GB2377922A

GB2377922A - Collapsible packaging case

Info

Publication number: GB2377922A
Application number: GB0128848A
Authority: GB
Inventors: James O'brien; Connor O'brien; Peter Smith
Original assignee: Individual
Current assignee: Individual
Priority date: 2000-12-20
Filing date: 2001-12-03
Publication date: 2003-01-29
Also published as: GB0128848D0; GB0031414D0

Abstract

A packaging case (36) is formed from a base (37), side (30, 28), end (25, 28), and lid (39) wall panels. Each panel is constructed by joining together several elongate plastic extruded plate members (10) that have mutually engaging profiles (11, 15) along their edges so that they lie in a common plane when so joined. Joining members (22) having a profile (23) engagable with a profile (20) on a plate member and a formation (24) to receive the end of a plate member (10) are used to join the base (37), side (30, 28), end (25, 28), and lid (39) wall panels in mutually perpendicular disposition. Frame members (34. 35) around the edges of the base (37) and lid (39) wall panels strengthen those panels. The case (36) can be constructed to any desired size in small increments, and can be dismantled after use for reuse in a case of different size or for return flat packed.

Description

PACKAGING CASE This invention relates to packaging cases for transportation or storage of goods, in particular air cargo.

Historically, the protection of goods during transportation or storage has been accomplished by means of wooden pallets or cases. Such cases often comprise plywood panels framed or strengthened with temperate softwood, and can be time consuming to construct. Wood has many disadvantages, in that it is limited with respect to strength to weight ratio, chemical and environmental resistance and impact absorption, and is subject to moisture retention, pest, mould and fungal damage. Furthermore, wood tends not to be reusable, often splits when dry, is flammable, and due to dust and splinters is not compatible with"clean room" environments. Careless handling of such cases can lead to extensive damage of the goods despite such cases being a good balance between cost, weight and protection. These disadvantages, coupled with European legislation and increased environmental awareness in industry, has led to the consideration of alternatives. Plastics materials have been proposed in order to produce reusable pallets and cases, but the design and tooling costs for small volume bespoke manufacturing in such materials is prohibitive for most potential users. As an alternative, oversize"off-the-shelf'plastic palletised crates may be used together with suitably designed internal packings. However, such a solution leads to increased transportation costs due to the increased weight and volume of the packaged goods.

It is an object of the present invention to provide a packaging case for the transportation or storage of goods that avoids, at least to a substantial extent, most if not all of the abovementioned disadvantages.

The invention provides a packaging case having wall panels formed of a plurality of elongate plate members, each plate member having along its length at least first and second profiles adapted whereby a first profile on one plate member is engagable by a second profile on another of such plate members so that the two plate members lie in a common plane.

The packaging case may comprise a pair of side wall panels, each side wall panel formed of a plurality of plate members mutually engaged in a common side plane. The packaging case may comprise a pair of end wall panels, each end wall panel formed of a plurality of plate members mutually engaged in a common end plane. The packaging case may comprise a base wall panel formed of a plurality of plate members mutually engaged in a common base

plane. The packaging case may comprise a lid wall panel formed of a plurality of plate members mutually engaged in a common lid plane.

Each plate member may have along its length a third profile, and the packaging case may comprise an elongate joining member having along its length a fourth profile adapted to engage the third profile of a plate member whereby the joining member extends in a plane perpendicular to the plane of the plate member. The joining member may have a formation adapted to engage a second plate member whereby the two plate members engaged by a joining member lie in mutually perpendicular planes. A joining member may be engaged by one plate member of a side wall panel and one plate member of an end wall panel with the side plane perpendicular to the end plane.

The first profile may comprise a pair of spaced tongued ribs, and the second profile may comprise a pair of spaced grooved ribs. The first profile may comprise a locating rib and the second profile may comprise a pair of receiving ribs forming a receiving recess therebetween adapted to receive the locating rib of a first profile. The locating rib and the receiving recess may be centrally disposed between the tongued ribs and the grooved ribs respectively. The third and fourth profiles may be in the form of co-operating slot and flange, in which case the slot and flange may be T-shaped. The joining member formation may comprise a channel adapted to receive an edge of a plate member therein.

