# US 2014/0150954 A1 · Method of Manufacturing Custom Sized Plastic Tote Having Intermediate Sleeve

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- Number: US 2014/0150954 A1
- Document ID: US20140150954A1
- Status: Published application
- Kind: A1
- Application number: 14/177,529
- Filed: 2014-02-11
- Published: 2014-06-05
- Earliest claimed: 2009-03-24
- Assignees: Bradford Company
- Applicants: Bradford Company
- Inventors: William J. Vroon
- Web page: https://patentgrep.com/patent/US20140150954A1

## CPC

- B29C 65/72: by combined operations {or combined techniques}, e.g. welding and stitching
- B23P 15/00: Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
- B29C 45/0055: {Shaping}
- B29C 65/08: using ultrasonic vibrations {(non-plastics element to plastics elements B29C65/645)}
- B29C 65/56: using mechanical means {or mechanical connections, e.g. form-fits}
- B29C 65/60: Riveting {or staking}
- B29C 66/1222: {comprising at least a lapped joint-segment}
- B29C 66/1224: {comprising at least a butt joint-segment}
- B29C 66/21: {said joint lines being formed by a single dot or dash or by several dots or dashes, i.e. spot joining or spot welding}
- B29C 66/5344: {said single elements being substantially annular, i.e. of finite length, e.g. joining flanges to tube ends (B29C66/5346 takes precedence)}
- B29C 66/53461: {joining substantially flat covers and/or substantially flat bottoms to open ends of container bodies}
- B29C 66/542: {joining hollow covers or hollow bottoms to open ends of container bodies}
- B29C 66/543: {joining more than two hollow-preforms to form said hollow articles}
- B29C 66/61: {Joining from or joining on the inside (for making tubes by bending sheets and joining from the inside B29C53/387)}
- B29C 66/723: {being multi-layered (B29C66/7292, B29C66/72941 take precedence)}
- B29C 66/72523: {multi-channelled or multi-tubular (B29C66/438, B29C66/5227 take precedence)}
- B29C 66/8322: {Joining or pressing tools reciprocating along one axis}
- B65D 11/10: {of polygonal cross-section and all parts being permanently connected to each other (B65D11/18 takes precedence)}
- B65D 11/105: {the container being formed by two mating U-shaped halves connected to each other after a rotation of 90 degrees}
- B26D 1/00: Cutting through work characterised by the nature or movement of the cutting member {or particular materials not otherwise provided for}; Apparatus or machines therefor; Cutting members therefor
- B29C 66/71: {characterised by the composition of the plastics material of the parts to be joined (welding bar compositions B29C65/125)}
- B29C 66/7392: {characterised by the material of at least one of the parts being a thermoplastic}
- B29C 2045/0067: {interposing an insert between the parts to be assembled}
- B29C 2793/00: Shaping techniques involving a cutting or machining operation
- B29C 2793/0081: before shaping
- B29C 2793/009: after shaping
- B29K 2023/12: {PP, i.e. polypropylene}
- B29L 2031/7126: {large, e.g. for bulk storage}
- B29L 2031/7162: {Boxes, cartons, cases}
- Y10T 29/49716: Converting
- Y10T 29/49721: with disassembling
- Y10T 29/49815: Disassembling
- Y10T 29/49817: with other than ancillary treating or assembling
- Y10T 29/49826: Assembling or joining
- Y10T 29/49956: Riveting
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- B23P: METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS (arrangements for copying or controlling B23Q)
- B65D: CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
- B26D: CUTTING; DETAILS COMMON TO MACHINES FOR PERFORATING, PUNCHING, CUTTING-OUT, STAMPING-OUT OR SEVERING (for growing crops or plants A01D, A01G; for fodder or straw A01F; for bulk butter A01J; for dough A21C; slaughtering A22B; for tobacco, cigars or cigarettes A24; marking-out, perforating or making buttonholes A41H25/00; manufacturing footwear A43D; brushmaking A46D; surgery A61B; disintegrating, mincing or shredding in general B02C; cutting wire, making pins or nails B21F, B21G; of the kind used formetal B23; cutting by abrasive fluid jets B24C5/02; hand-held cutting tools B26B; perforating, cutting-out, stamping-out or punching, or severing by means other than cutting B26F; for wood B27; for stone B28D; working of plastics or substances in a plastic state B29; making boxes, cartons, envelopes or bags, of paper or similarly worked materials, e.g. metal foil, B31B; article or web delivery apparatus incorporating cutting or line-perforating devices B65H35/00; for leather or upholstery B68, C14B; for glass C03B; making matches C06F; for peat C10F; for sugar C13B45/00; for textile materials D06H; civil engineering, building, mining, see Section E; for light guides G02B6/25; cutting processed photographic material G03D15/04)
- B29K: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR {MOULDS, } REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

A method of manufacturing a custom sized plastic tote lighter in weight than heretofore known custom sized plastic totes is provided. The method comprises separating an injection molded tote into upper and lower portions by cutting the injection molded tote. A sleeve or middle portion of plastic material is secured to the upper and lower portions of the injection molded tote to create a custom sized plastic tote of a desired height. Alternatively, portions of different injection molded totes may be used to create a custom sized plastic tote. The sleeve may be made from different materials and may be made of multiple pieces.

