GB2247004A

GB2247004A - Collapsible container assembly

Info

Publication number: GB2247004A
Application number: GB9110390A
Authority: GB
Inventors: Terrence James Healey
Original assignee: Amcor Pty Ltd
Current assignee: Amcor Pty Ltd
Priority date: 1990-07-26
Filing date: 1991-05-14
Publication date: 1992-02-19
Also published as: GB9110390D0

Abstract

A collapsible container assembly includes a base, two opposed wall panels (21), 22 and a rear wall panel 24. Each said opposed wall panel (21), 22 has two diagonal fold lines, one said diagonal fold line 31 extending from a perimeter fold line and terminating adjacent an upper corner of the one panel, the other said diagonal fold line 32 extending from a spaced location on the perimeter fold line to a location at an upper edge of the panel spaced from an opposed upper corner of the panel by a distance corresponding to the distance between that said corner of the panel and the perimeter fold line. The fold lines 31, 32 facilitate collapsing of the container. <IMAGE>

Description

COLLAPSIBLE CONTAINER ASSEMBLY.

THIS INVENTION relates to an improved container assembly. In particular, the invention concerns a collapsible bulk shipping container assembly which is disposable after use.

Collapsible containers have previously been suggested. Such containers generally fall into two categories. Representative of one category is United States patent specification 3,443,737 which relates to a collapsible reusable bulk shipping container particularly suitable for air freight use and having a pallet, a collapsible wall element permanently secured along one edge to the pallet and having other edges securable to the pallet. A separate lid was provided which formed a storage element for the pallet and wall element when the container is in the collapsed condition.

The container of Patent 3,443,737 requires erection of the wall element and then'attachment of the unsecured edges thereof to the pallet and this additional operation is time consuming and tedious.

A second category of container is shown in United States patent specifications 4,252,266 and 4,405,077. In Patent 4,252,266 a collapsible shipping container with an integral base element is shown. The container had four side walls and a lid. Each side wall had a single fold line extending diagonally from a lower to an upper corner. Such containers, because they were intended for shipping bulk goods, were of a substantial size. With a container of such a size and having two pairs of opposed side walls, it was only possible to top load them and this was not always desirable or convenient.

Patent 4,405,077 also shows a collapsible bulk shipping container with opposed pairs of walls. Each wall of one pair of walls had a diagonal fold line extending from a lower corner to a top corner. Both walls of the other pair of walls had a fold line commencing at a lower left hand corner and extending to a point on an upper edge spaced a short distance from the diagonally opposite corner. One wall of the other pair had an additional fold line extending from where the other fold line terminated at the upper edge and extending to the right hand lower corner. With such a configuration not only were there four walls (and hence the need for top loading) but the resultant container was by necessity of square shape when viewed in plan. Such a square transverse shape was not an optimum shape for aircraft cargo holds where rectangular container footprints made optimum use of cargo space.

Australian Design Registration 109139 by the present applicant discloses a collapsible bulk shipping container assembly which has a rectangular base tray normally securable to a pallet, a collapsible wall element which when erected extended around three sides of the base tray, a rectangular lid, a front panel member and a perimeter frame. Two of the wall panels comprising the collapsible wall element had diagonal fold lines commencing part way up side edges of the panels and converging at a location midway along an upper edge of the panel. With such a configuration side loading was possible but when collapsed the container had a height corresponding to the combined height of the base tray, the lid and the pallet. This meant that only a limited relatively small number of collapsed containers could be shipped as one truck load from the container manufacturer to the end user.

It is-an object of the present invention to provide an improved container assembly which at least minimises the disadvantages referred to above.