The packaging case may comprise a plurality of elongate frame members, and may comprise a plurality of inner and outer frame members. Each inner frame member may have along its length a third profile. The base wall panel and the lid wall panel may each have an inner and an outer frame member extending along each edge thereof. The Inner frame members may be disposed respectively between the base wall panel and the side and end wall panels, and between the lid wall panel and the side and end wall panels, with the respective joining members engaging the inner frame member and the side or end wall panel.

Each plate member may have at least one cavity extending longitudinally thereof. Each plate member, each joining member and each frame member may be of a plastics material, and may be an extruded section. Each plate member may be substantially 10 cm wide.

The packaging case may comprise at least one dividing wall panel, the wall panel being formed of a plurality of plate members mutually engaged in a common dividing plane. The dividing wall panel may be joined to a base, side or end wall panel by means of a joining member.

The invention will now be described with reference to the accompanying drawings in which: Fig. 1 is a perspective end view of a plate member, Fig. 2 is a perspective end view of a joining member, Fig. 3 is a plan view of a side wall panel and end wall panel joined together, Fig. 4 is a perspective end view of an outer frame member, Fig. 5 is a perspective end view of an inner frame member, and Fig. 6 is a section through a side of an assembled packaging case.

Refernng now to Fig. 1, there is shown a perspective end view of a plate member 10, formed from an extrusion of a suitable plastics material, for example polypropylene or woodfill polystyrene. The plate member 10 may be cut to any appropriate length, preferably to several standard lengths for use in standard sizes of packaging cases. Extending along one edge of the plate member 10 is a first profile 11 formed with a pair of spaced ribs 12 having outwardly facing tongues 13. Centrally disposed between the ribs 12 is a locating rib 14. Extending along the opposed edge of the plate member 10 is a second profile 15 formed with a pair of spaced ribs 16 having Inwardly facing grooves 17. Centrally disposed between the ribs 16 are a pair of receiving ribs 18 forming a receiving recess 19 therebetween adapted to receive the locating rib 14 of a first profile 11. Extending along one face of the plate member 10 is a third profile 20 in the form of a T-shaped slot. Also extending along the plate member 10 are several cavities 21 to reduce the weight of the plate member 10 without significantly sacrificing the strength or rigidity of the plate member 10.

Referring now to Fig. 2, there is shown a perspective end view of a joining member 22, formed from an extrusion of a suitable plastics material. The joining member 22 may be cut to any appropriate length, preferably to the same standard lengths as the plate members 10. The joining member 22 has along its length a fourth profile 23 in the form of a T-shape adapted to engage the T-shaped third profile 20 of a plate member 10 whereby the joining member 22 extends in a plane perpendicular to the plane of the plate member 10. The joining member 22 also has a formation 24 in the form of a channel adapted to engage a second plate member 10 whereby the two plate members 10 engaged by a joining member 22 lie in mutually perpendicular planes as will be described below.

Referring now to Fig. 3, there is shown in plan view an end wall panel 25, formed in this case of three plate members 26,27, 28. The first profile 11 of plate member 26 is engaged in the second profile 15 of plate member 27, and the first profile 11 of plate member 27 is engaged in the second profile 15 of plate member 28 so that the plate members 26,27 and 28 lie in a

common end plane. Such location is provided by the receipt of the locating rib 14 in the receiving recess 19, and maintained due to the receipt of the tongues 13 in the grooves 17.

