AU2019101840A4

AU2019101840A4 - A collapsible container

Info

Publication number: AU2019101840A4
Application number: AU2019101840A
Authority: AU
Inventors: Bipin Patel
Original assignee: Piber Plastics Australia Pty Ltd
Current assignee: Piber Plastics Australia Pty Ltd
Priority date: 2018-04-23
Filing date: 2019-04-04
Publication date: 2023-03-30
Anticipated expiration: 2027-04-04
Also published as: AU2019202335A1

Abstract

P1491AUAU ABSTRACT A collapsible container 100 includes a base 160 and walls 120, 140 respectively pivotally attached to the base to enable the container to collapse. Each of the walls 120, 140 respectively includes insulation and a plastic outer enclosing the 5 insulation. 111 100 120 120 140 160 FIGURE 1A 100 FIGURE 1B

Description

100

120 120

140

160

FIGURE 1A

100

FIGURE 1B

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A COLLAPSIBLE CONTAINER FIELD

The present invention relates to a collapsible container.

The invention will be described with reference to the storage of fresh produce by way of example only. Other examples of the invention may suit other applications.

BACKGROUND

Existing containers for storing fresh produce include plastic containers. These containers are not suitable for transporting produce over long distances. Fresh produce stored in these plastic containers will lose their freshness if stored in the container for extended periods of time.

Other existing containers include polystyrene containers. The insulation properties provided by these containers allow a freshness of the stored produce to be reserved for a longer period of time. These containers are however limited in their reusability. In particular, these containers are prone to contamination for example by bacteria. If the container stores a meat product for example that leaks during transportation, the polystyrene will absorb the leakage, which results in the container becoming contaminated. Sanitising or cleaning the polystyrene to remove the contamination is a difficult and expensive process.

In addition, transporting and storage of empty polystyrene containers (i.e. that are not being used to store produce) consumes space and is expensive.

It is not admitted that any of the information in this patent specification is common general knowledge, or that the person skilled in the art could be reasonably expected to ascertain or understand it, regard it as relevant or combine it in any way before the priority date.

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SUMMARY

The present invention seeks to provide a container that addresses one or more of the disadvantages of the existing containers described above. Embodiments of the present invention seek to provide a container that can preserve an item's freshness for longer periods of time and that is less vulnerable to contamination. The present invention additionally or alternatively seeks to at least provide the public with a useful choice.

According to one aspect, the present invention provides a collapsible container including

a base; and

walls respectively pivotally attached to the base to enable the container to collapse;

each of the walls respectively including insulation and a plastic outer enclosing the insulation.

Each respective wall of the one or more walls may include a respective member of the plastic outer of the respective wall by which the insulation of the respective wall is at least partly enclosed; and a respective formation integral to the respective member and engaged with the base to form a snap fit hinge by which the respective wall is pivotally attached to the base.

The base preferably includes a plurality of snap-fitting hooks. Preferably respective formation of the respective wall having a rod that is engaged by a respective one of the snap-fitting hooks of the base to form the snap fit hinge. Alternatively or additionally, the base may include a plurality of rods, and the respective formation of the respective wall may have a snap-fitting hook engaging a respective one of the rods of the base to form the snap fit hinge.

Each of the plastic outers may be a respective integral body of plastic.

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Preferably there are two or more of the walls. Optionally each wall has a respective pivot axis about which the wall is pivotable relative to the base. The pivot axis of each wall may be vertically offset from the pivot axis of each adjacent wall by a distance corresponding to a thickness of the adjacent wall to enable the walls to lay flat when the container is collapsed. Each of the walls preferably has a thickness of between about 13 mm and 15 mm, and the pivot axis of one of the walls is vertically offset from the pivot axis of an adjacent wall by about 13mm to 15mm. Preferably, each wall has a thickness of about 14 mm, and the pivot axes of adjacent walls are offset by each other by about 14 mm.

The plastic outer of at least one of the one or more walls may include a respective inner member and a respective outer member, the insulation preferably being sandwiched between the respective inner member and the respective outer member. The respective inner and outer members of the plastic outer preferably releasably engage each other to trap the insulation therebetween.

