AU752153B1 - A collapsible insulated freight container - Google Patents

Description

P/00/011 Regulation 3.2

AUSTRALIA

Patents Act 1990

ORIGINAL

COMPLETE SPECIFICATION STANDARD PATENT Invention Title: "A COLLAPSIBLE INSULATED FREIGHT CONTAINER" The following statement is a full description of this invention, including the best method of performing it known to us: "A COLLAPSIBLE INSULATED FREIGHT CONTAINER" THIS INVENTION relates to a collapsible insulated freight container and methods of assembly thereof.

BACKGROUND OF THE INVENTION The prior art is replete with collapsible freight containers, many of which suffer from a variety of problems. Amongst such problems are included the complexity of assembly of said containers, the poor structural strength of some of the collapsible freight containers and the requirement for additional linings when transporting perishable goods.

An example of a prior art collapsible freight container is US patent number 4,090,659, in the name of J. Galmicke and R. Blesco, which describes a container constructed from corrugated cardboard and involves an intricate interweaving and overlapping of end walls to provide some structural strength to the container. In US patent number 4,090,659 the box, when erected, may be attached to a standard wooden pallet. It may also be lined with a separate insulating material for transport of perishable goods.

The disadvantage of this construction is the time required in collapsing and/or erecting the container for return freight and/or re-use, not to mention the inconvenience of having to insert and remove insulation materials/layers.

US patent number 5,794,542, in the name of L. G. Vesaw, is directed to a light weight disposable or recyclable corrugated cardboard container.

The construction of this container involves the interlocking of four corrugated sheets to form the walls of the container, which in turn interlock into a pallet formed from corrugated plastic or cardboard. The pallet aspect of this container involves a number of layers to reinforce the feet or support areas of the pallet. The container described in US 5,794,542 whilst collapsible and described as multi-use in nature, is not suitable for the transport of perishable goods due to being constructed from paper and/or corrugated cardboard.

US patent number 4,760,922 in the name of R. D. Northgrave, is directed to a paperboard container formed from one sheet of paperboard wherein the side walls are identified through scoring of the paperboard, and the top and base of the container are formed through the interlocking of flaps cut out along the longitudinal edges of the paperboard. US 4,760,922 describes that the container may, when in a semi-erect state, be secured to a standard wooden pallet typically through stapling. The container of the type described in the US 4,760,922 is not suitable for the transport of perishable goods due to inherent lack of material strength of the paperboard used to construct the container. Furthermore, the container may become separated from the pallet during transport and result in the damage of goods contained therein.

The disadvantages of the prior art are such that they do not provide for use of forklifts or pallet jacks, which limits their use in transporting a variety of goods particularly perishable goods, they cannot be collapsed for return to the point of origin or do not provide sufficient insulation to allow for door-to-door transport of perishable goods.

OBJECT OF THE INVENTION It is an object of the present invention to provide a collapsible insulated freight container for transport of perishable goods which overcomes or ameliorates at least some of the problems associated with the prior art.

Further objects will become evident from the following description.

DISCLOSURE OF THE INVENTION In one form, although it need not be the only or indeed the broadest form, the invention resides in a collapsible insulated freight container for transport of perishable goods comprising; a base, having four perimeter walls, a perimeter recess in the base along the inside of each perimeter wall; two end walls and two side walls inserted in the perimeter recess of the base to form the walls of the container in an erect state, and to be placed horizontally within the perimeter walls of the base when in a collapsed state; and a lid engageably positioned either on.top of the end and side walls of the container when in an erect state, or the top of the perimeter walls of the base when in a collapsed state.

The collapsible insulated freight container may further comprise a seal in the perimeter recess of each perimeter wall. Another seal may be offset from the edge of the lid and located on the underside of the lid and/or located on an inner face of a flange, the flange extending substantially at right angles from the underside of the lid. Further seals may be located on the side walls or on the end walls at the abutments of the side walls and the end walls.

The container may also comprise an adjustable securing means for holding together the lid, side and end walls and base of the container in its erect state and in its collapsed state.

Each end wall may be connected to each side wall via an interlocking mechanism. The mechanism may comprise a peg attached to an end wall and a bracket attached to a side wall, or vice versa, at each abutment between the end and side walls.