Further plate members 10 may be added to the end wall panel 25 dependent on the size of the packaging case required. The second profile 15 has been removed from plate member 26 to provide a smooth edge 29 to the packing case. A joining member 22 is received in the Tshaped third profile 20 adjacent the smooth edge 29. A side wall panel 30 is formed in this case of three plate members 31, 32, 33. The first profile 11 of plate member 32 is engaged in the second profile 15 of plate member 31, and the first profile 11 of plate member 33 is engaged in the second profile 15 of plate member 32 so that the three plate members 31,32, 33 lie in a common side plane. The first profile 11 has been removed from plate member 31 to facilitate receipt of the plate member 31 in the channel formation 24 of the joining member 22. Due to the configuration of the joining member 22, the end wall panel 25 and the side wall panel 30 lie in mutually perpendicular planes. Similar joining arrangements are made at the other three comers of the packaging case.

Referring now to Figs. 4 and 5, there are shown respectively perspective end views of an outer and an inner frame member 34,35. The outer frame member 34 is formed from the lower portion of the plate member 10 as shown in Fig. 1, whilst the inner frame member 35 is formed from the upper portion of the plate member 10 as shown in Fig. 1.

The assembly of a packaging case is illustrated in Fig. 6. The packaging case 36 comprises a base wall panel 37, a side or end wall panel 38 and a lid wall panel 39. The base wall panel 37 is formed by joining the required number of plate members 10 in the manner described above in relation to the side and end wall panels 25,30. Around and supporting each edge of the base wall panel 37 is an outer frame member 40, and around and supported by each edge of the base wall panel 37 is an inner frame member 41. These frame members 40,41 provide support and stiffening to the base wall panel 37, to minimise bending of the base wall panel 37 or separation of the first and second profiles 11,15 joining each plate member 10 forming the base wall panel 37. Received in the third profile 20 of the inner frame member 41 is a joining member 42, into the channel formation 24 of which is received the side or end wall panel 38. Two side wall panels and two end wall panels 38, joined to each other at the four comers of the packaging case 36 as shown in Fig. 3, are erected in the inner frame members 41 and joining members 42 around the base wall panel 37 The tops of the side and end wall panels 38 and are received in the channel formations 24 of a further set of joining members 43. The joining members 43 are received in the T-shaped third profiles 20 of a second set of inner frame members 44 which support the lid wall panel 39. A second set of outer frame members 45 is provided around the upper edge of the lid wall panel 39. The inner and outer

frame members 44,45 support and strengthen the lid wall panel 39 in the same manner as frame members 40,41 strengthen the base wall panel 37.

The packaging case 36 thus formed is supported on blocks 46, of wood or other suitable material, disposed beneath the outer frame members 40 adjacent the ends thereof and at discrete intermediate points if required. The blocks 46 may be supported on further outer frame members 47, thereby facilitating the lifting of the packaging case 36 by means of a fork lift truck or by use of one or more slings. If desired, adhesive (for a permanent construction) or screws (for a reusable construction) may be used to secure the side and end wall panels 38 to the base wall panel 37 during transportation. Alternatively or in addition, bands may be placed around the packaging case 36. By inserting further joining members 48 in the Tshaped third profiles 20 of the plate members 10 forming the base, side or end wall panels 37 t 38, 39, dividing wall panels 49 may be disposed within the packaging case 36 at appropriate locations. The dividing wall panel or panels 49 are formed from an appropriate number of plate members 10 in the same manner as the base, side and end wall panels 37,38, 39.

By means of the invention, a packaging case is provided that may be reused many times, and can be transported flat-packed when not used for transporting goods. In particular, after the transportation of goods to one customer, the case can be disassembled and reassembled to a different size and/or different internal configuration for other goods to be transported to another customer. The case may be constructed to any desired size in relatively small increments. Intemal dividing walls can be readily incorporated at small incremental positions.

