CA2136554C - Collapsible container - Google Patents

Abstract

A collapsible container for use in the shipping of goods is formed from a single sheet (10) of a plastic material to form a box. The container has a bottom panel (12) and first (14) and second (16) pairs of like wall panels integrally hingedly connected to the bottom panels so that the walls can be erected from a collapsed position to an upright position and vice versa. The end pan els include hinged locking flaps (f) formed with locking ribs to releasably enga ge with the adjacent edges of the side panels. The container is adapted to nest in superposed relationship with a like container wh en the containers are in a collapsed condition so that the height of a stack of collapsed containers is minimized.

Description

t. ~ 93/243 78 2 1 3 6 S 5 4 pcr/ us 93/04862 ., ~ COLLAPSIBLE CONTAINER

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v This invention relates to a collapsible container and particularly, although not exclusively, a container for the . shipping of perishable goods such as fish. A container according s 5 to this invention is formed from a single moulding of a plastics ., material such as polyethylene to form a box or transport case which comprises a bottom panel and first and second pairs of like wall panels hingedly connected to the bottom panel. A lid or cover may be provided preferably as a separate item to close the i 10 open top of the box. Contalners according to the in~ention may also be stacked one upon the other o that it is often unnecessa~y to provide a lid for each container.

Non-collapsible cases with insulating properties for shipping ~ish and formed from expanded or foamed polystyrene are known but these known cases are not returnable and have become regarded by ~irtue of their composition, as being environmentally unacceptable.

Such containers do ha~e the advantage of low co~tO A
collap~ible, returnable and reusable co~t iner is desirable for the shippi~g of fresh (chilled~ or frozen fi~h. A unitary knockdown foamed polystyre~e shipping container is know from US-A-3 675 808 but i~ not robust enough for repeated return (round~
trip~ journeys. Moreover, the fo~med material, at least to some extent, absorbs fluids and would on this count alone be - 25 unsuitabl~ as a reusable fi~h box. US-A-4 235 346 discloses a ~ 1 t W093/~4378 ~ i 3 6 S ~ ~ PCT/US93/~48 lightweight collapsible shipping container having a unitary moulded construction in which a bottom panel is integrally hinged to fcur peripheral side panels and a top panel is hinged to one of the side panels. However, this container is also intended to be formed from a foamed plastics material and is unsuitable for use as a reusable fish box for the reasons given above.

Collapsible contai~rs having ~ more robust and acceptable compo~ition are known from e.g. US-A-4 O~S 7g5 which discloses a container formed from a unitary blank of polypropylene in which side panels are integrally hinged to a bottom panel. There are provisions to lock together with side and end panels when they are brought into an upright position comprising stud and socke~
connections. ~owever, the particular arrangement disclosed is insufficiently se~ure in view of the anticipated static and impact loading imposed upon a container according to the present i~vention utilized as a shipping cont~;ner for fish. US-A-3 675 808 discloses a collap~ible ~ox in which the side and e~d panels are ~cur~d together by me~n~ o~ a do~etail type tongue and recess.

~he present invention ~eek~ to achieve a robust but relatively low cost collapsible, returnable and reusable shipping container which for return shipme~t, can be put into ne~ted superpo~ed relationship with like eontainer8 / when collapsed 60 that the height and space occupied by a ~tack of collapsed containexs is mlnlmi2ed.

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.,. ~93/24378 PCT/US93/04862 The present invention provides a collapsible container for use in the shipping of goods, including perishable goods, a~d ~ comprises a single moulding of a plastics material to form an !~ open-topped box which comprises a bottom panel and first and second pairs of like wall panels hingedly connected to said bottom panel and wherein each wall panel and said bottom panel are integrally hinged together so that the walls can be erectéd ~rom a collapsed position to an upright position and vice versa, wherein complementary locking me ns are provided at adjacent .'10 ed~es of ~aid ~irst and second pairs of wall panels so that said side and end panels are mutually lockable, wh~n the corners of the container ar~ formed by putting the wall panQls into an upright attitude, wherein said container is adaptRd to nest in superpo~ed relationship with respect to another liks container when said containers are in collap~ed condition so that the height ~f a stack of collap ed containers is m; n; ml zed.

