Container with cutaway corners

Abstract

The present invention provides a container for holding product therein during shipment, storage, or display and being returned for reuse. The container has a base and perpendicular side walls. The side walls are not attached to each other. The base and side walls are adapted, individually or in combination, to flex so that a second container can be nested within a first container. When the second container is placed within the first container, a portion of the base and the side walls of the first container form an obtuse angle. The base and the side walls are biased to form a right angle before the second container is nested within the first and after the second container is unstacked from the first container.

1 . A first stackable container comprising: 
 a base;    a plurality of side walls integral with the base and extending upwardly from the base, the side walls being unattached to one another and perpendicular to the base;    wherein the side walls are adapted to flex outwardly upon a second stackable container being nested within the first stackable container.    
   
   
       2 . The first stackable container of  claim 1  wherein a portion of the base and the side walls of the first stackable container form an obtuse angle when the second stackable container is nested within the first stackable container.  
   
   
       3 . The first stackable container of  claim 1  wherein the base and the side walls are biased to form a right angle between the base and the side walls before the second stackable container is nested within the first stackable container and after the second stackable container is removed from inside the first stackable container.  
   
   
       4 . The first stackable container of  claim 1  wherein the first stackable container is made of a thermoplastic material.  
   
   
       5 . The first stackable container of claim of  claim 1  wherein the first stackable container is made of polypropylene foam.  
   
   
       6 . The first stackable container of claim of  claim 1  wherein the base has a plurality of openings therethrough.  
   
   
       7 . The first stackable container of claim of  claim 1  wherein the base has a plurality of tabs.  
   
   
       8 . The first stackable container of claim of  claim 1  wherein the base has a hinge which enables the side walls to pivot about the hinge when another container is nested inside the first stackable container.  
   
   
       9 . The first stackable container of claim of  claim 8  wherein material has been removed from the base to define the hinge.  
   
   
       10 . The first stackable container of claim of  claim 1  wherein an outside portion of the base and each sidewall remain perpendicular to each other after at least one other container is nested inside the first stackable container.  
   
   
       11 . A stack of containers adapted for holding a product comprising: 
 a first and second container each having a base and a plurality of side walls, the side walls being unattached to one another;    wherein the second container is nested inside the first container such that a portion of the base and side walls of the first container form an obtuse angle.    
   
   
       12 . The stack of containers of  claim 11  wherein the base and the side walls of each of the containers are biased to form a right angle between the base and the side walls before the containers are nested together and after the containers are separated.  
   
   
       13 . The stack of containers of  claim 11  wherein the containers are made of a thermoplastic material.  
   
   
       14 . The stack of containers of  claim 11  wherein the containers are made of polypropylene foam.  
   
   
       15 . The stack of containers of  claim 11  wherein the bases of the containers have openings therethrough.  
   
   
       16 . The stack of containers of  claim 11  wherein the bases of the containers have tabs formed therein.  
   
   
       17 . A method for making a stackable container comprising the steps of: 
 providing a blank and a heat source;    heating the blank with the heat source along fold lines;    bending the blank at the fold lines so as to create a container having a base and side walls perpendicular to the base, the side walls being unattached to each other; and    allowing the base and side walls to cool.    
   
   
       18 . The method of  claim 17  wherein heating the blank along fold lines comprises heating a blank of thermoplastic material along fold lines.  
   
   
       19 . The method of  claim 17  further comprising the step of creating a plurality of openings in the base.  
   
   
       20 . The method of  claim 17  further comprising the step of creating a plurality of tabs in the base.