pair of sidewalls. 5 Preferably, said base, top and sidewalls are separately manufactured and subsequently connected to form the crate. Preferably, the crate is adapted for transporting bottled beverages. 10 In a fifth aspect, the present invention provides a crate comprising: a generally rectangular base having a pair of opposite ends and a pair of opposite sides; an open and generally rectangular top; and four sidewalls extending between said base and said top; is wherein said base, top and sidewalls are separately manufactured and subsequently assembled to form the crate. Preferably, said four sidewalls include: a first pair of sidewalls, each of which is located at a respective one of said pair of 20 opposite ends of said base, wherein each one of said first pair of sidewalls is connected to one of said base or said top and is at least connectable to the other of said base or said top; and a second pair of sidewalls, each of which is located at a respective one of said pair of opposite sides of said base, wherein each of said second pair of sidewalls is 25 connected to one of said base or said top and is at least connectable to the other of said base or said top. Preferably, each of said first pair of sidewalls is hingedly connected to one of said base or said top and rotatable between a first position in which said first pair of sidewalls are 30 connected with the other of said base or said top and a second position in which said first pair of sidewalls are disconnected from the other of said base and said top. In a preferred form, each one of said first pair of sidewalls is generally parallel to said base when in said second position. More preferably, each one of said first pair of sidewalls is hingedly connected to said top. Even more preferably, each one of said first pair of sidewalls is 35 snap-lockingly connectable with said base.
-8 Preferably, each one of said first pair of sidewalls includes locating apertures and said base includes locating lugs engageable with said locating apertures for securing vertically adjacent said crates together when stacked. 5 Even more preferably, said base includes stop means to prevent rotation of said first pair of sidewalls outwardly with respect to an enclosed volume of said crate. In a preferred form, said stop means is a flange extending generally perpendicularly from said base toward said top. 10 Preferably, each one of said second pair of sidewalls is hingedly connectable at one end to said base and at the other end to said top. More preferably, each one of said second pair of sidewalls has at least one intermediate hinge to allow said second pair of sidewalls to fold. 15 Preferably, at least one of said sidewalls includes an opening to allow product carried in said crate to be accessed and removed therethrough. More preferably, a said opening is provided in each one of an opposite said pair of sidewalls. Even more preferably, a said opening is provided in one or both of said second pair of sidewalls. 20 The crate may be square or oblong depending on the intended use of the crate. In embodiments where the crate is oblong, the second pair of sidewalls is preferably longer than the first pair of sidewalls. 25 Preferably, the crate is adapted for transporting bottled beverages. Brief Description of the Drawings A preferred embodiment of the present invention will now be described, by way of an example only, with reference to the accompanying drawings, in which: Fig. I is a perspective view of a preferred embodiment of a crate according to the present 30 invention; Fig. 2 is a perspective view of the crate of Fig. 1, shown rotated by 900 about a vertical axis; Figs. 3A, 3B, 3C, 3D and 3E are views showing the progressive collapsing of the crate of Fig. 1; -9 Fig. 4 is an end view of the crate of Fig. 1 in a collapsed configuration; Fig. 5 is a side view of the crate of Fig. 1 in a collapsed configuration; Fig. 6 is an end view of the crate of Fig. 1 in an expanded configuration; Figs. 7 and 8 are perspective view of two embodiments for stacking the crates of Fig. I in 5 an expanded configuration; Fig. 9 is an underside view of the crate of Fig. I in an expanded configuration; Fig. 10 is a plan view of the crate of Fig. 1 in an expanded configuration; Fig. 11 is a plan view of the crate of Fig. I in a collapsed configuration; and Fig. 12 is a perspective view of an embodiment for stacking the crates of Fig. I when in a 10 collapsed configuration. Detailed Description of the Preferred Embodiment Referring to the drawings, the crate 10 comprises a generally rectangular base 12 having a pair of opposite ends 12a and a pair of opposite sides 12b and an open and generally rectangular top 14. The top 14 is of unitary construction for strength and stability. 15 Each one of a first pair of sidewalls 16 is located at a respective opposite end 12a of the base. The sidewalls 16 are each hingedly connected to the top 14 and are rotatable between a first position in which the sidewalls 16 are snap-lockingly connected with the base 12, as shown in Fig. I and 2, and a second position in which the sidewalls 16 are 20 disconnected from the base 12, as shown in Figs. 3A to 3E and Figs. 4 and 5. The base 12 includes stop means, in the form of a flange 18 extending generally perpendicularly from each end 12a of the base 12 toward the top 14, as best seen in Fig. 6, to prevent rotation of the sidewalls 16 outwardly with respect to an enclosed volume of 25 the crate 10. Each one of a second pair of sidewalls 20 is located at a respective opposite side 12b of the base 12, and each one of sidewalls 20 is hingedly connectable at one end to the base 12 and at the other end to the top 14. Each one of the second pair of sidewalls 20 has a 30 central intermediate hinge 22 to allow the second pair of sidewalls 20 to fold, as best shown in Fig. 3B and 3C. The second pair of sidewalls 20 each also includes a window 23 to allow product to be accessed even when the crate stacked, as shown in Figs. 9 and 10.
