FIELD OF THE INVENTION

The invention relates to a reusable modular container having synthetic resin molded parts or pieces that are able to be assembled together by hand without tools. The container is reusable and recyclable.

DESCRIPTION OF RELATED ART

Containers for storage and transport are well known and widely used. These include cardboard containers and containers formed of synthetic resin. In the transportation of articles via cardboard containers, the cardboard containers are primarily intended for single use and then recycled or otherwise subject to disposal. Containers molded from synthetic resin (plastic containers) have the benefit of durability and strength, assuring more cycles of use than cardboard containers. However, plastic containers are primarily molded in specific sizes for transportation of articles or storage of articles and the containers are molded of a specific type and size depending on the articles to be contained therein. Therefore, plastic containers are not generally thought to be sufficiently versatile and cost effective to replace cardboard containers in the transportation of articles of various sizes and quantities.

Plastic containers are able to be formed in many shapes and sizes, and are nestable and stackable for ease of shipping and return. However, plastic containers of the prior art do not compare to cardboard containers which are formed without the requirement of tools from a blank and easily broken down for recycling after use.

However, there are many disadvantages to cardboard containers. First, cardboard containers are not modular. A wide range of different sized blanks are required to be available in order to assemble cardboard containers of different sizes and shapes. Also, taping of the joints and the application of glue is required for strengthening cardboard, which presents a recycling problem. Plastic containers, on the other hand, are each typically made from just a single type of resin and are therefore more conveniently recycled, by grinding and reclamation, for example. On the other hand, known plastic container are not easily separated into component parts in a manner that permits the component parts to be returned to a recycling center in the same manner as cardboard.

SUMMARY OF THE INVENTION

A reusable and recyclable modular container having synthetic resin molded parts according to the invention is able to be assembled by hand without tools into various sizes.

The container is able to be assembled from one set of four side pieces that are each of the same configuration in combination with one set of top/bottom pieces that are each of the same configuration. One exemplary container is able to be assembled from only two different pieces in this respect since one part is molded for the side pieces and the other part is molded for the top/bottom pieces.

Containers of various sizes are available from combinations of different sized side pieces. Each sized set of four side pieces may be combined with correspondingly sized top/bottom pieces, with the understanding that the size of the top/bottom pieces depends on the polygonal shape, in top view, which results from the assembly of the set of side pieces.

Further, the container is also modular and, in this way, two or more sets of four side pieces may be joined together with a separate extension joining piece that joins each of the sets of four side pieces to increase the size and volume of the container. Therefore, the container of the invention is modular in that each section or module is comprised of a set of four side pieces and multiple sets of the four side pieces are able to be joined together to provide a wide range of sizes of containers.

Further, the separate joining piece that joins each of the sets of four side pieces to increase the size of the container may be a divider joining piece in some embodiments that physically separates one or more modules (sets of four side pieces) from another set to provide separated compartments within the same container. As a result, articles of different type, purpose or function may be shipped in the same container and separated in different modules of the container.

In view of the modular assembly of different sized plastic side pieces and correspondingly sized top/bottom pieces, containers are provided that are assembled by hand from a minimum number of separately molded component parts. Further, the overall shape of each of the component parts is able to be essentially thin walled and flat. Therefore, the side piece, top/bottom piece, and optional extension and divider joining pieces (component parts of the plastic container of the invention) are able to be stored until used in stacks of flat or thin walled pieces, essentially as blanks from which the plastic containers are to be assembled by hand.

The container is able to be opened by hand from either end or both ends to access the article(s) inside the container. The container is also able to be disassembled by use of a simple hand tool enabling the disassembly of the corner joints of the container (top/bottom pieces removed) to separate the component pieces from one another. The disassembly does not break apart the pieces, i.e. break off any small parts when the material and the dimensions of the pieces enable sufficiently flexibility. Accordingly, the disassembled pieces of the container are able to be subsequent reassembled from the same, previously assembled component pieces for additional use(s) of the container. This additionally provides for ease of replacement of damaged pieces in the event that small parts of the pieces do break off or otherwise become damaged. Accordingly, the container is able to be assembled and disassembled, for reuse and/or continued use of the container in many transportation and/or storage cycles.

Alternatively, the assembled or disassembled component pieces are able to be recycled. When the component pieces are disassembled, the disassembled component pieces are able to be stacked together in dense flat stack, suitable for collection and recycling.