Preferably the inner and outer members are mutually cooperable to be clipped together.

One of the respective inner or outer members may include one or more clips and the other one of the respective inner or outer members includes one or more slots that are each engageable by a respective one of the clips. The other one of the respective inner or outer members preferably includes a rim for surrounding the insulation, the slots being provided at or near a base of the rim.

The one or more walls may include two walls that are adjacent to each other, one of the two walls having a locking feature for engaging the other of the two walls to lock the walls in place relative to each other when the container is configured to contain an item.

The insulation may include at least one of polystyrene, expanded polystyrene (EPS), and polyurethane.

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Each of the walls may include an insulation panel with the insulation, the insulation panel preferably having a thickness of between about 5 mm and 15 mm. The thickness of the insulation panel is preferably about 10 mm.

The respective inner member may have a surface with one or more raised areas and/or recessed areas. The insulation panel preferably has a first panel-facing surface that contains one or more recessed areas and/or raised areas corresponding to, and for cooperating with, respective raised areas and/or recessed areas of the respective inner member.

The respective outer member may also have a surface with one or more raised areas and/or recessed areas. The insulation panel preferably has a second panel-facing surface that contains one or more recessed areas and/or raised areas corresponding to, and for cooperating with, respective raised areas and/or recessed areas of the respective outer member.

The base may include a base insulation and a plastic outer enclosing the base insulation.

The collapsible container may further include a lid. The lid preferably includes a lid insulation and a plastic outer enclosing the lid insulation.

The walls may include one or more upper engagement portions and the base may include one or more lower engagement portions. The upper-engagement portion(s) may be provided at a top of the wall for example. The lower-engagement portion(s) may be provided on the outer member of the base for example. Preferably, the upper engagement portion(s) of the container are engageable with the lower engagement portion(s) of another container to securely stack the container and the other container. Optionally, the lower engagement portion(s) of the container may be engageable with the upper engagement portion(s) of another container to securely stack the container and the other container. The upper engagement portion(s) and lower engagement portion(s) are preferably arranged to allow the container and the other container to be securely stacked transversely to each other.

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The container has a non-unitary width-to-length ratio of a first integer to a second integer. The first integer may be in the range of 1 to 10 inclusive. Preferably, the first integer is in the range of 1 to 5 inclusive. The first integer may be 2 for example. The second integer may be in the range of 1 to 10 inclusive. The second integer may be in the range of 1 to 5 inclusive. The second integer may be 3 for example.

BRIEF DESCRIPTION OF DRAWINGS

An embodiment of the apparatus will now be described by way of non-limiting example only with reference to the accompanying drawings in which:

Figures 1A to 1C show the container according to an embodiment of the present invention in an assembled configuration, a collapsed configuration, and an exploded view respectively;

Figures 2A to 2C show different views of an inner member of one of the front or rear walls of the container of Figures 1A to 1C;

Figure 3 shows an outer member for the front/rear wall of Figures 2A to 2C;

Figure 4 shows an insulation for the front/rear wall of Figures 2A to 2C;

Figures 5A and 5B show different views of an inner wall member of one of the side walls of the container of Figures 1A to 1C;

Figure 6 shows an outer member for the side wall of Figures 5A and 5B;

Figure 7 shows an insulation for the side wall of Figures 5A and 5B;

Figures 8A to 8G show different views of an inner member of the base of the container of Figures 1A to 1C;

Figure 9 shows an outer member for the base of Figures 8A to 8G;

Figure 10 shows a base insulation for the base of Figures 8A to 8G;

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Figure 11 shows a container accosting to another embodiment of the present invention with a lid;

Figures 12A to 12D show an exploded view of the lid of the container of Figure 11 and views of the outer member, lid insulation, and inner member respectively of the lid; and

Figures 13A and 13B show containers according to another embodiment of the present invention in a stacked arrangement.

DESCRIPTION OF EMBODIMENTS

Figures 1A to 1B shows a collapsible container 100.