The peg is preferably generally right angled in shape comprising a generally horizontal arm and a generally vertical peg.

The bracket may comprise a first aperture connected to a second aperture, the apertures being located on substantially perpendicular faces of the bracket. The apertures are preferably of different heights. Alternatively, the apertures may be the same height and offset with respect to each other.

The peg may be inserted into the first aperture and the vertical peg aligned with the second aperture to lock together the side and end walls.

Preferably the base, end walls, side walls and lid are constructed from an insulating material sandwiched between two outer layers. More preferably the insulating material is an insulating foam such as expanded polystyrene. Most preferably, the insulation material is polyurethane close cell refrigeration insulation foam.

Preferably, the outer layers are made of fibreglass. Alternatively, the outer layers may be made from a high impact plastic or sheet metal..

Extra strengthening may be used in the base, end walls and/or side walls, to prevent bowing.

Most preferably one or both of the end walls is bifurcated to allow ease of access to goods upon delivery. Along the bifurcation of the end wall(s), preferably one of the abutting edges comprises a seal.

Preferably the base is adapted to receive the forks of a forklift or pallet jack. Suitably the base may be adapted to receive the forks of a forklift by either having spaced integral feet or spaced hollow channel sections.

The integral feet of the base are most preferably formed from moulded, reinforced fibreglass outer layers comprising a high density foam insert. Alternatively, the integral feet may be formed from a moulded plastic, such as PVC. Suitably, the integral feet of the base are positioned to facilitate access by a forklift and allow the container to be lifted from either the end positions or side positions of the container. Most suitably, the integral feet of the base consist of four corner feet, two side supports, two end supports and a larger central support. The end supports and side supports may be located at the centre of each end and side respectively.

The spaced hollow channel sections are preferably located at the sides of the base and shaped and spaced so as to receive the forks of a forklift or pallet jack. Preferably the base having hollow channel sections is formed from an outer fibreglass casing having apertures in the sides to receive a forklift's forks; an internal frame having two tubular sections spaced to correspond with the forks of a forklift and two or more cross supports; and an inner floor. The inner floor is preferably shaped at its perimeter so as to form a perimeter recess along the perimeter of the walls of the base, when in use. The outer base and internal frame may have corresponding apertures through the underside of broad tubular sections adapted to receive the wheels of a pallet jack.

In another form, the invention resides in a method of erecting a collapsible insulated freight container comprising the steps of: inserting a first side wall into a perimeter recess of a base; inserting a first end wall into the perimeter recess of the base; connecting the first side and end walls together; inserting a second side wall and a second end wall into the perimeter recess of the base; connecting the second side and end walls together; connecting the first side wall and the second end wall together and connecting the first end wall and the second side wall together; and, placing a lid on top of the side and end walls.

BRIEF DETAILS OF THE DRAWINGS To assist in understanding the invention, preferred embodiments will now be described with reference to the following figures, in which: Fig 1 is a perspective view of an erected collapsible insulated freight container.

Fig 2 is a cross-sectional front view of the freight container of Fig 1.

Fig 2a is an end view of the freight container of Fig 1.

Fig 3a is a bottom view of the integral feet of the base.

Fig 3b is a side view of the base.

Fig 3c is an end view of the base.

Fig 3d is a perspective underside view of an alternative embodiment of the base.

Fig 3e is a schematic drawing showing a base formed from an outer shell, an internal frame and an inner floor.

Fig 3f is a schematic drawing showing underneath view of the internal frame of Fig 3e.

Fig 3g is a schematic drawing showing a cross-sectional view of the collapsible freight container having a base of Fig 3e.

Fig 4 is a truncated view of the freight container in a collapsed state.

Fig 5 is a perspective view of the interlocking mechanism for the end walls and side walls.

Fig 6 is a truncated cross-sectional view of the base, the perimeter wall and one integral foot.

