GB1601365A

GB1601365A - Container assemblies and collapsible pallet units for use therewith

Info

Publication number: GB1601365A
Application number: GB2466677A
Authority: GB
Original assignee: Lin Pac Corrugated Cases Ltd
Current assignee: DS Smith Packaging Ltd
Priority date: 1978-05-22
Filing date: 1978-05-22
Publication date: 1981-10-28

Description

(54) IMPROVEMENTS IN OR RELATING TO CONTAINER ASSEMBLIES AND TO COLLAPSIBLE PALLET UNITS FOR USE THEREWITH (71) We, LIN PAC CORRUGATED CASES LIMITED, of Charles Street, Louth, Lincolnshire LNl 1 OLA, a British company, do hereby declare the invention, for which we pray that a patent may be granted to us, and the method by which it is to be performed, to be particularly described in and by the following statement:- This invention relates to container assemblies, that is to say, container assemblies which incorporate a base pallet unit of the kind which allows the containers to be handled by means of fork-lift trucks. The invention is especially, but not exclusively, related to such assemblies which are supplied to a user in a substantially flat, collapsed form for subsequent erection and assembly.The invention also relates to a pallet unit per se, for co-operation with a container unit to form a collapsible palletised transportable container.

In accordance with one aspect of the invention, a container assembly comprises an upper container unit which is erectable from a collapsed condition and a pallet unit having, at its under side, at least two spaced supports which are collapsible into a substantially planar form, the container unit, when erected from the collapsed condition, being detachably securable to the upper side of the pallet unit, by means of outwardly-facing flaps adjacent at least one of two opposed pairs of sides of a base on the upper side of the pallet unit, the flaps being hingedly attached to the base and extending towards the adjacent sides.

In accordance with another aspect of this invention, a collapsible pallet unit is provided.

The container assembly or the pallet unit per se of one or other aspect of the invention, the pallet unit and the associated supports are collapsible into a substantially planar form.

In this way, not only are the supports themselves collapsible, but also the pallet unit itself is collapsible, so that the entire components constituting the unit can assume a substantially planar form.

Preferably, in accordance with another preferred feature of the invention, the container unit is collapsible into a substantially planar form, when detached from the base pallet unit. Desirably, three spaced supports are provided.

Preferably, the spaced supports are tubular when erected and rigid removable members are provided which, when inserted in the supports, maintain the latter in their erected tubular form, so that they cannot be collapsed until the rigid members have been removed.

Where three spaced supports are provided under the pallet unit, the two gaps defined between the supports can receive respective arms of the lifting mechanism of a fork-lift truck, in the spaces between a supporting surface, upon which the assembled container assembly rests, and the pallet unit. The supports, when erected into a tubular form, are preferably of square or, in general, rectangular cross-section, for receiving correspondingly cross-sectioned rigid members, which may advantageously be made of expanded polystyrene.

Most desirably, flaps are provided adjacent each of the two opposed pairs of sides of the base. These preferred embodiments of the pallet unit are most desirably constructed in accordance with a further and especially preferable and advantageous arrangement, in which the flaps comprise the edge portions of a rectangular sheet attached to and overlying the base, the flaps being defined between the free edges of the rectangular sheet and respective fold lines located inwardly from and parallel to such edges. Where as is preferred flaps are provided at all the four edges of the base, a most convenient arrangement is to form the latter from a true rectangle, whereby the fold lines defining one of the pairs of flaps intersect the fold lines defining the other of the pairs of flaps.This gives additional advantage, in that inward folding of the one opposed pair of flaps, for assembling the container and pallet units, so as to overlie the nearest parts of the fixed central rectangular region of the base, involves the corner regions as well; when the other opposed pair of flaps are then also folded inwards about the second pair of fold lines, the corner regions undergo reverse folding about the first pair of fold lines. If the other pair of flaps are then held in this inwardly folded position, they hold the first pair of flaps similarly and it is unnecessary to provide specifically for holding the latter pair of flaps, when preparing the container unit in this way for assembly with the pallet unit.

The container unit, which effectively forms a box or carton, preferably has upright walls with, at their lower ends, at least one opposed pair of flaps, whereby the pallet unit is removably attachable to the container unit by inter-engagement of the respective flaps. Those on the container unit can be positioned to project inwardly of the erected carton and so interengage by co-operating with a corresponding opposed pair of flaps on the upper side of the pallet unit, to connect the two together.

