Reinforcement structures for a foldable, reusable storage container, storage containers incorporating the structures, and methods of making same

Abstract

A reinforced storage container assembly, formed by connecting plural storage containers end-to-end, includes a first storage container, a second storage container, a connector, and at least one reinforcement structure. The storage containers each have an open end formed by removal of an end wall, and are oriented with the open ends facing toward one another, and attached at the open ends by a connector. Each reinforcement structure includes an inner reinforcement panel, used singularly, and an outer reinforcing member used in combination with a stiffening member, modified stiffening member or reinforcing channel. Each reinforcement structure reinforces at least one corresponding side wall or the floor of the storage container assembly. Each reinforcement structure and attaching hardware are sufficiently recessed into a storage container side wall or floor to allow the storage container assembly to be collapsibly folded without interference between any of the side walls, floor, reinforcement structures, or hardware.

1 . A collapsible, reinforced storage container assembly formed by connecting two or more storage containers, said reinforced storage container assembly comprising: 
 a first storage container having an open end formed by removal of an end wall thereof;    a second storage container having an open end formed by removal of an end wall, said second storage container open end abutted against said first storage container open end;    a plurality of fasteners interconnecting a base portion of said first storage container and a base portion of said second storage container, for connecting said base portions together;    a stiffening member attached to abutted side walls of said first and second storage containers and interconnecting said side walls together, the stiffening member extending longitudinally of the reinforced storage container assembly and being disposed proximate upper edge portions of said side walls; and    a reinforcing member extending along a junction between said abutted side walls of said first and second storage containers and operatively engaging said stiffening member.    
   
   
       2 . The collapsible, reinforced storage container assembly of  claim 1 , wherein said junction between said abutted side walls is recessed inwardly from outer surfaces of said side walls, and said reinforcing member includes a first portion that fits in said recessed junction such that an outer surface of said first portion is substantially flush with said outer surfaces of said side walls.  
   
   
       3 . The collapsible, reinforced storage container assembly of  claim 2 , wherein said reinforcing member includes a second portion connected to one end of the first portion, the second portion extends substantially perpendicular to the first portion and is fixed to said abutted side walls, and an opposite end of said first portion operatively engages said stiffening member such that the opposite end is prevented from moving relative to said abutted side walls.  
   
   
       4 . The collapsible, reinforced storage container assembly of  claim 1 , wherein said reinforcing member is substantially T-shaped, with a stem portion thereof extending along the junction between said abutted side walls substantially flush with outer surfaces of the side walls, and a crossing portion thereof disposed at a lower end of the stem portion and fixed to said abutted side walls.  
   
   
       5 . The collapsible, reinforced storage container assembly of  claim 4 , wherein an upper end of said stem portion operatively engages said stiffening member such that the upper end is prevented from moving relative to said abutted side walls.  
   
   
       6 . The collapsible, reinforced storage container assembly of  claim 5 , wherein said stiffening member is substantially U-shaped in cross section opening downwardly, and securely receives the upper end of the stem portion therein.  
   
   
       7 . The collapsible, reinforced storage container assembly of  claim 6 , wherein said stiffening member also receives upper edge portions of said side walls therein.  
   
   
       8 . The collapsible, reinforced storage container assembly of  claim 1 , wherein said abutted side walls of said first and second storage containers are foldable along longitudinally extending fold lines thereof, and said reinforcing member being disposed above said longitudinally extending fold lines.  
   
   
       9 . The collapsible, reinforced storage container assembly of  claim 1 , wherein said stiffening rails are formed of metal.  
   
   
       10 . The collapsible, reinforced storage container assembly of  claim 1 , further comprising a third stiffening member attached to lower inner surfaces of said abutted side walls of said first and second storage containers and interconnecting said side walls together, said reinforcing member engaging outer surfaces of the side walls.  
   
   
       11 . The reinforced storage container assembly of  claim 9 , said stiffening member having a plurality of holes formed therethrough, further comprising a fastening hardware including a plurality of bolts and nuts, each said hole for receiving one said bolt therethrough, for bolting said stiffening member to corresponding said side wall.  
   
   
       12 . The reinforced storage container assembly of  claim 11 , wherein the stiffening member vertically compresses portions of said side walls to which it is attached, such that the top surface of said stiffening member is flush with the portion of the top surface of corresponding said side wall not covered by said stiffening member.  
   
   
       13 . The reinforced storage container assembly of  claim 11 , said stiffening member further having a plurality of recesses formed therein, each recess concentrically located about a corresponding one of said holes, for receiving a bolt head therein.  
   
   
       14 . The reinforced storage container assembly of  claim 11 , wherein each head of a stiffening member attachment bolt having a height no greater than the depth of corresponding said recess.