DETAILED DESCRIPTION OF THE DRAWINGS In general, Fig 1 shows a freight container 1 in an erected state comprising a base 2, having integral feet supports 3, perimeter walls 4 and a perimeter recess 11(shown in Fig 2 and 4 in more detail) inside the perimeter walls 4 5, side walls 6 7, end walls 8 9 and a lid The side walls are generally 1 to 1.8 metres in height and 1 metres in length. The end walls are typically 1 to 1.8 metres square. It will be appreciated by a person skilled in the art that the size of the panels may be varied depending on the nature and volume of the goods to be transported. One or both of the end walls may be bifurcated to allow for access to goods, as shown in Fig 1 at the end wall 9. Any suitable means known in the art may be used to produce the hinging effect of the bifurcated end wall. Both the end and side walls are generally between 90 to 110 mm thick, but preferably they are 105 mm in thickness. The side and end walls may also be tapered for insertion in the perimeter recess of the base. The engagement of the side walls with the perimeter recess 11 is shown in Fig 2.

The base member 2 generally is 1 to 1.8 metres in width and 1 to metres in length. The perimeter walls 4 5 of the base 2 are approximately 220 mm in height. The integral feet 3 of the base 2 are approximately mm in height. The base 2 has an overall height of approximately 310 mm. It will be appreciated by a person skilled in the art that the dimensions of the base may vary depending on the size of the side and end walls, which may vary with the nature and volume of the goods to be transported.

As shown in Fig 6, the base 2 comprises a base section 17, integral feet 3 and perimeter walls 4 and 5. (Fig 6 shows one of the integral feet and one perimeter wall In the embodiments in which the base section 17, perimeter walls and integral feet 3 are composed of fibreglass outer layers, the base components are bonded together with resins and fibreglass such that the base 2 is effectively a single unit. The perimeter recess 11 of the base 2 includes a rubber seal 18 that is engaged by the side walls 6 and 7 and end walls 8 and 9 when the walls are inserted into the recess. The rubber seal ensures a seal between the base and the walls and minimises any change in temperature inside the insulated container. The seal helps prevent the ingress of moisture and the like. The seal 18 may be of the compressible foam rubber type or of any other suitable type known in the relevant art.

The lid member 10 is generally 1 to 1.8 metres in width and 1 to metres in length and approximately 41 mm in height. It will be appreciated by the person skilled in the art that the dimensions of the lid may vary with the dimensions of the side and end walls and the base. The lid may contain a flange 16 (shown in Fig 4) of resilient material, which may be offset from the edge of the lid and is suitable for engaging with the side and end walls, and the perimeter walls 4 5 of the base 2. The flange 16 (shown in detail in Fig 4) of the lid 10 may be made from the same material as the lid. In the case that the lid is formed from an insulating foam sandwiched between two outer layers, the flange 16 is formed from the same material as one of the outer layers.

For the same purpose as the seal 18 in the perimeter recess 11, the lid 10 also includes a rubber seal offset from the perimeter of the lid and adjacent the flange 16. With reference to Fig 4, the seal may lie parallel to and abut the underside 20 of the lid 10, extending from the flange 16 away from the edge of the lid. Alternatively, the seal may lie parallel to and abut an interior face of the flange 16, extending away from the underside of the lid A further alternative comprises the seal 19 abutting both the flange 16 and the underside of the lid 10, as shown in Fig 4. In each of the lid seal embodiments, the seal is located on the lid such that it is engaged by the walls to provide the aforementioned thermal and moisture seal when the container is erected.

The lid 10 is connected to the base 2 via an adjustable, tensioned webbing strap or adjustable securing means, shown as 30 in Fig 2a. Fig 2a shows an end view of the freight container, having an adjustable, tensioned webbing strap 30 fastened to the lid 10 and the base 2. The webbing strap can be placed under tension using a cam lock type arrangement, shown schematically as 31 in Fig 2a. Alternatively when the container is erected the webbing strap 30 may pass over the lid 10 and walls 6, 7, 8 and/or 9 and underneath the base 2. Thus, the lid, walls and base are securely held together. The webbing strap is an additional securing means for the container in addition to the perimeter recess 11 in the base and flange 16 of the lid, both of which contribute to maintaining the integrity of the container.

The webbing strap is shortened to securely hold together the base, walls and lid of the container in its collapsed state shown in Fig 4.

In the preferred embodiment, the lid, base, side and end walls are constructed from an insulating material sandwiched between two outer layers. Preferably the insulating material is a reinforced foam and most preferably is polyurethane close cell refrigeration insulation foam. The outer layers are preferably fibreglass, although they may be high impact plastic or sheet material. Strengthening may be used to prevent bowing of the lid, base and/or side walls.