Advantageously, the pallet unit flaps are located at regions which are closer together than the free-inwardly-projecting edges of the container unit flaps and the pallet unit flaps also are slightly wider than the container unit flaps, so that the erected container unit can be received conveniently on the pallet unit, the container unit flaps being received between the pallet unit flaps and the pallet unit itself, by raising these flaps and lowering the erected container unit on to the upper face of the base; alternatively, it may be preferable to adopt a different assembly technique, for instance in which the erected container unit is inverted, so that the flaps are uppermost; the pallet unit flaps are then folded inwardly so that they and the central region of the base can be passed through the aperture defined by the free inward edges of the inturned container unit flaps; when the pallet unit flaps are then pivoted outwards to trap the container unit flaps between them and the base, the container unit (when turned base downwards, if necessary) is ready for receiving its contents, which then serve to hold the pallet unit flaps flat. In other words, the loaded container unit tends to remain in the erect condition with the container unit and the pallet unit firmly assembled into a single entity. Preferably, the pallet unit and the container unit are both rectangular and each has two opposed pairs of flaps. In the case of the pallet unit, where these flaps comprise the free edge regions of a rectangular sheet, the sheet itself is desirably slightly smaller than the base and is attached to the base over a smaller rectangular region.

In order that the invention may be more fully understood, a preferred embodiment thereof will now be described by way of example and with reference to the accompanying drawings, in which: Fig. 1 shows a container unit in flat blank form; Figs. 2 and 3 respectively show, in plan view, the base and the rectangular sheet with flaps of a pallet unit; Fig. 4 shows diagrammatically in perspective view the relationship between a collapsible base pallet unit support and a rigid member for holding the support in the erected condition, both being square or rectangular in cross-section; Figs. 5 and 6 show perspective views of the base unit, Fig. 5 showing it collapsed substantially flat, i.e. in planar form and Fig. 6 showing it erected, with the first pair of opposed flaps folded inwards and the second pair partly folded inwards;; Fig. 7 shows diagrammatically the container and pallet units being assembled; Fig. 8 shows the container assembly in partly broken-away view.

In the drawings, an upper container unit is formed from a container blank 1 (Fig. 1), which has fold lines or creases 2 extending longitudinally and fold lines or creases 3 extending transversely with respect thereto.

These creases 2, 3 divide the blank 1 into side wall portions 1 la and end wall portions 1 lib, with a terminal glue flap 1 lie on one of the side wall portions 1 la for attachment to the free edge of the farther end wall portion 1 ib.

The creases 2, 3 also permit the blank 1, when glued up and partly assembled, to be collapsed flat, by folding about each alternate transverse crease 3, and further to be erected into a rectangular container unit having top flaps 4a and bottom flaps 4b (Fig. 8). The bottom flaps 4b form respective pairs of opposed flaps which project inwardly from the lower ends of the walls lla, llh of the erected container unit as shown best in Fig. 8, the width of each flap 4b being represented by "x" (Fig. 1).

A base pallet unit, shown per se in Figs. 5 and 6, comprises a rectangular planar base 5 (Figs. 2, 5 and 6) which has secured thereto by adhesive, stitching or any other suitable means a rectangular sheet 6 (Figs. 3, 5 and 6).

The sheet 6 has fold lines or creases 7 extending longitudinally and transversely with respect thereto at regions located inwardly from its free edges, so that the central region of the sheet 6 constitutes a smaller rectangle. If adhesive is used to attach the sheet 6 to the base 5, it is applied over this smaller rectangle, while fixing by stitching or other means also is confined to the smaller rectangle, so that all the edges form free flaps 8. This construction allows the flaps 8 to pivot with respect to the base 5, the width of each flap 8 being repre sented by "y", which is dimensionally somewhat greater than "x".In the base pallet unit shown in Figs. 5 and 6 and also included in Figs. 7 and 8, the rectangular sheet is substantially coextensive with but smaller than the base and has a first pair of the flaps extending fully along an opposed pair of the edges of the sheet and a second pair of the flaps extending along the other opposed pair of the edges between the fold lines defining the first pair.

