GB2303620A - Returnable transport container - Google Patents

Abstract

A returnable transport container, especially for the transportation of food stuffs, comprises at least one plastics folding component (1), and a separate lid (2) and base (3). The folding component (1) has deep-drawn, double-layer walls (4-6) of which the layers form cavities.

Description

Returnable transport container This invention relates to a returnable transport container, especially for the transporting of food stuffs, consisting of at least one plastics folding component, especially comprising a separate lid and separate base.

Returnable transport containers of this type are known, for instance, by the name Boxer-Pax. These involve versatile storage and distribution systems for bulk materials or goods or articles intended for assembly.

Systems of this type comprise a lid and base and folding or collapsible component, preferably of plastics. The folding component is situated between lid and base. The folding of the folding component is so designed that the folding component can be folded down for empty transportation and enclosed in space-saving folded form between lid and base.

To fill the container, the lid and base are separated and the folding component is opened out and placed on the base, so that a container results which can be filled from the top. After filling, the container can again be closed with the lid. The folding component possesses six hinge locations for a concertina-like folding. The folding component is most commonly made from corrugated cardboard or corrugated boxing.

After being emptied, the container is again collapsed and ready for a new transportation operation.

When corrugated cardboard is used, only about three transportation Journeys can be acheived, especially in the transporation of food stuffs.

The corrugated cardboard very easily becomes dirty and is then scarcely suitable for the transportation of foods.

The known containers comprise, in one form of construction, a folding component of plastics material. In any form of construction, the carrying capacity of the folding component is very limited. The limit is a nominal load of about 500 kg for containers with external dimensions of 1.2 x 1 x 1 m.

The objective of the present invention is to create a folding component of plastics material having a very much higher load-bearing capacity and thus to extend considerably the range of use of the containers. This is achieved, according to this invention, with the help of deep-drawn walls for the plastics component of double-layer construction with hollow chambers between the layers. By the double-layer construction and the similtaneous forming of hollow chambers between the layers, a much higher strength of the folding component is achieved with the same use of plastisc material. For example the strength can be doubled with a comparable amount of plastis material.

The double-layer construction combined with formation of cavities is achieved in that at least one shell body, preferably two shells are produced from the two plastics layers. It is advantageous here to provide the one or both shell bodies or the one layer or both layers with spacing webs. The thus formed shell bodies are glued, preferably welded, to one another at the edge.

With advantage, in the case of two shell bodies, both are produced simultaneously and pressed against each other in the soft state, so that a connection is made at the contact positions which is termed pressure welding (pressure sealing), because a connection is produced by the pressure without the contact surfaces having been melted. For the production of a shell body a mould is used. Vith the simultaneous production of two shells, two moulds are disposed preferably one above the other. For each mould a foil or plate of plastics material is used and deep-drawn to form the shell body. Immediately after shaping, the pressing together of the shell bodies takes place. Advantageously, this manner of shaping can simultaneously be used for moulding handling holes and/or handling depressions into the shells.The same is true for other openings in order, for example, to make a connection to the lid and/or base of the container.

Advantageously, the openings can also be formed later by machining. As a machining operation for forming openings, milling is particularly suitable.

For the plastics folding component, the hinges for folding and opening out are also of particular importance.

According to the invention, the following alternative hinge systems may be used: - hinges with pins or - hinge bar or - hinge kink.

Hinges with pins provide, in one simple form of construction, that the folding components to be articulated together possess pin openings, into which a separate pin can be pushed. The pin openings can very advantageously be produced by means of deep-drawn, double-walled workpieces. This is done by the mould possessing, in the region of the pin openings, a corresponding pocket or depression. The plastics material enters this depression or pocket due to the deep-drawing and forms a cavity for the pin. It is favourable if each layer forms one half-cavity for the pin. When the two components are joined together, the whole cavity for the pin is then produced. Optionally, instead of separate pins, pins may be formed on individual walls, which engage into corresponding openings of the other walls.

Hinge kinks according to the invention are produced by recesses or tapers of the material. V-shaped grooves are particularly favourable. At the grooves the bending resistance of the plastics is low, so that the plastics easily deforms. The V-shaped grooves preferably enclose a right angle. The right angle contributes to a quite considerable extent to stabilizing the folding component, because in this way a pivoting angle of 90 on closing the groove cannot be exceeded.