The erection of the container 1 involves inserting a first side wall 6 into the perimeter recess 11 of the base 2, thus contacting the seal 18 therein. A first end wall 8 is then placed into the perimeter recess 11 of the base 2.

The side wall 6 and the end wall 8 are connected together by means of an interlocking mechanism 21 shown in Fig 5. Attached to the edge of the side wall 6, by any suitable means known in the art, is a generally right angled peg 22. Attached to the edge of the end wall 8, by any suitable means known in the art, is a bracket 23 comprising a socket 24 shaped to receive the peg 22. The socket 24 comprises a first aperture 25 on a face of the bracket that lies substantially perpendicular to the plane of the end wall 8.

The first aperture 25 is shaped and sized to permit ingress of the peg 22. On a face of the bracket 23 substantially parallel to the plane of the end wall 8, there is a second aperture 26, which is connected to the first aperture Aperture 26 is generally the same width as peg 22, but is of a height smaller than the peg 22. Alternatively, the apertures may be the same height and offset with respect to each other.

The peg 22 is inserted into the first aperture 25 and aligned generally with the second aperture 26. The generally horizontal arm 27 of the peg is then allowed to rest on the edge 28 of the second aperture 26, thus locking the side wall and end wall together. The side wall and end wall are disconnected by reversing the aforementioned connecting process.

The peg 22 and bracket 23 are comprised of any known material that is sufficiently strong to withstand multiple connections and disconnections of the side and end walls and that may be securely attached to the container wall material being utilised.

In the embodiment described, the peg 22 is attached to the edge of the side wall 6 and the bracket 23 is attached to the end wall 8. At the opposite edge of the side wall, there may be provided another peg.

Alternatively it may be a bracket. Similarly, the opposite edge of the end wall 8 may comprise either a peg or a bracket. Any combination of the described interlocking pegs and brackets are within the scope of the invention, providing that the end walls and the side walls may be connected together to form the walls of the insulated freight container.

The interlocking mechanism may be positioned at any location along the height of the side and end walls that affords secure connection between the side and end walls. A preferred location is generally around the midpoint of the overall height of the walls.

To maintain a thermal and moisture seal between the walls, rubber seals are employed. These may be of the same type used on the lid 10 and in the perimeter recess 11 of the base 2.

It is necessary to provide a seal where two walls abut. This is preferably achieved by attaching a seal in the form of a foam rubber strip, to the surface of each side wall where the end walls abut.

Alternatively, seals may be achieved by attaching a foam rubber strip or the like to the edge of the end walls that abut the side walls.

A seal is also provided along the edge of one of the abutting edges of the bifurcation of any bifurcated wall.

Once the first side wall 6 and first end wall 8 are in place and connected, the other side wall 7 and end wall 10 are placed into the perimeter recess of the base 2 and interlocked with the other walls in the same manner.

Perishable goods, to be transported, may be placed into the container whilst still under construction, such as when one or two of the walls are yet to be put in place. After placing the perishable goods into the container the lid is placed on top of the side and end walls 6-9 such that the edges of the side and end walls abut the seal 19 of the lid.

Fig 2 shows a cross sectional view of the container 1 in an erect state having a lid 10 with a flange 16, two side walls 6 7 engaged with the perimeter recess 11 of the base 2, which comprises perimeter walls 4 and integral feet 3. The flange 16 assists in locating the lid 10 on the walls 6- 9 and prevents any splaying of the walls.

Fig 3a shows a bottom view of the base 2 and an arrangement for the Sintegral feet 3, comprising four corner feet 12, two end supports 13, two side supports 14 and a central support 15. The integral feet are generally in height and are preferably formed from moulded reinforced fibreglass outer layers with a high density foam insert. Alternatively the integral feet 3 may be formed from a moulded plastic, such as PVC. Fig 3d shows an alternative configuration for the integral feet 3. In this embodiment each of the integral feet are substantially the same size. The number and configuration of the integral feet may be selected, for example, according to the size of the container and/or the weight of the contents. The integral feet 3 of the base 2, have a height and arrangement to facilitate access by a forklift and allow the container to be lifted from either the end or side positions of the container.