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Accordi~g to a ~eatuxe of the invention, said panels may include features which protrude beyo~ the me~;~l planes of ~aid pan~ls, t' ,,i said features bein~ formed and positioned so as to permit nesting of superposed containers.

A~Gording to a~other feature of the invention, said locking means may comprise a ret~;~ing ~ace pro~ided by the panels of one pair f panels engagable with a ret~;n;ng ~ace provided by the panel~
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of the other pair of panel8 to prevent collaps~ of said wall panels.
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~. 3 W093/2437~ PCT~;S93/0486' According to yet another feature of the invention, the retaininq ~; face of a panel of one pair of panels may be mutually engaged with the retaining face of a panel of the other pair of panels when the corners of the container are formed and locked thereby to prevent collapse of the containers.

According to another feature of the invention the retainlng face of said one panel may be provided by a rib adjacent an end face of that panel. In constructlons where ~ rib is provided, the rib may be received in a channel provided by the said other panel, one fac~ of the ~hannel providing the retaining face of the other ' panel to prevent collapse of the one panel. Preferably, a releasable locking face is hinged to said other panel for engagement with the ret~ ng face of said one panel to prevent ~' collapse of the other panel. Pre~erably, the locking face is carried by a locking flap hinged to said other panel which locking flap is integral with other panel and f QrmS a part of said ret~; n; ng ~hAn~el fac~ when locked.
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~According to yet another feature of the invention, said locking face may co~prise a rib extending perpendicularly from said locking flap.

., , Accordi~g to a further feature of ~e invention, said locking rib and said one panel may comprise rel~as~ble com~lementary fastening means~ Preferably, said complementary fastening means are a push-snap fit. Moreover, it is also preferred that said fastening m~s comprise complementary notches and pegs formed ;

~ 213~5~
'093/~378 PCT/US93/0~62 along the mating adjacent vertical edges of said first and second pairs of wall panels and which are hinged into engagement when ~ the 1ocking ~1ap ls engaged after said wall panels are put into ; their fully upright positions to form said box.
i, ,~ S According to a still further feature of the invention, a secondary retaining face may be provided within the channel of said other panel to engage an end edge of said one panel within said channel.
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According to yet another feature of the invention, ~aid wall 10 panels may be formed with integral handling recesses adjacent their uppermost ends.
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According to a further feature of the invention the underface of said bottom panel of one container may be formed with locating means adapted to engage complementary locking means formed upon ~n uppermost r~m of a~other like container, said complementary .~, locating m~ans being engagable to ~n~ce secur~ st~ki n~ of those cont~ rsO
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According to yet a~other feature of the invention, the ( .... .
~- complementary locating ~e~ns formed upon said uppermost rLm may 0 be adapt~d to engage locating means provided on the underside of a lid so that the lid can be ~~cured to close said co~tainer and wherein the upwardly expo~ed face of said lid also inclndes lo¢ating ~Q~n~ adapt~d to be engaged ~y the said locating mea~s provided on the underface of the bottom panel of another like ~ !
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~, i~' WO ~3~24378 2 1 3 6 5 ~ ~ PCr/US93/04862 ~' container thereby to enhance secure s~ac~ing of those containers.
~' ,;, i~ According to a still further feature of the invention, s~id '! .
integral hinges between each wall panel and said bottom pan~l may be continuous along the length oi the respective wall panel.
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, According to yet another feature of the invention, said containér '~ may be substantially sized to fit a standard European pallet ~! measuring 1.2 x a . 8m for return shipment when said container is in a collapsed substantially flat condition.