According to an aspect of the invention there is provided a collapsible container assembly movable from a collapsed state to an erected state, the assembly including a base, a perimeter wall forming three wall panels extending around three sides of the base, two said panels forming opposed wall panels and the third panel forming a rear wall panel, a fold line extending along the perimeter wall and adjacent the base, one said opposed wall panel having two diagonal fold lines, one said diagonal fold line extending from the perimeter fold line and terminating adjacent an upper corner of the one panel, the other said diagonal fold line extending from a spaced location on the perimeter fold line and a location at an upper edge of the panel spaced from an opposed upper corner of the panel by a distance corresponding to the distance between that said corner of the panel and the perimeter fold line, the other said opposed panel having two diagonal fold lines each extending from spaced locations on the perimeter fold line and a location at the upper edge of the panel spaced from opposed upper corners of the panel by a distance corresponding to the distance between the corner and the perimeter fold line, the rear panel having a diagonal fold line extending from the perimeter fold line and a location at the upper edge of the panel and spaced from an upper corner of the rear panel by a distance corresponding to the distance between the corner and the perimeter fold line.

The base may be provided as a separate component to the perimeter wall and in the assembly of the invention the base may be secured to the perimeter wall. Fasteners or an adhesive or a combination of both of these may be used. The base may comprise a tray. The tray may be provided by a slotted container formed from a blank of foldable material.

The tray typically may have a base panel, two pair of opposed side wall panels and each panel of one pair of wall panels may have joinder flaps extending from opposed ends thereof. Fold or crease lines may separate the wall panels from the base panel.

The perimeter wall may be made from a unitary blank.

However, if the assembly is intended for use as a bulk shipping container, it is preferred that the perimeter wall be made of at least two separate blank portions securable to one another.

The perimeter fold line, as mentioned, is adjacent the base. Where the base is provided by a tray the perimeter fold line is located immediately adjacent the upper edge of the tray wall panels. With the diagonal fold lines mentioned the perimeter wall can be collapsed right down to the upper edge of the tray wall panels and in this way the assembly in its collapsed state has a minimal height.

The perimeter wall portions may be such that one portion provides one opposed perimeter wall panel and the rear panel while the other portion provides the other opposed perimeter wall panel. While all perimeter wall panels are of the same height the opposed perimeter wall panels may have a width greater than the width of the rear wall panel. In this way a rectangular prismatic container assembly is provided.

The perimeter wall preferably has joinder panels hinged to a lower edge thereof by a fold line. These joinder panels may overlie the base and be secured to it as previously mentioned.

Since the container assembly has three walls, the fourth wall is open and provides a loading aperture through which the contents may be introduced. It is preferred that the perimeter wall have opposed narrow wall panels which partially extend across and reduce the width of the loading aperture. The narrow wall panels may be provided by one or more extension panels hinged to edges of the perimeter wall.

Where the perimeter wall is made up of two portions the extension panel(s) may be hinged to edges of those portions.

The container assembly may include a sleeve. In use, the sleeve locates inside the assembly and immediately adjacent the interior faces of the perimeter wall panels. The sleeve assists in retaining the assembly in its erected state.

Preferably the sleeve has three panels which overlie the opposed perimeter wall panels and the rear panel. In one embodiment the sleeve has narrow sleeve panels which overlie the narrow wall panels of the perimeter wall.

The sleeve may be made of a single blank of foldable material. Alternatively, the sleeve may be made from a plurality of sleeve portions secured to one another.

The container assembly may include a cover sheet for closing off the loading aperture after the assembly has been filled. The cover sheet may have a width equal to or approximating the loading aperture. Preferably, where there are narrow wall panels, the cover sheet overlaps the narrow panels to some degree. It is preferred that the cover sheet have a height less than the height of the opposed perimeter wall panels such that for storage purposes when the assembly is collapsed it may be stored in the base of the assembly.

The assembly preferably includes a lid. The lid may be formed from a blank of foldable material - preferably the lid is provided as a separate component to the perimeter wall.

The lid may comprise a tray. The tray may be provided by a slotted container formed from a blank of foldable material.

The lid tray may typically have opposed side wall panels and a lid panel. Each side wall panel of one pair may have joinder flaps extending from opposed ends thereof. It is preferred that the lid be of a size such that when the assembly is in its collapsed state the lid fits over the base tray.

Preferably the height of the side wall panels of the lid is equal to or less than the height of the side wall panels of the base tray. The lid panel of the lid may have an inspection opening provided by an inspection flap.