The item for storing in the collapsible container may include fresh produce or other goods. For example, the item may include meat, vegetables, or fruit for example. In addition, the item may include ice or a cold-pack for cooling other items in the storage space.

The container 100 is an insulated folding container with insulation (such as expanded polystyrene (EPS) or polyurethane for example) for maintaining the temperature of the item stored in the container at a low temperature to preserve the item for longer.

In addition, the container has a plastic outer that encloses the insulation. The plastic outer protects the insulation from contamination from both the item carried by the container and from the environment in which the container is located. The plastic outer prevents fluid from flowing therethrough into the insulation enclosed therein. In particular, the plastic outer prevents water, or other liquid, from entering into an enclosed space defined by the plastic outer where the insulation is located that would compromise the insulation. The plastic outer may be made from polypropylene. Alternatively, the first and second panels may be made from a high-density polyethylene (HDPE).

The container 100 includes front and rear walls 120, side walls 140, and a base 160. The base 160 has a rectangular shape. The base may be any other shape, such as a

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square shape for example. The walls 120, 140 are each pivotally connected to respective sides of the base 160 and surround the base 160 to define an enclosed storage space between the walls and the base in which the item can be stored (as shown in Figure 1A). Each of the walls 120, 140 of the container is pivotable relative to the base 160 about a respective pivot axis to allow the container to collapse (as shown in Figure 1B). The pivot axes of the front and rear walls 120 are higher than the pivot axes of the side walls by a distance corresponding to the thickness of the side wall.

A top of the walls 140, 160 includes protrusions that cooperate with corresponding recesses on an underside of the base of another container that has a similar construction as the container of Figure 1. The engagement between the protrusions and the recesses of the containers allow the containers to be stacked securely, for example during transportation. The protrusions on the upper surface of the walls and recesses on the underside of the base are arranged in such a way to allow the containers to be securably stacked transversely relative to each other. In other variations, the protrusions and recesses are arranged to allow the containers to be securably stacked in-line with each other. Other interengageable or cooperable engagement portions, besides the protrusions and the recesses, for securely stacking the containers are also possible.

To collapse the container, the side walls 140 are first folded onto the base 160 such that the side walls 140 form a substantially flat surface on the base. The front and rear walls 120 are then folded onto the side walls 140. By having the flat surface provided by the side walls, the front and rear walls can rest stably on the flat surface when folded. In addition, the front and rear walls also form a substantially flat surface when folded onto the side walls such that another container can rest stably on the collapsed container.

In other embodiments of the container, the pivot axes of the side walls 140 are higher than the pivot axes of the front and rear walls. In this embodiment, to collapse the container, the front and rear walls are first folded onto the base, followed by the side walls. In yet other, the pivot axes of the front, rear and side walls may be substantially level with each other (i.e. no vertical offset between vertical axes).

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Referring to Figure 1C, each of the walls 120, 140 and the base 160 includes an inner member 122, 142, 162; an outer member 124, 144, 164; and an insulation panel 126, 146, 166 sandwiched between the inner and outer members. The inner member and outer members define a plastic outer that encloses the insulation panel to thereby protect the insulation panel from contamination. The inner member protects the insulation panel from contamination or exposure to the item stored in the storage space, while the outer member protects the insulation panel from exterior contamination, for example from an environment in which the container 100 is located.

The inner and outer members are made from plastic such as polypropylene, while the insulation is expanded polystyrene (EPS). Other suitable plastic or other materials that can prevent fluid from flowing through the respective first or second panel into the space between the panels may be used to form the inner and outer members. For example, the inner and outer members may be made from high-density polyethylene (HDPE). The insulation may also include other materials such as extruded polystyrene or polyurethane for example.

The inner member 122 of the front wall will now be described with reference to Figures 5A and 5B. The inner member of the rear wall has a similar construction to that of the inner member 122 of the front wall.

The inner member 122 has a base portion 1221 with a rim portion 1222 surrounding the base portion 1221. The rim portion 1222 surrounds and area above the base portion 1221 in which the insulation panel is provided. The rim portion 1222 has a height of about 10 mm from the base portion 1221. The rim portion 1222 surrounds the insulation panel.