On the other side of the base 5 to the sheet 6, i.e. the under side, three collapsible tubular supports 9 are secured which are substantially square in cross-section and which are made so as to receive rigid, expanded polystyrene blocks of corresponding cross-section (Figs. 4 and 5). An assembled container illustrated thus comprises a container unit in the form of a sub-assembled blank 1, a base pallet unit as shown in Fig. 5 and 3 of the blocks 10; as delivered to the user, the blank 1 and the pallet unit would normally be collapsed substantially flat.

On assembly of the container, the container blank 1 (which as stated would normally be already part-assembled into a flattenable tube, by having the glue or stitch flap 1 attached to the opposite wall portion 1 lib) is erected and opened out, with the two opposed pairs of flaps 4b projecting inwardly with respect to the erected container unit. The flaps 8 on the sheet 6 are pivoted upwardly so as to allow the unit to be placed on the base 5.

This is most conveniently done as shown in Figs. 6 and 7, by folding one opposed pair of the flaps 8 inwardly and then folding the other pair upwardly, with the corner regions as well (Fig. 6) and then inwardly (Fig. 7). In this way, when all the flaps 8 are pivoted outwardly, the flaps 4b of the container unit are received and held between the flaps 8 and the base 5 (Fig. 8). The collapsed supports 9 are then erected and the expanded polystyrene blocks 10 are inserted therein; the pallet unit can alternatively have the supports 9 erected first, the container unit being located in place secondly. A suitable lining, e.g. a plastics bag of the same nominal inner shape as the container, may be used to hold the contents, if desired.Thus, when the articles, to be transported in the container, are placed in the erected container unit e.g. by filling the plastics bag, the bottom flaps 4b of the container unit are clamped between the sheet flaps 8 and the base 5. This provides reinforcement and strengthening of the container.

The blank 1 is preferably made from cardboard, as also are the supports 9 and the sheet 6. The base 5 is preferably made from a more rigid material, for example plywood or hardboard, but, if necessary, it may also be made from cardboard.

Thus the invention provides a transportable container assembly of two-part construction which may be supplied in a substantially flat and collapsed form, for ease of packaging and transportation, and which is made from comparatively cheap and easy-to-handle materials.

WHAT WE CLAIM IS 1. A container assembly comprising an upper container unit which is erectable from a collapsed condition and a pallet unit having, at its under side, at least two spaced supports which are collapsible into a substantially planar form, the container unit, when erected from the collapsed condition, being detachably securable to the upper side of the pallet unit, by means of outwardly-facing flaps adjacent at least one of two opposed pairs of sides of a base on the upper side of the pallet unit, the flaps being hingedly attached to the base and extending towards the adjacent sides.

2. An assembly according to claim 1, in which the upper container unit, when detached from the upper side of the pallet unit and collapsed, is in a substantially planar form.

3. An assembly according to claim 1 or 2, in which the pallet unit has three spaced supports defining gaps therebetween, 4. An assembly according to claim 1, 2 or 3 in which the supports are tubular, when erected, and are maintained in the erected form by rigid removable members inserted therein.

5. An assembly according to claim 4, in which the erected tubular supports are of square or rectangular cross-section.

6. An assembly according to claim 4 or 5, in which the rigid members are made of expanded polystyrene.

7. An assembly according to any preceding claim, in which the base of the pallet unit has flaps adjacent each of two opposed pairs of sides.

8. An assembly according to any preceding claim, in which the flaps comprise the edge portions of a rectangular sheet attached to and overlying the pallet unit, the flaps being defined between the free edges of the rectangular sheet and respective fold lines located inwardly from and parallel to such edges.

9. An assembly according to claim 7 or claim 8, when dependent upon claim 7, in which fold lines defining one of the pairs of flaps intersect fold lines defining the other of the pair of flaps.

10. An assembly according to any preceding claim, in which the container unit has upright walls and at least one opposed pair of flaps at their lower ends, whereby the pallet unit is detachably connectable to the container unit by interengagement with respective flaps of the pallet unit.