Fig 3b and Fig 3c are elevation views of the side and ends, respectively, of the base 2, with perimeter walls 4 5, corner feet 12 and a side support 14 and an end support 13, respectively.

Fig 3e is a schematic view of an alternative base comprising an outer base 32, an internal frame 33 and an inner floor 34, in its separate parts.

The outer base 32 is preferably formed from fibreglass and has two or four apertures 35, only two apertures are shown in Fig 3e, in the side walls for receiving the forks of a forklift or pallet jack. The internal frame 33 is preferably formed from a light alloy and constructed to have two broad tubular base sections 36 and two or more smaller cross members 37. The inner floor 34 is preferably formed from insulated foam sandwiched between outer fibreglass sheets. The perimeter of the inner floor 34 is preferably shaped to form a recess along the inside of the perimeter walls of the base.

Alternatively the inner floor 34 maybe formed to incorporate the smaller cross members 37 of the internal frame 33.

The outer base 32 may be moulded so that the inner surface of the floor is contoured in such a way that when the internal frame 33 is in place the inner contours of the floor of the outer base 32 are at approximately the same height as the two broad tubular base sections 36 of the internal frame 33.

Fig 3f shows a schematic under view of the internal frame. The internal frame 33 may be constructed of aluminium and formed from two broad tubular base sections 36 and three narrower cross members 37. The broad tubular base sections 36 may have apertures 38 located on the underside of the inner frame and towards the midway point of the tubular base sections 36. Preferably the apertures 38 are adapted to receive the wheels of a pallet jack. When an internal frame 33 having apertures 38 is in use the outer base 32 will have corresponding apertures to accommodate the wheels of the pallet jack.

Fig 3g shows a schematic cross section view of the freight container in a collapsed state. The base 2 is of the type having an outer base 32 having apertures 35 in the side walls of the outer base, and an inner floor 34. In Fig 3g the inner floor 34 is formed to incorporate the smaller cross section members of the internal frame 33. The lid 10 shows a flange 16 which engages with the outside of the perimeter walls 4 of the base 2, in a collapsed state or when the freight container is in an erect state the outside of the side and end walls 6-9.

The alternative base to the integral feet, as described in Fig 3e to 3g provides better weight distribution within the freight container when carrying heavy or extreme weights.

Fig 4 is a truncated cross-sectional view of the freight container in a collapsed position. To collapse the container, the lid 10 is removed from the erect container and set aside, before the side and end walls 6 9 are lifted from the base 2 and placed horizontally within the perimeter walls 4 5 of the base 2. (Only perimeter wall 4 is shown in Fig The lid 10 is placed on the top of the base 2 which contains the side and end walls 6-9. The resilient flange 16 of the lid 10 engages with the perimeter walls 4 5 of the base 2 to secure the lid in place for return transport. It will be appreciated that the resilient flange 16 may engage with the external surface of the perimeter walls 4 and 5, as shown in Fig 3g. That is to say the flange 16 may be external or internal relative to the perimeter walls 4 and 5 of the base 2. The aforementioned tensioned webbing strap is passed around the collapsed container and adjusted for a secure fit.

The freight container may be adapted to receive a net type harness with adaptation made to the base, side and end walls to secure and fasten the harness in place. The net type harness may be used in the transportation of easily bruised or damaged perishables, such as whole fish.

The metal base in Fig 3e may form the foundation for or be adapted to receive a collapsible frame for use in carrying products on different shelves or in harnesses attached thereto.

The freight containers' lid, side walls, end walls and/or base may be adapted to receive frames to carry dry ice or other ice packs to allow for continuous cooling of goods during transport.

It will be appreciated by the person skilled in the art that the freight container may be adapted depending on the nature and volume of goods being transported without departing from the essence of the invention.

The collapsable freight container of the invention allows for the safe and cost effective transport of all perishable goods, such as frozen products, fresh fruit and vegetables and meat products. The collapsible freight container is strong enough to withstand the strains of multiple use and overcomes the need for additional linings and or insulation as required in the prior art, for the transport of perishable goods. The light weight construction of the collapsible freight container and the fact that the container is collapsible reduces the transport costs, through reduced weight and volume.