The inner member 122 has three raised areas 1223, which are elevated relative to the base portion 1221. Each raised area has a height from the base portion 1221 of up to about 5 mm. Each raised area 1223 also has a width in the range of about 100 mm to 110 mm inclusive, and a length in the range of about 130 mm to 150 mm inclusive. In addition, adjacent raised areas 1223 are separated from each other by a distance of about 70 mm to 80 mm inclusive. The insulation panel of the front wall is

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arranged to fit snugly within the space between the base portion 1221 and the wall portion 1222, and has recessed areas that cooperate with the raised areas 1222 of the first panel.

The inner member 122 further includes four rods 1224 at a bottom edge of the inner member 122 that are pivotally connected to the base of the container. The four rods 1224 are integrally moulded with the rim portion 1222 and spaced along a length of the inner member 122. Each rod 1224 is an integral formation of the inner member 122. For the avoidance of any doubt, 'integral formation' and similar terminology is used herein in its conventional sense to refer to a single continuous body of material. Two bodies may be integrated by welding but not by typical over-moulding or typical mechanical fastening. Each rod 1224 engages a respective snap-fitting hook on the base (shown in and described below with reference in Figure 8E) to form a snap-fit hinge about which the front wall is pivotable. As shown in Figure 2C, the rod 1224 has a generally circular cross-section with a flat edge. The flat edge engages a corresponding flat edge of the snap-fitting hook of the base to limit the range of pivoting movement of front wall relative to the base. In particular, upon pivoting the front wall relative to the base, the flat edge of the rod 1224 of the inner member 122 will be in contact with the flat edge of the respective snap-fitting hook of the base to thereby prevent further pivoting movement of the front wall. The range of pivoting movement of the front wall is limited by up to 900 from the base.

The inner member 122 further includes apertures (or slots) 1225 around a perimeter of the base portion 1221. These apertures 1225 are engageable by corresponding clip portions of the outer member that will be discussed in further detail below (with reference to Figure 3).

The inner member includes castellations 1226 on sides of the inner member 122. The castellations 1226 cooperate with corresponding castellations in each side wall (shown in and described in further detail below with reference to Figure 5B) to maintain the front wall relative to the side walls. The castellations 1226 of the front wall in particular interlock with the castellations of the side walls. Other forms of interlocking features are possible.

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The inner member 122 includes a locking feature 1227 provided on the base portion 1221 for locking the front wall relative to the side wall. The locking feature 1227 is a resiliently flexible arm to engage a portion of the side walls in a snap-fit engagement. The arms 1227 are located on opposite sides of the inner member for engaging a respective one of the side walls.

The outer member 124 of the front wall will now be described with reference to Figure 3. The outer member of the rear wall has a similar construction to that of the outer member 124 of the front wall.

The outer member 124 covers the space defined between the base portion and rim portion of the inner panel described above. The outer member 124 has a thickness of about 2 mm.

The outer member 124 has four raised areas 1241. When the outer member 124 engages the inner member previously described above, the raised areas 1241 protrude in a direction towards the inner member. The raised areas 1241 cooperate with corresponding recessed areas of the insulation panel. The outer member and the insulation are thus interlocked. Other interlocking arrangements are possible. This arrangement provides a snugness of fit between the outer member 124 and the insulation panel. Each raised area 1241 has a height of about 5 mm. The raised areas have a width of about 60 mm, and a length of about 120 mm.

The outer member 124 further includes clip portions 1242 distributed about a perimeter of the second panel for engaging corresponding apertures in the inner member described previously above. Each clip portion 1242 includes a hooked end for latching onto the first panel. The clip portion has a trapezoidal profile with a length of about 12 mm and a free end having a width of about 4 mm. The hooked end is provided on the free end and protrudes from the clip portion by about 1.3 mm. When the clip portions engage the corresponding apertures in the inner panel, the hooked end of the clip portions will retain the outer member 124 in place relative to the inner member. In addition, when the clip portions 1242 engage the outer member with the insulation panel located inside the inner member, the outer member 124 presses against the insulation panel.