According to another aspect o~ the invention, there is provided a collapsi~le container for u~e in the shipping of goods which compxi~es a single mounding of a plastics material to form an open-topped box which comprises a ~ottom panel and first and ~ . , .
6econd pairs of like wall panels hingedly connected to ~aid bottom panel and wherein each wall panel and said bottom panel ,;'.
and first and ~econd pairs of like wall panels hingedly connected ~i; to said bottom panel and wher~in each wall panel and said bottom ,, .
~;. panel are integrally hinged together so that the walls can be ~' erected from a collap~ed position to an upright position and vice .
ver~a, wherein complementaxy locking means are provided a~
~: 20 adjacent edges of said first and second pairs of wall panels so that ~aid side and end panels are mutually lockable~ when the ~; eor~er~ of the contai~er are formed by putting the wall panels into an upright attitude, ~aid locking means compri3es a ~; ret~;n;ng face pro~ided by the panels of one pair of panels 2S engagable with a ret~; n i ng face provided by the panels of the .~, i.',:
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~ ,r. ' ~ i '093/2~37~i 2 1 3 6 ~ 5 4 PCT/US93/04862 ~ other pair of panels to prevent collapse of said wall panels, '' wherein the retaining face o~ said one panel is provided by a rib . adjacent an end face of that panel and wher~in a r~leasable ': locking ~ace is hinged to said other panel ~or engagement with the retaining faoe of said one panel, said locking face being ~arried by a locking flap hinged to said other panel and forming a part of the ret~' ni ~g face of said other panel when locked.

A collapsible container suitable for use as a ~ish box according . to the invention, will now be described~ by way of example, with ; 10 reference to the accom~anying drawings, in which:-. ~
FIGURE 1 is a plan view of a unitary blank of moulded plastic materiai compri~ing a base panel and four integrally hinged wall -i' ~:. panels from which the hox can be iormed, three of the wall panels being partly rai~ed;
, ~, ~ FI~UR~ 2 is a perspective view of an erected open-topped ;~ .
~'~ con~; n~r ~ormed from the blank shown in Figure l;
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'';? FIGURE 3 iR a per~pectiv~ view of an erected open-topped . ~
., CO~ A i n~r ~ormed from the blank shown in Figure 1 and al~o comprising a f itted lid;

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20 FIGUR~i 4 is a per~pective view of the co~t~i n~r showing the urld~irside of the ba~e panel;

-FIGURE S is an end view showing the end wall panel along an edge .
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-~ W093~24378 PCT/~!S93/04862 .:
~.~ with the locking flap in coplanar relationshlp with respect to '~; the end wall panel;
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'~ FIGU~E 6 is an end elevational view of a par~ially-erected open-.
topped container formed ~rom the blank shown in Figure 1, as viewed from an end of the container that has its end wall pivoted downward, further illustrating the elements shown in Figure 5;

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FIGURE 7 is the same end elevational view of a partially-erected open-topped container as is illustrated in Figure 6 but wherein ~,' the bla~k of Figure 1 possesses additional elements; and , ','' 1' Xyi10 FIGURE 8 is a perspective view of an open topped container formed .~ from the blank ~hown in Figure 7 ..";
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~ Referring first to Figur~ 1, there is ~hown a unitary blank lO
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;' of moulded suitable plastic material comprising a rectangular . .
bottom panel 12 to the peripheral edges of which are hing -d first !~',, 15 and second pairs~ 14, 14a and 16, 16a re~pectively, of like wall panels Side wall panel~ 14, 14a are hinged to the oppo~ed ,.. 1 ' .' longitudinal peripheral edg~ of bottom panel 12 along integral ~ . ~
;';! continuous hi~ges 18, 18a so that the wall pan21s can be erected ~",, ~, from the collapsed'position, in which they are substantially co-. ,~

2 0 planar ' with the bot~om panel ~ until they are upst;l n~ i ng ~ubstantially ~ormal ~o the bottom panel, and vice Yer~a.
~i Likewise, end wall pa~ 16 l 16a are hinged to the oppo~ed t~ansverse peripheral edges of bottom panel 12 aloIlg inteyral hinges 2 0, 2 Oa .