The reinforced fibreglass construction of the invention contributes to the collapsible container being capable of carrying greater weights.

The integral base obviates the need for a separate pallet to be attached to the container and ensures safe transportation by, for example, fork lift.

The collapsible freight container permits the transportation of chilled and/or frozen products with minimal temperature rise of the products and without the need for mechanical refrigeration of the transport vehicle.

The preferred embodiment of fibreglass and foam construction allows the container of the invention to be used in situations where, for example, metal containers are unsuitable, such as with airfreight.

The fibreglass outer layers may be easily repaired using fibreglass and resins, prolonging the life of the containers.

Throughout the specification the aim has been to describe the preferred embodiment invention without limiting the invention to any one embodiment or a specific collection of features.

Claims (15)

1. A collapsible insulated freight container for transport of perishable goods comprising; a base, having four perimeter walls, a perimeter recess in the base along the inside of each perimeter wall characterised in that the inner surface of the perimeter walls forms a vertical wall of the perimeter recess; two end walls and two side walls inserted in the perimeter recess of the base to form the walls of the container in an erect state, and to be placed horizontally within the perimeter walls of the base when in a collapsed state; and a lid engageably positioned either on top of the end and side walls of the container when in an erect state, or the top of the perimeter walls of the base when in a collapsed state; wherein the side and end walls are interconnected via an interlocking mechanism comprising a peg attached to an end wall and a bracket attached to a side wall, or vice versa, at each abutment between the end and side walls..

2. The collapsible insulated freight container of claim 1, wherein the peg is right angled in shape comprising a horizontal arm and a vertical peg.

3. The collapsible insulated freight container of claim 1, wherein the bracket comprises a first aperture connected to a second aperture, the apertures being located on substantially perpendicular faces of the bracket.

4. The collapsible insulated freight container of claim 3, wherein the apertures are of different heights or the same height and offset with respect to each other.

The collapsible insulated freight container of claim 3, wherein the peg may be inserted into the first aperture and the vertical peg aligned with the second aperture to lock together the side and end walls.

6. The collapsible insulated freight container of claim 1, further comprising a seal in the perimeter recess of each perimeter wall.

7. The collapsible insulated freight container of claim 1, further comprising an additional seal, offset from the edge of the lid and located on the underside of the lid and/or located on an inner face of a flange, the flange extending substantially at right angles from the underside of the lid.

8. The collapsible insulated freight container of claim 1, further comprising seals located on the side walls or on the end walls at the abutments of the side walls and the end walls.

9. The collapsible insulated freight container of claim 1, further comprising an adjustable securing means for holding together the lid, side and end walls and base of the container in both its erect and collapsed state.

10. The collapsible insulated freight container of claim 1, wherein the base, end walls, side walls and lid are constructed from an insulating material sandwiched between two outer layers.

11. The collapsible insulated freight container of claim 10, wherein the insulating material is an insulating foam such as expanded polystyrene or polyurethane close cell refrigeration insulation foam.

12. The collapsible insulated freight container of claim 10, wherein the outer layers are made of fibreglass, a high impact plastic or sheet metal.

13. The collapsible insulated freight container of claim 1, wherein one or both of the end walls are bifurcated to allow ease of access to goods upon delivery.

14. The collapsible insulated freight container of claim 1 wherein the base is adapted to receive the forks of a forklift or pallet jack by having either spaced integral feet or spaced hollow channel sections.

15. A method of constructing the collapsible insulated freight container 6-'7of claim 1, comprising the steps of: inserting a first side wall into a perimeter recess of a base; inserting a first end wall into the perimeter recess of the base; connecting the first side and end walls together by interlocking the respective peg and bracket attachments; inserting a second side wall and a second end wall into the perimeter recess of the base; connecting the second side and end walls together by interlocking the respective peg and bracket attachments; connecting the first side wall and the second end wall together and connecting the first end wall and the second side wall together by interlocking the respective peg and bracket attachements; and, placing a lid on top of the side and end walls. DATED the Twelfth day of July 2002. TRANSKOOL INTERNATIONAL PTY LTD By its Patent Attorneys FISHER ADAMS KELLY