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The insulation panel 126 of the front wall will now be described with reference to Figure 4. The insulation panel of the rear wall has a similar construction to that of the insulation panel 126 of the front wall.

The insulation panel 126 has a shape that corresponds to the space between the rim portion and the base portion of the outer panel (described with reference to Figures 2A and 2B). In particular, the insulation panel 126 fits snugly into a space between the base and rims portions.

The insulation panel 126 has a thickness of about 10 mm. The insulation panel 126 has a width of about 153 mm and a maximum length of about 563 mm. A first side of the insulation panel 126 contains three recessed areas for cooperating with raised areas of the inner member, while a second side of the insulation panel 126 contains four recessed areas 1261 for cooperating with raised areas of the second panel. The recessed areas have a depth of up to about 5 mm inclusive. Each recessed area has a width in the range of about 50 mm to 100 mm inclusive, and a length in the range of about 100 mm to 150 mm inclusive. The dimensions of the recessed areas on the first side of the insulation panel may be different from the dimensions of the recessed areas on the second side of the insulation panels. For example, the recessed areas on the first side of the insulation panel may have a width of about 71 mm and a length of about 123 mm; while the recessed areas on the second side of the insulation panel may have a width of about 63 mm and a length of about 123 mm.

For the front wall, the insulation panel 126 of Figure 4 is sandwiched between the outer panel 122 of Figures 2A to 2C and the inner panel 124 of Figure 3. There is substantially no or a very minimum air gap between the insulation panel 126 and the inner and outer members 122, 124. The rear wall of the container has a similar construction as the rear wall. The substantially no or minimal air gap increases the overall insulating efficiency provided by the front/rear wall.

The inner member 142 of one of the side walls will now be described with reference to Figure 6.

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The inner member 142 includes a base portion 1421 with a rim portion 1422 substantially surrounding the base portion 1421. The rim portion 1422 has a height of about 10 mm from the base portion 1421. The rim portion 1422 defines a space above the base portion 1421 in which the insulation panel of the side wall is provided.

The inner member 142 further includes two raised areas 1423 having a height from the base portion 1421 in the range of up to about 5 mm inclusive. Each raised area 1423 has a width of about 70 mm, and a length of about 135 mm. In addition, the raised areas 1423 are separated from each other by a distance of about 170 mm. The insulation panel is arranged to rest within the space defined by the base portion 1421 and the rim portion 1422, and has corresponding recessed areas that cooperate with the raised areas 1423 of the inner member such that the insulation panel fits snugly within the inner member 142.

The inner member 142 further includes four rods 1424 at a bottom edge of the inner member 142 that pivotally connected to the base of the container. The two rods 1424 are integrally moulded with the rim portion 1422 and spaced along a length of the inner member 142. Each rod 1224 is an integral formation of the inner member 122. Each rod 1424 engages a respective snap-fitting hook on the base (shown in and described below with reference in Figure 8D) to form a snap-fit hinge about which the front wall is pivotable. Similar to the rod described with reference to Figure 2C, the rod 1424 has a generally circular cross-section with a flat edge. The flat edge engages a corresponding flat edge of the snap-fitting hook of the base to limit the range of pivoting movement of side wall relative to the base. In particular, upon pivoting the side wall relative to the base, the flat edge of the rod 1424 of the inner member 142 will be in contact with the flat edge of the respective snap-fitting hook of the base to thereby prevent further pivoting movement of the side wall. The range of pivoting movement of the side wall is limited by up to 900 from the base.

The inner member 142 further includes apertures 1425 that are engageable by clip portions of the outer member that will be described in further detail below. The apertures are distributed around a perimeter of the base portion 1421.

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The inner member 142 includes castellations 1426 on a side of the inner member 142. The castellations 1426 cooperate with corresponding castellations in the front/rear wall (shown in and described in further detail below with reference to Figure 2B) to maintain the front/rear walls relative to the side walls. The castellations of each side wall in particular interlock with the castellations of the front/rear walls.