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'093/2437~ 2 1 3 6 ~ S 4 PCT/US93/04862 Hinges 18, 18a and 20, 20a, sometimes referred to as "living hinges,'~ comprise integrally moulded continuous strips of plastics materlal which are moulded together with the panels of the bla~k and are slgnificantly thinner and hence more flexible S than the wall thickness elsewhere in the blank. Although such continuous hinge strlps will u~ually be formed from the material injected during the moulding process to form the panels of the hlank, other hinge constructions are envisaged.

Reference is now made to Figures 2 to 5 . In order to mairltain '10 the wall panels upright to form the open topped eontainer the side wall panels are loc~ed to the end wall panels. To this e~d, the opposed vertical edges of the end wall panels are each provided with a locking flap "f" which engages the external face of a side wall and is locked to it in a snap-fit. Further, the vertical internal ~ace of the end wall adjacent each end edge is formed with a channel "C,ll the outermost wall 22 of which provides a ret~;n;ng face to prevent collapsing movement of the ~ide walls~ e.g. side wall 14 is fur~ished, adjacent it8 end edge, with an integral perpendicular flange or rib 24. When the end edge o~ ~ide wall 14 is rec~ived in the channel "C", which occ~rs only whe~ the cor~er of the contA;n~r is properly fonmed by erecting the wall panels, rib 24 abuts the inter~al ~ace 25 of ch~n~el wall 22 (~igur~ 5)O ~his abutment retains the ide wall panel in its upright attitude and prevent~ it from collap~e.
Likewis~ rib 24 provide~ a retA;n;~g ace to prevent ollapse of end wall 16. However, in order to effe~tively engage rib 24 the locking flap "f" must be engaged~ The arrangement at each end w~ g3,24378 2 1 3 ;~ S 5 4 PCT/US93/0~62 of the box is sLmilar and therefore only one corner construction is described, it being understood that the descriptions of the other corner constructions follow. Locking flap "f" is ; integrally hinged to the end edge of the end wall and includes a perpendicular locking rib 26. When the locking flap "f" is engaged it is folded into face contacting relationship with the external. face of side wall panel 14. In so doing, the portion , ., "fl" of the flap between channel wall 22 and locking rib 26 forms a part of the channel wall 22 and the locking rib 26 engages ,10 behind the rib 24. Thus, the mutual engagement between the ribs .,:;
' 24 and flap l-fl- prevent collapse of the end wall panel 16 4 ~ ' .
In order to achieve a positive fastening between the locking flap "f" and the side wall panel 14~ the side wall is ~ormed with a .~ pair of spaced pegs 28 locatad behind rib 24. Pegs 28 locate as 1~ a "snap-fit" into spaced notches 3V formed in the locking ri~ 26.

A secondary locking rib 32 is formed within ch~nnel "C'l agai~st ~ which the extreme end face 33 of the side wall pan~l engages and '~ thereby gives better locking ~ecurity and a more po~itive engagement of ~he wall panel edges when the corner of the container is being formed.

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~. i In order to facilitate h~n~l ing of the box, the end walls are ';' ~orm~d, adjacent their top ends with an inwardly projectlng ,; recess 34 whi~h ~ot only increases the vertica~ compre~sion ,. ~trength and the rigidity of the end wall but provides a h~n~le feature for the end walls of the box. SImilar handle recesses ~ i ' ,i 1 0 ~' ;,, i , ... .