11. An assembly according to claim 10, in

**WARNING** end of DESC field may overlap start of CLMS **.

Claims

**WARNING** start of CLMS field may overlap end of DESC **. sented by "y", which is dimensionally somewhat greater than "x". In the base pallet unit shown in Figs. 5 and 6 and also included in Figs. 7 and 8, the rectangular sheet is substantially coextensive with but smaller than the base and has a first pair of the flaps extending fully along an opposed pair of the edges of the sheet and a second pair of the flaps extending along the other opposed pair of the edges between the fold lines defining the first pair. On the other side of the base 5 to the sheet 6, i.e. the under side, three collapsible tubular supports 9 are secured which are substantially square in cross-section and which are made so as to receive rigid, expanded polystyrene blocks of corresponding cross-section (Figs. 4 and 5). An assembled container illustrated thus comprises a container unit in the form of a sub-assembled blank 1, a base pallet unit as shown in Fig. 5 and 3 of the blocks 10; as delivered to the user, the blank 1 and the pallet unit would normally be collapsed substantially flat. On assembly of the container, the container blank 1 (which as stated would normally be already part-assembled into a flattenable tube, by having the glue or stitch flap 1 attached to the opposite wall portion 1 lib) is erected and opened out, with the two opposed pairs of flaps 4b projecting inwardly with respect to the erected container unit. The flaps 8 on the sheet 6 are pivoted upwardly so as to allow the unit to be placed on the base 5. This is most conveniently done as shown in Figs. 6 and 7, by folding one opposed pair of the flaps 8 inwardly and then folding the other pair upwardly, with the corner regions as well (Fig. 6) and then inwardly (Fig. 7). In this way, when all the flaps 8 are pivoted outwardly, the flaps 4b of the container unit are received and held between the flaps 8 and the base 5 (Fig. 8). The collapsed supports 9 are then erected and the expanded polystyrene blocks 10 are inserted therein; the pallet unit can alternatively have the supports 9 erected first, the container unit being located in place secondly. A suitable lining, e.g. a plastics bag of the same nominal inner shape as the container, may be used to hold the contents, if desired.Thus, when the articles, to be transported in the container, are placed in the erected container unit e.g. by filling the plastics bag, the bottom flaps 4b of the container unit are clamped between the sheet flaps 8 and the base 5. This provides reinforcement and strengthening of the container. The blank 1 is preferably made from cardboard, as also are the supports 9 and the sheet 6. The base 5 is preferably made from a more rigid material, for example plywood or hardboard, but, if necessary, it may also be made from cardboard. Thus the invention provides a transportable container assembly of two-part construction which may be supplied in a substantially flat and collapsed form, for ease of packaging and transportation, and which is made from comparatively cheap and easy-to-handle materials. WHAT WE CLAIM IS

1. A container assembly comprising an upper container unit which is erectable from a collapsed condition and a pallet unit having, at its under side, at least two spaced supports which are collapsible into a substantially planar form, the container unit, when erected from the collapsed condition, being detachably securable to the upper side of the pallet unit, by means of outwardly-facing flaps adjacent at least one of two opposed pairs of sides of a base on the upper side of the pallet unit, the flaps being hingedly attached to the base and extending towards the adjacent sides.

3. An assembly according to claim 1 or 2, in which the pallet unit has three spaced supports defining gaps therebetween,

4. An assembly according to claim 1, 2 or 3 in which the supports are tubular, when erected, and are maintained in the erected form by rigid removable members inserted therein.

11. An assembly according to claim 10, in

which the container unit has flaps at the upper ends of the walls for forming a closure.

12. A collapsible pallet unit as defined in any of claims 1 and 3 to 9.

13. A pallet unit as defined in any of claims 7 to 9, in which the pallet unit base is rectangular and comprises a sheet overlying the upper side of the pallet unit and attached thereto in surface to surface relationship over a smaller rectangular area.

14. A pallet unit according to claim 13, in which the rectangular sheet is substantially co-extensive with but smaller than the upper side of the pallet unit and has a first pair of the flaps extending fully along an opposed pair of edges of the sheet and a second pair of the flaps extending along the other opposed pair of the edges between the fold lines defining the first pair.

15. A container assembly according to claim 1, substantially as herein described with reference to the accompanying drawings.

16. A pallet unit according to claim 12, substantially as described with reference to Figs. 2 to 6 of the accompanying drawings.