The assembly may include a brace which extends around the erected container assembly to resist outward bulging of the perimeter wall and cover sheet. It is preferred that the brace consist of a band made of a plurality of connectable brace members. Where the assembly is of rectangular prismatic shape, the members consist of two long members and two short members. In use the band extends around the assembly approximately half way up the height of the perimeter wall panels. When the container assembly is collapsed, the band members may be stored in the base tray.

A particular preferred embodiment of the invention will be described with reference to the drawings in which: Figure 1 is a perspective view of the container according to an embodiment shown in its collapsed state; Figure 2 is a perspective view of the container shown in its erected state; Figure 3 is an elevational side view of the container of Figure 2; Figure 4 is an elevational rear view of the container of Figure 2; and Figures 5 to 8 show the container in various progressive stages of erection.

Figure 1 shows a container 10 in its collapsed state. The container would normally be mounted to a pallet 11 (see Figure 2). The lid 12 has a lid panel 12a and two opposed pairs 13, 14 of side wall panels (one of each panel of a pair is visible). Each panel 13 has opposed joinder flaps 15. Lid panel 12a has an inspection flap 16 with a gripping block 17 secured to it. The lid is of a size such that it normally fits over the base 20 (see Figure 2).

Figure 2 shows the container 10 in its erected state. The container has opposed wall panels 21, 22 (only one of which is visible in the Figure), a cover sheet 23 of a width less than the width of the container, and a rear wall panel 24 (not visible in this Figure). Panel 21 has two diagonal fold lines 26, 27.

The base 20 is in the form of a tray and has a base panel (not visible) which forms the floor of the container 10 and opposed pairs 28, 29 of side panels (only one panel of each pair is visible). Each panel 28 has opposed pairs of joinder flaps 30.

Figure 3 shows side wall panel 22 which is opposed to panel 21 (see Figure 2). Panel 22 has fold lines 31, 32.

A brace 33 extends midway around the container to resist bulging of the walls when the container is full. Brace 33 comprises two pairs of opposed connectable brace members 34, 35.

In Figure 4 the rear wall panel 24 is visible. This panel has a fold line 40 which extends diagonally across the panel and terminates short of an upper corner of the panel.

The distance from the upper end of fold line 40 to the right hand corner is equal to the height of that corner above the upper edge of the base.

Figures 5 to 8 show various stages in the erection of the container assembly. Initially the assembly appears as shown in Figure 1 with the cover sheet 23, sleeve 45 and brace members 34, 35 inside the base 20 and with the wall panels which make up a perimeter wall folded over the base. The lid 12 is in place and extends over the base 20.

The lid is removed and side wall panel 21 is stood up. Fold lines 26, 27 extend from a perimeter fold line 41 which extends along all the wall panels 21, 22, 24 adjacent the upper edge of the base 20. Fold lines 26, 27 terminate from an opposed corner of panel 21 by a distance equal to the height of the panel above an upper edge of the base.

Once wall 21 is up it is possible to stand up rear wall 24 and side wall. Walls 21, 22 have short wall portions 42, 43 of multiple thickness which extend part way across a loading aperture 44. Fold line 32 terminates at the upper edge of the panel 22 spaced from an upper corner by a distance equal to the height of that corner above the free edge of the base 20.

To ensure that the side and rear walls retain the configuration of Figure 7 a sleeve 45 is placed inside the container assembly and extends from edge 46 to edge 47 and overlies the inside surface of the wall panels. The sleeve has fold lines 48, 49, 50 and 51 which enable the sleeve to be folded flat for storage against base panel 52.

Brace members 34, 35 are coupled together and placed to extend arourid the assembly. After the assembly has been filled cover sheet 23 is placed to overlie portions 42, 43 and extend between those portions and side wall panel 28 of the base. The sheet 23 may be of a height less than the height of the assembly such that it may also be stored flat against the base panel 52 when not in use. The lid 12 can be placed over the wall panels 21, 22, 24 to complete the assembly as shown in Figure 2. As shown in Figure 8 a fold line 53 extends along the wall panels. This line serves as a line along which the wall panels may be cut to shorten the overall height of the assembly if this is desired. A similar fold line 54 extends around the sleeve 45.