Optionally, the hinge may also be formed by a hinge bar, around which the walls fit like a fork or which is fixed directly to the wall or to flanges of the wall. The hinge bar has the advantage that a different plastics material may be used for the hinge bar, especially a relatively resilient material, whereas the stiffest possible material is used for the walls.

The hinge bars form a hinge by possessing, as in the case of a hinge kink, a preferably V-shaped groove with a cross-sectional angle of 90 formed by tapering or recessing.

Optionally, the folding component according to the invention is provided with a viewing window and/or a pocket and/or a flap.

The viewing window is produced, like the openings, by integrally moulding and/or machining. The resultant opening is closed with a transparent plastics. The transparent plastics can be glued or pushed in. Pushingin requires suitable guides, which can be especially easily formed by the double-layer nature of the material for the folding component. One or two layers are, for this purpose, provided spaced apart in the region of the guides. Then an opening can be milled out, which is then closed by pushing-in the transparent plastics.

The pockets according to the invention are optionally produced similarly to the viewing windows, utilizing the double-layer construction, by providing a spacing between the two layers in the region of the pockets.

As a difference from the production of the viewing windows, only the outer layer is then cut through, for example, with a milling cutter, so that transportation documents or the like can be pushed into the opened cavity.

For the flap arrangement according to the invention also, the doublelayer construction is a great advantage. The double-layer construction can then be utilized for forming an attachment profile at the edge of the folding component intended for the flap. As attachment profile, a profile having the shape of an arrow head in cross-section is especially suitable and this can be gripped and engaged by the intended hinges or hinge bars. In this way the hinges or hinge bars can be simply pressed onto the connecting profiles.

Such connecting profiles are also advantageous at the already described hinges of the folding component.

For the flap according to the invention, in each relevant wall of the folding component a flap opening is cut out. According to the invention, the cut-out edge portion is used also as flap. In this way waste is avoided and the use of new material for the flap is dispensed with.

The joint produced between the flap and the other part of the wall by the cutting-out is closed in the region of the intended hinge connection between flap and wall by the hinges or hinge bars according to the invention. At the sides of the flaps, a profile can be pushed onto the edge of the wall, which closes the gap and at the same time contributes to arresting the flap in that it encompasses the edge of the flap with a rear and front or inner and outer strip. The rear or inner strip forms the boundary of the flap travel and prevents the flap from being pressed inwards. The front or outer strip/arm has small dimensions and can therefore be easily released by hand with the force available.

Various examples of embodiment of the invention are illustrated in the accompanying drawings, in which: Figure 1 illustrates a first example of a container with the component in its partially folded configuration; Figure 2 illustrates the component being opened out; Figure 3 illustrates the component when erected; Figures 4 and 5 illustrate the individual walls of the component shown in Figures 1 to 3; Figure 6 is a partial cross-section through one of the walls of the folding component; Figure 7 is a partial view from above and one side of adjacent walls and a hinge of a folding component in a second example; Figure 8 is a plan of the part shown in Figure 7; Figures 9 and 10 are views similar to Figures 7 and 8 but of a third example; Figures 11 and 12 are views similar to Figures 7 and 8 but of a fourth example;; Figures 13 and 14 are views similar to Figures 7 and 8 but of a fifth example; Figure 15 illustrates the folding component of a sixth example; Figure 16 illustrates the component shown in Figure 15 when fully opened; Figure 17 illustrates part of a starting product for producing one of the walls shown in Figures 15 and 16; and, Figure 18 is a section taken along the line A in Figure 17.

Fig. 1 shows a returnable container in a space-saving configuration.

The returnable container possesses a base 3, a lid 2 and a folding component 1. According to figure 2, the folding component consists of wisps 4,5 and 6. Itch of the walls is Fnwirkr;l as a ctii li. 2n parts 4 possess gripping openings 9, and the parts 6 gripping openings 13.

For setting up the returnable container and after loosening the lid 2 from the base 3 and pulling out the folding component 1, the walls 4 are pulled apart in the direction of the arrow 10 until the walls 4 reach the lines 11, illustrated in broken line. In this form, the walls 5 and 6 stand perpendicularly to the walls 4.

Figures 4 and 5 show individual views of the walls 4, 5 and 6.

Figure 6 shows further details of the walls. All the walls consist of double-layer plastics. The boundary surface between the two layers is shown in dot-and-dash line and is referenced 15. The individual layers 16 and 17 are deep-drawn and, immediately after the deep-drawing, are pressed against each other at the edges and at all webs in a still pressure-weldable state, so that a pressure welding is created there.