The inner member 142 further includes a portion 1427 that is part of the base portion 1421 that is not surrounded by the rim portion 1422. The portion 1427 is engageable by the locking feature in the front/rear wall as described previously above.

The outer member 144 of the side wall will now be described with reference to Figure 6. Unless otherwise described, the outer member 144 is generally similar to the outer member of the front wall previously described above.

The outer member 144 includes one raised area 1441. The raised area 1441 cooperates with a recessed area of the insulation panel. This arrangement provides a snugness of fit between the outer member 144 and the insulation panel. The raised area 1441 has a height of about 2 mm. In addition, the raised area has a length of about 139 mm and a width of about 69 mm.

The outer member 144 further includes clip portions 1442 for engaging corresponding apertures in the outer member 144 described previously above. Each clip portion includes a hooked end for latching onto the first panel. The clip portion has a trapezoidal profile with a length of about 12 mm and a free end having a width of about 4 mm. The hooked end is provided on the free end and protrudes from the clip portion by about 1.3 mm. When the clip portions engage the corresponding apertures, the hooked end of the clip portions will retain the outer member 144 in place relative to the inner member. In addition, when the clip portions engage the inner member with the insulation panel located inside the inner member, the second panel 146 presses against the insulation panel.

The insulation panel 146 of the side wall will now be described with reference to Figure 7.

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The insulation panel 146 has a shape that corresponds to the space between the rim portion and the base portion of the outer panel (described with reference to Figures 5A and 5B). In particular, the insulation panel 146 fits snugly into a space between the base and rims portions.

The insulation panel 146 has a thickness of about 10 mm. The insulation panel has a width of about 170 mm and a length of about 330 mm. The insulation panel 146 fits snugly into a space between the base portion and rim portion of the inner member of the side wall described previously above. A first side of the insulation panel 146 contains two recessed areas for cooperating with the raised areas of the inner member, while a second side of the insulation panel 146 contains one recessed area 1461 for cooperating with raised areas of the outer member. The recessed areas have a depth in the range of up to about 5 mm inclusive. The two recessed areas 1441 on the first side have a width 70 mm and a length of about 134 mm, while the recessed area 1442 on the second side has a width of about 67 mm and a length of about 137 mm.

For each side wall, the insulation panel 146 of Figure 7 is sandwiched between the outer panel 142 of Figures 5A and 5B and the inner panel 144 of Figure 6. There is substantially no or a very minimum air gap between the insulation panel 146 and the inner and outer members 142, 144. The substantially no or minimal air gap increases the overall insulating efficiency provided by the side wall.

In Figures 5A ,5B, 6 and 7, the side wall has an aperture 148 extending therethrough that acts as a handle for allowing the container 100 to be carried. The aperture is surrounded by a rim portion of the inner member to protect the insulation panel 146.

The inner member 162 of the base of the container will now be described with reference to Figures 8A to 8G.

The inner member 162 includes a base portion 1621 with a rim portion 1622 surrounding the base portion. The rim portion 1622 has a height of about 10 mm from the base portion 1621. The inner member 162 further includes a ribbed area 1623 on an underside of the base (shown in Figure 8G) for strengthening the base

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and for cooperating with corresponding recessed areas of the insulation panel such that the insulation panel fits snugly within the first panel.

The inner member 162 includes snap fitting hook portions 1623 for a side wall of the container (shown in Figure 8D) and snap fitting hook portions 1624 for a front/rear wall of the container (shown in Figure 8E). Each of the snap fitting hook portions together with the rim portion 1621 defines a slot for receiving the rods of the respective front/rear walls and side walls previously described above. The rods of each wall engage the base to form a snap fit hinge about which the wall is pivotable. The snap fitting hook portions 1623, 1624 are resiliently deformable to allow the respective rods to be pushed into or pulled out from the respective slot. As previously described above, the snap-fitting hooks have a flat surface below the hook portion of the snap-fitting hook that is cooperable with a respective flat portion of the rod to limit the pivoting range of the wall.