:,~,'j ~ -'093/~78 2 1 ~ 6 5 ~ ~ PCT/US93/04862 ,. . .
~,~ 36, 38 re~pectively, are formed in each of the side walls of the . .
container, ~ach recess 36 and 38 belng separated by horizontal ;, 40 and vertical 42 ribbing of the ex~ernal face of the wall which improves the stiffness and stacking strength of the longer side ~'.; 5 wall panels.
. ., Each of the wall panels includes an inwardly directed ~op flange 44, 44a and 46, 46at respecti~ely, which together form a rai~ed ~'~ upper rim R of the container'when the wall panels are in their ~i~ erected positions-i~;
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.~10 Top lid "L" ~Figure 3~ has a peripheral complementary chAnn~l ~' (not shown) which can be ~nap-fitted onto the raised rim R of the cont~ r. Around the edges on the top faoa o~ the lid "L"
'~ is formed a series of upst~;ng lips 4~ and 48a and the '~ underside of bottom panel 12 is formed, adjacent its periphery, ;r,'.;,'~ 15 with a peripheral ~h~nn~l 50 (Figure 4~ so that the lip 9f the .;~; .
}id "L" of a~ upper cont~; ner can be located in the channel 50 of a lower conta~ nçr to facilitate locking and enh~n~e stac~ing 6tability. Mor~over, since the rai~ed rLm R around the top panel walls is vertically aligned with the channel S0 of a base, boxes 2~ can be ~tacked by e~gagement of the rLm and channel o~e upon the ~ ~ex~ in the ab6e~ce of lids ~o that only the top box of a stack t ' I need be~ e~. The lid "L" also include~ two pairs of transverse lips 52l 52a which ar~ received in a relieved s~ction 54 o~ ~he bot~om panel of another like container. Lips 48, 52 and 48a, 52a ~o that each of those above groups engage~: and half ~~ the bottom panel of a container stacked tra~ersely thQreon.

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Referring now to ~i~ure 6, the alignment of ~ome of the interlockable elements of the contalner shown in Figure 6 and previou~ illustrations, is further lllustrated in this end view , of a partially-erected container. In Figure 6, one end wall 16a and the two side walls have been ~rected. The container is viewed from an open end wherein the end wall 16 is pivoted downward. The manner in which the channel ~C~' formed at each end . of the end wall 16 is aligned to receive the elements formed at the ends of the side walls 14, 14a is illustrated. When the end wall 16 is pivoted upward into adjolning relationship with the I end~ of the side walls ~4, 14a, the innermost wall of each ,ij channel "C" receives the extreme face 33 of a respective side ;'t wali 14, 14a~ At the same tLme, the internal face 25 of the outermost wall 22 of each channel "C" receives and abuts the edge of the perpendicular flange or rib 24 of each respective side .:
wall 14/ 14a. Also upon joining of the end 16 and side walls 14, 14a, the secondary rib 32 within each channel "C" is brought into abutting relation~hip with the outex surface of the perpendicular flange or rib 24 of each re pective sid~ wall 14, 14a.

~! 20 Referring now to Figure 7, which i~ the same end elevational view ~'~ of a partially-erected conta1~er as i~ illustrated in Figure 6, ?
and, sImultaneously, also referring to Figure 8, additional ~ j elements of the container are illustrated. Proper alignment of ? the joining eleme~ts of the ~nd wall 16 and side walls 14, 14a 'j 25 is promoted by ~e~n~ of a tab-lik~ m~her 56 protruding from each channel "C" and a ~orre~ponding co~plementary notch 58, formed in each respective perpendicular flange or rib 24, for receiving ..
r 1 2 r ~' ,, 213655 " 093/24378 PCT/US93/0~62 the tab member 56. A tab member 56 and corresponding complementary notch 58 are ~ormed and aligned to engage one another when the ends of end walls 14, 14a and side walls 16, 16a are brought into contact with one another. The tab member 56 is tapered, or bevelled, so that its narrowed leading end can easily ~ engage the correspending complementary notch 58. As the end wall ';' 16, 16a is pressed against the side walls 14, 14a, each tab 56 ~;' is forc~d through a corresponding comple~entary notch 58 until the ~lared, or wider, portlon of the tab member 56 extends into the ~omplementary notch 58. It is the forcing of the flared tab member 56 through the complementary notch 58 which bri~gs the edge of an end wall 14, 14a into deslred alignment with the edge of a side wall 16, 16a~
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.ii An additional feature which is illustrated in Figures 7 and 8 i8 a modification of the perpendicular locking rib 26 of each flap "~." Each perpendicular loc~ing rib 26 may be ~;fied to faailitate eng~gement of each notch 30 in a locking rib 26 with a c~rresponding peg 28 (not visible in Figure~ 7 and 8 but 3 previously discus~ed above). To alleviate any difficulty that might occur in engaging a notch 30 and corxesponding peg 28 due to alignment variances caused ~uring manufacture or eo~tinued use of the container, a secondary notch 60 is placed in the locki~g ~,; rib 26 near ~a~h notch 30 to form a ~e~ondary peg 62. The econdary peg 62 that is ~ormed is flexible due to the notches 30, 60 on either gide. The flexibllity of th~ ~e~ondary peg 62 ~I help~ alleviate po~sible difficulty in s~apping the peg~ 28 i~to ,' the notches 30 which may be caused by ~light misali~m~t of the .