Consequently, the two layers 16 and 17 enclose air chambers 18, 19 and 20. This formation of chambers provides, together with the multi-layer construction, a very stiff form of construction of the walls.

Figures 7 and 8 show a further embodiment comprising a single-piece folding component 1, the plastics facing of which is referenced 25 and 26. This folding component possesses hinge kinks which are formed by a V-shaped groove 28. The V-shaped groove 28 is milled out in this example. The remaining web of material is sufficiently thin for the parts on either side of the kink hinge easily to move relative to each other. The faces of the V-shaped groove 28 make a right angle, so that the components connected together by the hinge kink can pivot exactly through a right angle1 closing the V-shaped groove 28.

The boundary surface between the two material layers 25 and 26 is referenced 27. Figures 9 and 10 show a further embodiment having a hinge between the walls of the folding component 1, which is formed by hubs and a hinge pin 36. The walls again consist of two material layers 30 and 31, 32 and 33 respectively. The material layers 30 and 31 form a hub 34 and 35 with a pin opening. The walls 32 and 33 form a correspondingly shaped hub, so that the hubs can be brought into an aligned arrangement and the walls allowed to pivot during folding.

The boundary surface between the two material layers 30 and 31, 32 and 33, is referenced 38.

Figures 11 and 12 show a further embodiment of a special hinge between two walls. The walls are here formed by material layers 40 and 41, 42 and 43 respectively, the boundary surface having the reference 44.

According to figures 11 and 12, the hinge is formed by a hinged bar 45, which possesses a V-shaped groove 46 having the same function as the Vshaped groove 28 of figures 7 and 8. The hinge bar 45 is screwed to the walls. The screws are schematically illustrated by centre-lines 47 and 48. Whereas the walls are of relatively stiff plastics, a flexible material, also of plastics, is used for the hinge bar 45. With advantage, the walls possess recesses in the region of the hinge bar 45, into which the hinge bar 45 is recessed. The corresponding wall parts form flanges.

Figures 13 and 14 show also walls having a hinge formed of a hinge bar.

The hinge bar is here referenced 55, and its V-shaped groove is referenced 56. As a difference from figures 11 and 12, the hinge bar 55, however, has the walls fitting around it in the manner of forks. The material layers of the walls are referenced 50 and 51, 53 and 54 respectively, and the boundary surface 52. In this embodiment also according to figures 13 and 14, screws are provided. The screws are illustrated schematically as in figures 11 and 12 and referenced 57 and 58.

Figure 15 shows a further returnable container having a folding component of walls 104, 105 and 106. Each of the walls is of double construction.

The walls 104 possess handle openings, the walls 106 and 105 viewing windows 113. The viewing windows 113 are located at top and bottom. The viewing windows are produced by corresponding openings being milled into the walls 105 and 106 and transparent plastics being introduced into the openings and engaged there.

The wall 104 furthermore has a flap 116. The flap can be opened out forwards. The details are shown in figure 16 together with a lid 107.

Figure 16 shows the flap 116 in the opened state.

Furthermore, figure 16 shows a pocket 114 in the wall 106. The pocket 114 is produced by the two layers of the double-layer wall 106 having a spacing of some millimetres from one another in the region of the pocket 114 and the outer layer being sufficiently milled away for a U-shaped guide rail 115 to remain, into which freight documents or the like can be introduced. The format of the pocket 114 is, in this example, DIN A4.

Figure 17 shows a starting product for the production of the wall 104 and the flap 116. This starting product is a 2-layer product. The multilayer construction is clearly seen in various sections, which are explained below.

From the component shown in figure 17, the two layers have been brought into the desired form by deep-drawing and then, in the still warm state, pressed against each other so that the deep-drawn components could weld to each other.

The front deep-drawn component, seen in elevation according to fig. 17, comprises various raised zones, which become clear at the contour lines 125 and 127. For example, the contour line 125 shows that a depression 126 is present. An opening for lid/base connections will later be milled into the recess 126.

In addition, various raised zones 128, 135 and 136 are provided, which can be seen from the contour line 127.

After the two deep-drawn components have been connected together, a part 120 is milled out of the product, which later forms the flap 116. The milling cutter in doing this travels along the line 121 and 122. The vertical cut produces profile edges 124 and 136. The profile edges 124 and 136 are shown schematically in figure 17 at the corresponding position. This illustration contains a departure from known forms of illustration. Figure 18 contains an enlargement of this sectional view.