Each wall has a respective pivot axis about the snap fit hinge that is formed between the rods of each wall and the snap fitting hook portions of the base. The pivot axes of the front and rear walls are higher than the pivot axis of the side walls by about 14 mm, which corresponds to a thickness of the side wall. In this way, the front and rear walls will lie substantially flat about the folded side walls when the container is collapsed. In other variations, the side walls may have a higher pivot axis than the front/rear walls. In yet other variations, there may be no vertical offset between pivot axes. For example, two opposite facing walls may fold inwardly onto the base, and the other two opposite facing walls may be folded outwardly away from the base.

The outer member 164 of the base will now be described with reference to Figure 9. Unless otherwise described, the outer member 164 is similar to the outer member of the walls previously described in the relation to the front/rear wall and the side walls.

The outer member 164 includes clip portions 1641 for engaging corresponding apertures in the outer member. Each clip portion 1641 includes a hooked end for latching onto the inner member. The clip portion 1641 has a trapezoidal profile with a length of about 12 mm and a free end having a width of about 4 mm. The hooked end is provided on the free end and protrudes from the clip portion by about 1.3 mm.

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When the clip portions engage the corresponding apertures of the inner member, the hooked end of the clip portions will retain the second panel in place relative to the first panel. In addition, when the clip portions engage the inner member with the insulation panel located inside the first panel, the second panel 166 presses against the insulation panel.

The base insulation panel 166 of the base will now be described with reference to Figure 10. Unless otherwise described, the insulation panel 166 is similar to the insulation panel of the walls previously described in the relation to the front/rear wall and the side walls.

The insulation panel 166 has a thickness of about 10 mm. The insulation panel 166 fits snugly on an underside of the inner member (shown in Figure 8G) in the space defined by the rim portion and base portion of the inner member. On one side of the insulation panel 166 contains recessed areas 1661 for cooperating with ribs of the inner member. The recessed areas 1661 have a depth in the range of about 3 mm and 5 mm inclusive.

Another embodiment of the container 200 of the present invention is shown in Figure 11. In this embodiment, the foldable insulated container has a lid 280 for closing the container 200. The container 200 includes front and rear walls 120, side walls 140, and a base wall 160 that are similar to those of the container previously described above.

The lid 280 has a construction that is generally similar to the construction of the walls of the container previously described. In particular, referring to Figures 12A to 12D, the lid includes an outer member 282, an inner member 284, and an insulation panel 286. The insulation panel 286 is sandwiched between the inner and outer members 282, 284. In addition, the insulation panel 286 has recessed areas that cooperate with corresponding raised areas in the inner and outer members 282, 284 such that the insulation panel fits snugly within the first panel. The inner and outer members form a plastic outer that protects the lid insulation from contamination or exposure to the item stored in the storage space, as well as from contamination or exposure to the environment.

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Figures 13A and 13B show containers 300 in a stacked configuration. Each container 300 has a generally similar construction as the container that is described with reference to Figure 1A. Unless otherwise described, features of the container 300 are identical to features of the container 100 of Figure 1A.

The container 300 has front/rear walls 320 and side walls 340 that are pivotally connected to a base 360.

For each container 300, a top of the front/rear walls 320 includes protrusions 3227 spaced along a length of the front/rear wall. Similarly, a top of the side walls 340 includes portions 3427 spaced along a length of the side wall. The protrusions 3227, 3427 are integrally formed with the inner member of the wall.

The base 360 of each container 300 includes recesses 3647 along its edge that cooperate with corresponding protrusions 3227, 3427 on an upper surface of the walls 320, 340 of another container 300. The recesses 3647 are integrally formed with an outer member 364 of the base. The engagement between the protrusions and the recesses of the containers allow the containers 300 to be stacked securely, for example during transportation.

The protrusions 3227, 3427 and recesses 300 are respectively spaced apart to allow the containers 300 to be securely stacked transversely to each other as shown in Figures 13A and 13B. In other variations, the container has protrusions and recesses that allow the for containers 300 to be stacked in-line with each other.

Other interengageable or cooperable engagement portions, besides the protusions and recesses described previously above, for securely stacking the containers are also possible.