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':' W093/24378 213 6 5 ~ 4 PCT/US93/0486?
i', pegs 28 and re~pective notches 30. The use of the secondary peg ~ . 62 in the locking rib 26 greatly reduces or el;m;~tes the '; rigidity and inflexibility of the locking rib 26 when optimum alignment between the pegs 28 and respective notches 30 does not orcur.

'. ~he panels of the blank are configured so that a stack of blanks can be formed with the blanks disposed in superposed nested r~lationship~ For instance~ moulded ~eatures of each panel are all contained with a common plane on either side of a medial ~: 10 plane of that panelO Also certain features are adapted to nest ; in other like features such as the handle recesses of the wall panels. When the box is collapsed, it is sized to be received upon a st~n~rd European sized pallet mea~uring 1.2 x 0.8m for return shipment and refilling. For an outward journey, a pallet will receive thr~e containers in each stacked tier of containers~

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Claims (5)

C L A I M S

1. A collapsible shipping container for use in the shipping, handling and storing of goods, or in the shipping, handling or storing of goods, formed from a single molding of plastics material comprising:
a bottom wall having opposed side and end edges disposed adjacent each other, side wall panels hinged to said side edges of said bottom wall and end wall panels hinged to said end edges of said bottom wall so that said side and end wall panels can be erected from a collapsed position to an upright position, and means for locking said side and end wall panels together in said upright position, said locking means including channel means extending along end edges of said end wall panels and arranged to receive adjacent end portions of said side wall panels, and flap means hinged to and extending from said end wall panels and folded into overlapping relationship with adjacent end portions of said side wall panels and having means for engaging said end portions of said side wall panels within said channel means whereby said side and end wall panels are mutually supported and maintained in erected position, and wherein said end portions of said side wall panels include at least one outwardly extending rib which is received in said channel means, and said flap means includes a locking rib arranged to engage said outwardly extending rib formed along said adjacent end portion of said side wall panel when said side and end walls are erected.

2. The collapsible container according to claim 1 wherein said channel means is defined by a channel wall extending along the end edges of said end wall panels and wherein said flap means forms at least a part of said channel wall.

3. The collapsible container according to claim 1 wherein said locking rib and said end portion of said adjacent side wall panel comprises complementary fastening means.

4. The collapsible container according to claim 1 wherein cooperating alignment means are provided to facilitate erecting said side and end wall panels, said alignment means comprising a tab member extending into channel means associated with said end walls at the lower portion thereof and a complementary notch in the outwardly extending rib associated with the end portions of said side walls.

5. A blank for a collapsible container formed from a single molding of plastics material and comprising a bottom wall, side and end wall panels hinged to said bottom wall so that said wall panels can be erected from a collapsed to an upright position, and complementary locking means provided at adjacent end portions of said side and end wall panels for securing said wall panels in upright position, said blank being adapted to be stacked onto like blanks for shipment and storage, characterized in that said wall panels include formations which project beyond the interior surfaces of said wall panels and corresponding recesses are provided on the exterior surfaces of said wall panels and arranged to receive said projecting formations of a like blank positioned below and that at least certain of said formations provide handle means when said side and end walls are in upright position.