- 10 The individual components of the crate 10, including the base 12, top 14 and sidewalls 16 and 20 are separately manufactured and subsequently assembled to form the crate 10. The base 12 includes locating ribs 24, as best seen in Figs. 4 and 9, that engage with 5 locating channels 26, as best seen in Fig. 3E and Fig. 10 and 11, in the top 14 of an underlying crate 10 for stability when the crates are stacked, as shown in Figs. 7, 8 and 11. The base also includes locating lugs 28, an outer row of which engages with the inside of a top portion of the sidewalls 16 and, in combination with the ribs 24 and channels 26, secures the stacked expanded crates 10. The lugs 28 also engage with i0 complimentary locating recesses 30 in the sidewalls 16 to secure the collapsed crates 10 when stacked. The base 12 also includes apertures 32 to reduce weight and to allow spilt product or cleaning fluids to drain therethrough. The first sidewalls 16 each include a handle 34 to is allow the assembled crate 10 to be carried. The second sidewalls 20 also include ventilation apertures 36. To expand the crate from a flat storage configuration shown in Fig. 3E, the top 14 of the crate 10 is lifted away from the base 12 and the first pair of sidewalls 16 are rotated 20 inwardly with respect to the volume enclosed by the crate 10 until the sidewalls 16 snap lock with the base 12, as shown in Figs. 1 and 2. During this process, the second pair of sidewalls 20 are moved from a folded configuration, as shown in Fig. 3E, into an upright position, as shown in Fig. 3A. When product, in the form of bottled milk 38, is placed in the assembled crate, the product 38 pushes outwardly on the first sidewalls 16 and urges 25 the first sidewalls 16 into snap locking engagement with the base 12. To collapse the crate 10 from the expanded, in-use configuration shown in Figs. 1 and 2, the first pair of sidewalls 16 is rotated inwardly with respect to the volume enclosed by the crate 10. The hinge 22 of the second pair of sidewalls 20 is then pushed inwardly to 30 allow the second pair of sidewalls 20 to fold, as shown in Figs. 3B and 3C, and the top 14 is lowered toward the base 12, such that the crate 10 adopts the flat storage position shown in Fig. 3E, with the sidewalls 16 parallel to the base 12.
- 11 It will be appreciated that, as the illustrated crate 10 is able to be advantageously collapsed into a configuration occupying a reduced volume, it allows for the efficient use of space when in storage or during return transport to a beverage supplier, as shown in Fig 12. 5 In its expanded configuration, the crate 10 advantageously also allows for access to product even when the crates are stacked, by virtue of the window 23 in the second sidewalls 20. Also, because the crate 10 is not of unitary construction, a large tool is not required to form the crate 10, as was the case with the prior art, and the crate components 10 can instead advantageously be separately manufactured on smaller, more efficient machines. While the invention has been described with reference to specific embodiments, it will be appreciated that it may also be embodied in many other forms. For example: is . the first pair of sidewalls 16 may be hinged from the base 12 instead of from the top 14; * the window 23 may be provided in any or all of the sidewalls 16 and 20; * the second pair of sidewalls 20 may include more than one intennediate hinge 22 to allow the second sidewalls 20 to fold; 20 e the crate 10 may be square or oblong depending on the intended use of the crate. In embodiments where the crate 10 is oblong, however, the window 23 is preferably provided at least in the longer sidewalls, but may alternatively be provided in the shorter sidewalls; and/or e any of the sidewalls may contain one or more hinges and/or locking mechanisms.