Method of forming partition matrix

Claim 1

A method of forming a non-disassembling intersecting partition matrix, said matrix comprising at least one first slotted partition intersecting with at least one second slotted partition, each first and second slotted partition being made of double face plastic having multiple spacers sandwiched between two face plies, each first slotted partition having at least one slot extending inwardly from an edge of the first slotted partition, each second slotted partition having at least one slot extending inwardly from an edge of the second slotted partition, said method comprising the steps of: engaging said at least one slot of said at least one first slotted partition with said at least one slot of said at least one second slotted partition at an intersection to form a matrix; injecting molten plastic into a void between the face plies of intersecting partitions at at least one intersection, said void being formed at least in part by melting a portion of at least one spacer; and allowing said molten plastic to cool and solidify to permanently secure the intersecting partitions in a non-disassembling relationship.

Claim 2

A method of forming a non-disassembling intersecting partition matrix, said matrix comprising at least one first slotted partition intersecting with at least one second slotted partition, each first and second slotted partition being made of double face plastic having multiple spacers sandwiched between two face plies, each first slotted partition having at least one slot extending inwardly from an edge of the first slotted partition, each second slotted partition having at least one slot extending inwardly from an edge of the second slotted partition, said method comprising the steps of: engaging said at least one slot of said at least one first slotted partition with said at least one slot of said at least one second slotted partition at an intersection to form a matrix; injecting molten plastic into a void between the face plies of intersecting partitions at at least one intersection, said void being formed at least in part by melting a portion of at least one spacer; and allowing said molten plastic to cool and solidify to permanently secure the intersecting partitions in a non-disassembling relationship.

Claim 4

A method of forming a non-disassembling intersecting partition matrix, said matrix comprising a plurality of first slotted partitions intersecting with a plurality of second slotted partitions, each first and second slotted partition being made of double face corrugated plastic having multiple corrugations sandwiched between two face plies so as to define hollow parallel flutes therebetween, each first slotted partition having a series of slots extending inwardly from an edge of the first slotted partition, each second slotted partition having a series of slots extending inwardly from an edge of the second slotted partition, said method comprising the steps of: engaging at least one slot of a first slotted partition with a slot of a second slotted partition at an intersection to form a matrix; lowering a heated nozzle into a central flute at said intersection, releasing molten plastic through an orifice in said heated nozzle into said central flute, said molten plastic at least partially melting the corrugations between the face plies of the intersecting partitions. allowing said molten plastic to cool and solidify to permanently secure the intersecting partitions in a non-disassembling relationship.

Claim 5

A method of forming a non-disassembling intersecting partition matrix, said matrix comprising a plurality of first slotted partitions intersecting with a plurality of second slotted partitions, each first and second slotted partition being made of double face corrugated plastic having multiple corrugations sandwiched between two face plies so as to define hollow parallel flutes therebetween, each first slotted partition having a series of slots extending inwardly from an edge of the first slotted partition, each second slotted partition having a series of slots extending inwardly from an edge of the second slotted partition, said method comprising the steps of: engaging at least one slot of a first slotted partition with a slot of a second slotted partition at an intersection to form a matrix; lowering a heated nozzle into a central flute at said intersection, releasing molten plastic through an orifice in said heated nozzle into said central flute, said molten plastic at least partially melting the corrugations between the face plies of the intersecting partitions. allowing said molten plastic to cool and solidify to permanently secure the intersecting partitions in a non-disassembling relationship.

Claim 7

A method of forming a non-disassembling intersecting partition matrix, said matrix comprising a plurality of first slotted partitions intersecting with a plurality of second slotted partitions, each first and second slotted partition being made of double face corrugated plastic having multiple corrugations sandwiched between two face plies so as to define hollow parallel flutes therebetween, each first slotted partition having a series of slots, each slot extending from an edge of the first slotted partition towards the mid-point of said first slotted partition, each second slotted partition having a series of slots, each slot extending from an edge of the second slotted partition towards the mid-point of the second slotted partition, said method comprising the steps of: engaging a slot of a first slotted partition with a slot of a second slotted partition at an intersection to form a matrix; placing a supporting net over one edge of the matrix; injecting molten plastic into at least one flute at at least one intersection to permanently secure the intersecting partitions in a non-disassembling relationship and secure the supporting net to the intersecting partitions, said supporting net and said partitions defining a plurality of holding cells, each holding cell being capable of storing one or more items, said supporting net enabling items placed in the individual holding cells to rest upon and be supported by the net.

Claim 8

A method of forming a non-disassembling intersecting partition matrix, said matrix comprising a plurality of first slotted partitions intersecting with a plurality of second slotted partitions, each first and second slotted partition being made of double face corrugated plastic having multiple corrugations sandwiched between two face plies so as to define hollow parallel flutes therebetween, each first slotted partition having a series of slots, each slot extending from an edge of the first slotted partition towards the mid-point of said first slotted partition, each second slotted partition having a series of slots, each slot extending from an edge of the second slotted partition towards the mid-point of the second slotted partition, said method comprising the steps of: engaging a slot of a first slotted partition with a slot of a second slotted partition at an intersection to form a matrix; placing a supporting net over one edge of the matrix; injecting molten plastic into at least one flute at at least one intersection to permanently secure the intersecting partitions in a non-disassembling relationship and secure the supporting net to the intersecting partitions, said supporting net and said partitions defining a plurality of holding cells, each holding cell being capable of storing one or more items, said supporting net enabling items placed in the individual holding cells to rest upon and be supported by the net.

Claim 12

A method of forming a non-disassembling intersecting partition matrix, said matrix comprising a plurality of first slotted partitions intersecting with a plurality of second slotted partitions, each first and second slotted partition being made of double face corrugated plastic having multiple spacers sandwiched between two planar face plies, each first slotted partition having a series of slots, each slot extending inwardly from an edge of the first slotted partition, each second slotted partition having a series of slots, each slot extending inwardly from an edge of the second slotted partition, said method comprising the steps of: engaging the slots of the first slotted partitions with the slots of the second slotted partitions at intersections to form a matrix, said partitions of said matrix defining a plurality of openings in a first plane, said first plane being defined by coplanar edges of said partitions; placing a supporting net comprising crisscrossing individual net members over the intersecting partitions generally in said first plane such that said individual net members pass over said openings, and securing the supporting net to the intersecting partitions by injecting molten plastic between the planar face plies at selected intersections and allowing said molten plastic to cool; and turning said partition assembly over so that items may rest upon and be supported by the supporting net.

Claim 13

A method of forming a non-disassembling intersecting partition matrix, said matrix comprising a plurality of first slotted partitions intersecting with a plurality of second slotted partitions, each first and second slotted partition being made of double face corrugated plastic having multiple spacers sandwiched between two planar face plies, each first slotted partition having a series of slots, each slot extending inwardly from an edge of the first slotted partition, each second slotted partition having a series of slots, each slot extending inwardly from an edge of the second slotted partition, said method comprising the steps of: engaging the slots of the first slotted partitions with the slots of the second slotted partitions at intersections to form a matrix, said partitions of said matrix defining a plurality of openings in a first plane, said first plane being defined by coplanar edges of said partitions; placing a supporting net comprising crisscrossing individual net members over the intersecting partitions generally in said first plane such that said individual net members pass over said openings, and securing the supporting net to the intersecting partitions by injecting molten plastic between the planar face plies at selected intersections and allowing said molten plastic to cool; and turning said partition assembly over so that items may rest upon and be supported by the supporting net.