Still referring to Figures 13A and 13B, each container 300 has a width-to-length ratio of about 2:3. For example, the width of the container may be within the range of about 350 mm to 400 mm, preferably about 385 mm and the length of the container may be within the range of about 520 mm to 560 mm, preferably about 544 mm. Thereby, the containers can be transversely stacked to suit a conventional pallet

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such that a bottom level of containers on the pallet can have six containers having a 2 by 3 container arrangement, and an upper level of containers stacked transversely on top of the bottom level can also have six containers having a 3 by 2 container arrangement, with the outer walls of the lower level of containers being substantially flush with the outer walls of the upper level of containers (as shown in Figure 13A).

While the above description refers to some embodiments of a collapsible container according to the present invention, it will be readily appreciated that other embodiments can be adopted by way of different combinations of features. Such embodiments fall within the spirit and scope of this invention.

Claims

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1. A collapsible container including

a base; and

2. The container of claim 1 wherein each respective wall of the one or more walls includes

a respective member of the plastic outer of the respective wall by which the insulation of the respective wall is at least partly enclosed; and

a respective formation integral to the respective member and engaged with the base to form a snap fit hinge by which the respective wall is pivotally attached to the base.

3. The container of claim 2, wherein the base includes a plurality of snap-fitting hooks, the respective formation of the respective wall having a rod that is engaged by a respective one of the snap-fitting hooks of the base to form the snap fit hinge.

4. The container of any one of claims 1 to 3 wherein each of the plastic outers is a respective integral body of plastic.

5. The container of any one of claims 1 to 4, wherein the one or more walls includes a plurality of walls, each wall having a respective pivot axis about which the wall is pivotable relative to the base, the pivot axis of each wall vertically offset from the pivot axis of each adjacent wall by a distance corresponding to a thickness of the adjacent wall to enable the walls to lay flat when the container is collapsed.

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6. The container of claim 5, wherein each of the walls has a thickness of between about 13 mm and 15 mm, and the pivot axis of one of the walls is vertically offset from the pivot axis of an adjacent wall by about 13mm to 15mm.

7. The container of any one of claims 1 to 6, wherein the plastic outer of at least one of the one or more walls includes a respective inner member and a respective outer member, the insulation sandwiched between the respective inner member and the respective outer member.

8. The container of claim 7, wherein the respective inner and outer members of the plastic outer releasably engage each other to trap the insulation therebetween.

9. The container of claim 8, wherein one of the respective inner or outer members includes one or more clips and the other one of the respective inner or outer members includes one or more slots that are each engageable by a respective one of the clips.

10. The container of claim 8, wherein the other one of the respective inner or outer members includes a rim for surrounding the insulation, the slots being provided at or near a base of the rim.

10. The container of any one of claims 1 to 9, wherein the one or more walls include two walls that are adjacent to each other, one of the two walls having a locking feature for engaging the other of the two walls to lock the walls in place relative to each other when the container is configured to contain an item.

11. The container of any one of claims 1 to 10, wherein the insulation includes at least one of polystyrene, expanded polystyrene (EPS), and polyurethane.

12. The container of claim 11, wherein each of the walls includes an insulation panel with the insulation, the insulation panel having a thickness of about 10 mm.

13. The container of any one of claims 1 to 12, wherein the base includes a base insulation and a plastic outer enclosing the base insulation.

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14. The container of any one of claims 1 to 13 further including a lid.

15. The container of claim 14 wherein the lid includes a lid insulation and a plastic outer enclosing the lid insulation.

16. The container of any one of claims 1 to 15, wherein the walls include one or more upper engagement portions and the base includes one or more lower engagement portions,

the upper engagement portion(s) of the container engageable with the lower engagement portion(s) of another container, or

the lower engagement portion(s) of the container engageable with the upper engagement portion(s) of another container

to securely stack the container and the other container.

17. The container claim 16, wherein the upper engagement portion(s) and lower engagement portion(s) are arranged to allow the container and the other container to be securely stacked transversely to each other.