Here it can be seen that the profile edge 124 is enclosed by a clamping bar 130. The clamping bar 130 extends over the entire vertical length of the profile edge 124. It fits around, with arms 131 and 132, the profile edge 124. At the opposite end, the clamping bar possesses two arms 133 and 134. The arm 133 serves as abutment for the flap 116, by forming an inward limit to the movement of the flap. The arm 134 also forms an arresting device, in that its length and its nature are so chosen that the flap 116 can be pressed past the arm 134 into the space between the two arms and locked there, or can be pulled out again from the space.

At the horizontal run of the parting lines 121 and 122, edge profiles also are produced. The edge profiles can be seen from the contour 129 of the two deep-drawn parts. This contour in turn contains an approximate sectional view, as described above at the clamping strip.

Both the edge profiles are the same as the edge profile 124. Therefore the lower edge profile is also referenced 124. The upper, equivalent edge profile bears the reference 123.

Onto the two horizontal edge profiles 123 and 124, a film hinge is clamped, which consists of profiles 140 and 142, which are connected together by a hinge 141. The hinge 141 is formed by a flexible strip material.

The profiles 140 and 142 are intended for fitting around and engaging behind the edge profiles 123 and 124 with two arms in hook-shaped manner.

The length of the film hinge is so chosen that it is still in bearing against the arm 133 of the clamping strip 130, but no longer touches the arm 134.

The raised zones 128 and 135 create a substantial stiffening of the wall construction.

Claims (25)

1. Returnable transport container, especially for the transportation of food stuffs, comprising at least one plastics folding component, and a separate lid and separate base, the folding component having deep-drawn, double-layer walls of which the layers form cavities.

2. Container according to claim 1, wherein the folding component has one or more gripping depressions and/or fixing holes and/or depressions.

3. Container according to claim 1 or 2, wherein the folding component includes hinges comprising a pin or hinge bar or hinge kink.

4. Container according to claim 3, wherein the hinges comprise pins, the material boundary between the layers passing through the pin openings.

5. Container according to claim 3, wherein the folding component includes a hinge kink having a recess.

6. Container according to claim 3, wherein the folding component includes a hinge bar.

7. Container according to claim 6, wherein the hinge bar is held by forks and/or flanges.

8. Container according to claim 6 or 7, wherein the hinge bar is screwed in place.

9. Container according to any of claims 6 to 8, wherein the hinge bar is a flexible plastics material.

10. Container according to any of claims 3 to 9, wherein at least one of the hinges includes a V-shaped recess.

11. Container according to claim 10, wherein the crosssectional angle of the recess is 90".

12. Container according to any of the preceding claims, wherein an opening is disposed for gripping holes in an externally situated deep-drawn wall of the folding component and the internally situated deep-drawn wall is intact and/or a through opening is present in the wall for the fixing openings for lid and base.

13. Container according to at least claim 3, characterised by a film hinge.

14. Container according to claim 13, characterised in that the film hinge is provided with profiles which fit around the edge of the profile at the hinge position.

15. Container according to any one of claims 1 to 14, wherein the folding component includes a pocket and/or viewing window and/or a flap.

16. Container according to claim 15, characterised by a through opening in the walls which is closed by a transparent plastics.

17. Container according to claim 15 or claim 16, characterised in that the pocket is formed by an opening in the outwardly situated deep-drawn wall of the folding component.

18. Container according to claim 17, wherein the outwardly situated deep-drawn wall of the folding component forms a U-shaped guide.

19. Container according to any of claims 15 to 18, wherein the flap is connected in articulated manner to the wall.

20. Container according to claim 19, characterised by a horizontally orientated hinge and by vertically extending clamping rails at the flap aperture in the wall.

21. Container according to claim 20, characterised in that a clamping strip fits around the edge profile and is provided with two arms, of which the rear arm forms an abutment for the flap and the front arm has a length and nature such that the flap can be moved past it into the intermediate space between the two arms and moved out again from the intermediate space.

22. Container according to any of claims 18 to 21, characterised by a starting product for the wall and the flap which consists of two deep-drawn components welded to each other and possesses a cutting position.

23. Container according to any of the preceding claims, wherein the folding component comprises six walls articulated together for movement between an erected configuration defining a four sided structure, and a folded configuration in which two pairs of opposite walls fold inwardly between the remaining two, opposite walls.

24. Container according to any of the preceding claims, wherein the folding component fits between the lid and base when in its folded configuration.

25. Container substantially as hereinbefore described with reference to any of the examples shown in the accompanying drawings.