## Claims

### Claim 1

A method of manufacturing a custom sized plastic tote comprising:
separating an upper portion of an injection molded tote from a lower portion of said injection molded tote;
providing a four-sided sleeve made of corrugated plastic;
inserting the sleeve between said upper and lower portions of said injection molded tote to form a custom sized plastic tote having an upper portion, a lower portion and a sleeve extending therebetween, the sleeve fitting over sidewalls of said upper and lower portions of said custom sized plastic tote; and
securing said sleeve to said upper and lower portions of the custom sized plastic tote.

### Claim 2 (depends on 1)

The method of claim 1 wherein said sleeve is welded to said upper and lower portions of the custom sized plastic tote.

### Claim 3 (depends on 1)

The method of claim 1 wherein the corrugations of said sleeve are vertically oriented.

### Claim 4 (depends on 1)

The method of claim 1 wherein the sleeve is made of one piece of material having opposed side edges joined together.

### Claim 5 (depends on 1)

The method of claim 1 wherein said sleeve is made from multiple pieces of material.

### Claim 6 (depends on 5)

The method of claim 5 wherein said sleeve is made from two pieces of material.

### Claim 7 (depends on 1)

The method of claim 1 wherein the upper portion of the custom sized plastic tote has handles.

### Claim 8 (depends on 1)

The method of claim 1 further comprising removing exterior protrusions of the first and second injection molded totes.

### Claim 9 (depends on 1)

The method of claim 1 wherein said sleeve is made of polyethylene.

### Claim 10

A method of manufacturing a custom sized plastic tote comprising:
separating an upper portion of an injection molded tote from a lower portion of said injection molded tote;
providing a four-sided plastic sleeve made of a trilaminate material;
inserting the sleeve between said upper and lower portions of said injection molded tote to form a custom sized plastic tote having an upper portion, a lower portion and a sleeve extending therebetween such that the sleeve fits over sidewalls of said upper and lower portions of said custom sized plastic tote; and
securing said sleeve to said upper and lower portions of the custom sized plastic tote.

### Claim 11 (depends on 10)

The method of claim 10 wherein the upper portion of the custom sized plastic tote has handles.

### Claim 12 (depends on 10)

The method of claim 10 further comprising removing exterior protrusions of the injection molded tote.

### Claim 13 (depends on 10)

The method of claim 10 wherein the sleeve is made of a pair of face plies and a middle ply having a plurality of dimples.

### Claim 14 (depends on 10)

The method of claim 10 wherein the sleeve is made of one piece of material having opposed side edges joined together.

### Claim 15 (depends on 10)

The method of claim 10 wherein said sleeve is made from multiple pieces of material.

### Claim 16 (depends on 10)

The method of claim 10 wherein said sleeve is made from two pieces of material.

### Claim 17 (depends on 10)

The method of claim 10 wherein said sleeve is made of polypropylene.

### Claim 18

A method of manufacturing a custom sized plastic tote comprising:
cutting a first injection molded tote into multiple pieces;
providing a four-sided plastic sleeve made of corrugated plastic;
inserting the sleeve between pieces of said injection molded tote to form a custom sized plastic tote having an upper portion, a lower portion and a sleeve extending therebetween, the sleeve fitting over sidewalls of said upper and lower portions of said custom sized plastic tote; and
securing said sleeve to the sidewalls of the upper and lower portions of the custom sized plastic tote.

### Claim 19 (depends on 18)

The method of claim 18 wherein said sleeve is welded to said one of said upper and lower portions of the custom sized plastic tote.

### Claim 20 (depends on 18)

The method of claim 18 wherein the corrugations of said sleeve are vertically oriented.

### Claim 21 (depends on 18)

The method of claim 18 wherein the sleeve is made of one piece of material having opposed side edges joined together.

### Claim 22 (depends on 18)

The method of claim 18 wherein said sleeve is made from multiple pieces of material.

### Claim 23 (depends on 18)

The method of claim 18 wherein said sleeve is made from two pieces of material.

### Claim 24 (depends on 18)

The method of claim 18 wherein the upper portion of the custom sized plastic tote has handles.

### Claim 25 (depends on 18)

The method of claim 18 further comprising removing exterior protrusions of the injection molded tote.

### Claim 26 (depends on 18)

The method of claim 18 wherein said sleeve is made of polyethylene.