All diagonal fold lines extend from line 41 to an upper edge of an associated wall panel. In this way the wall panels may be collapsed down to line 41 to present an-assembly of minimal height for transport of a supply of collapsed container assemblies to an end user. Thus the shipment on a truck may include a greater number of assemblies than what would otherwise be the case had the collapsed container assemblies not collapsed to such a height. Loading aperture 44 enables side rather than top loading. By having the diagonal fold line configuration as described a rectangular container assembly is possible.

To load the assembly, the assembly first appears as in Figure 8 but without the brace. The assembly is loaded up to a predetermined height and then the brace is positioned to prevent bulging of the wall panels. Loading is then completed, cover sheet 23 is positioned and the lid 12 put in place.

After the container has been unloaded it may be collapsed and disposed of.

Claims

1. A collapsible container assembly movable from a collapsed state to an erected state, the assembly including a base, a perimeter wall forming three wall panels extending around three sides of the base, two said panels forming opposed wall panels and the third panel forming a rear wall panel, a fold line extending along the perimeter wall and adjacent the base, one said opposed wall panel having two diagonal fold lines, one said diagonal fold line extending from the perimeter fold line and terminating adjacent an upper corner of the one panel, the other said diagonal fold line extending from a spaced location on the perimeter fold line and a location at an upper edge of the panel spaced from an opposed upper corner of the panel by a distance corresponding to the distance between that said corner of the panel and the perimeter fold line, the other said opposed panel having two diagonal fold lines each extending from spaced locations on the perimeter fold line and a location at the upper edge of the panel spaced from opposed corners of the panel by a distance corresponding to the distance between the corner and the perimeter fold line, the rear panel having a diagonal fold line extending from the perimeter fold line and a location at the upper edge of the panel and spaced from an upper corner of the rear panel by a distance corresponding to the distance between the corner and the perimeter fold line.

2. The assembly of Claim 1 wherein the base is provided as a separate component to the perimeter wall.

3. The assembly of Claim 1 or 2 wherein the base comprises a tray having a base panel and two pairs of opposed side wall panels.

4. The assembly of any one of Claims 1 to 3 wherein the base is made from a blank of foldable material.

5. The assembly of any one of Claims 1 to 4 wherein the perimeter wall comprises two separate blank portions secured to one another.

6. The assembly of any one ofiClaims 1 to 5 wherein the perimeter fold line is located immediately adjacent an upper edge of the base.

7. The assembly of Claim 5 wherein one said perimeter wall portion provides one of said opposed perimeter wall panels and the rear panel and the other perimeter wall portion provides the other of said opposed perimeter wall panels.

8. The assembly of any one of Claims 1 to 7 wherein said opposed perimeter wall panels have a width greater than the width of the rear wall panel.

9. The assembly of any one of Claims 1 to 8 wherein said perimeter wall has joinder panels hinged to a lower edge thereof by a fold line, said joinder panels overlie and are secured to the base.

10. The assembly of any one of Claims 1 to 9 including a loading aperture opposed to said rear wall.

11. The assembly of Claim 10 wherein said loading aperture is defined in part by opposed narrow wall panels depending from free edges of the perimeter wall.

12. The assembly of any one of Claims 1 to 10 including a sleeve locatable inside the perimeter wall and immediately adjacent an interior face of the perimeter wall.

13. The assembly of Claim 11 including a sleeve locatable inside the perimeter wall and immediately adjacent the perimeter wall panels and the narrow wall panels.

14. The assembly of Claim 12 or 13 wherein the sleeve comprises a plurality of 'sleeve portions secured to one another.

15. The assembly of Claim 10 or 11 including a cover sheet for closing off the loading aperture.

16. The assembly of Claim 15 wherein the cover sheet has a height less than the height of the opposed perimeter wall panels.

17. The assembly of any one of Claims 1 to 16 including a lid.

18. The assembly of Claim 17 wherein the lid is made of foldable material and has a lid panel and opposed pairs of side wall panels.

19. The assembly of Claim 18 wherein said lid panel has an inspection opening closable by an inspection flap.

20. The assembly of any one of Claims 1 to 19 including a brace extending around the perimeter wall for resisting outward bulging of the perimeter wall.

21. A collapsible container assembly substantially as herein described with reference to the drawings.

22. Any novel feature or combination of features described herein.