The case is flame retardant, clean room compatible, effectively chemically inert, stronger than the softwood used heretofore, can be cleaned using high pressure wash and detergent, does not generate waste as both production waste and a non-usable case may be recycled, is relatively light in weight, and is relatively cheap to manufacture. No dust or splinters are generated, and the case is not prone to pest, fungi or mould damage. In addition, there is good thermal protection for the goods. Any damaged plate, joining or frame member can be easily replaced instead of scrapping the whole case. Other embodiments of packaging case will be readily apparent to persons skilled in the art. For example, other materials such as aluminium may be used if appropriate for the transportation of particular goods. The configuration of the profiles may be changed, for example a dovetail flange and recess. The frame members may be of a different configuration from that of the plate members instead of being formed from them as described. The dividing wall panels may be formed from plate members having a different section from that of the plate members of the base, side and end wall panels, since the structural strength and rigidity required for the former may be less than that required for the latter.

Claims

CLAIMS 1. A packaging case having wall panels formed of a plurality of elongate plate members, each plate member having along its length at least first and second profiles adapted whereby a first profile on one plate member is engagable by a second profile on another of such plate members so that the two plate members lie in a common plane.
2. A packaging case according to claim 1, comprising a pair of side wall panels, each side wall panel formed of a plurality of plate members mutually engaged in a common side plane.
3. A packaging case according to claim 1 or claim 2, comprising a pair of end wall panels, each end wall panel formed of a plurality of plate members mutually engaged in a common end plane.
4. A packaging case according to any one of claims 1 to 3, comprising a base wall panel formed of a plurality of plate members mutually engaged in a common base plane.
5. A packaging case according to any one of claims 1 to 4, comprising a lid wall panel formed of a plurality of plate members mutually engaged in a common lid plane.
6. A packaging case according to any one of claims 1 to 5, wherein each plate member has along its length a third profile.
7. A packaging case according to claim 6, comprising an elongate joining member having along its length a fourth profile adapted to engage the third profile of a plate member whereby the joining member extends in a plane perpendicular to the plane of the plate member.
8. A packaging case according to claim 7, wherein the joining member has a formation adapted to engage a second plate member whereby the two plate members engaged by a joining member lie in mutually perpendicular planes.
9. A packaging case according to claim 8, wherein a joining member is engaged by one plate member of a side wall panel and one plate member of an end wall panel with the plane of the side wall panel perpendicular to the plane of the end wall panel.

<Desc/Clms Page number 7>
10. A packaging case according to any one of claims 1 to 9, wherein the first profile comprises a pair of spaced tongued ribs.
11. A packaging case according to claim 10, wherein the second profile comprises a pair of spaced grooved ribs.
12. A packaging case according to claim 11, wherein the first profile comprises a locating rib and the second profile comprises a pair of receiving ribs forming a receiving recess therebetween adapted to receive the locating rib of a first profile.
13. A packaging case according to claim 12, wherein the locating rib and the receiving recess are centrally disposed between the tongued ribs and the grooved ribs respectively.
14. A packaging case according to claim 7, wherein the third and fourth profiles are in the form of co-operating slot and flange.
15. A packaging case according to claim 14, wherein the slot and flange are T-shaped.
16. A packaging case according to claim 8, wherein the joining member formation comprises a channel adapted to receive an edge of a plate member therein.
17. A packaging case according to any one of claims 1 to 16, comprising a plurality of elongate frame members.
18. A packaging case according to claim 17, comprising a plurality of inner and outer frame members.
19. A packaging case according to claim 18, wherein each inner frame member has along its length a third profile.
20. A packaging case according to claim 19, comprising a base wall panel and a lid wall panel, wherein the base wall panel and the lid wall panel each have an inner and an outer frame member extending along each edge thereof.
21. A packaging case according to claim 20, comprising a side wall panel and an end wall panel, wherein the inner frame members are disposed respectively between the base wall panel and the side and end wall panels, and between the lid wall panel and the side and end

<Desc/Clms Page number 8>

wall panels, with the respective joining members engaging the inner frame member and the side or end wall panel.
22. A packaging case according to any one of claims 1 to 21, wherein each plate member has at least one cavity extending longitudinally thereof.
23. A packaging case according to any one of claims 1 to 22, comprising a plurality of joining members and frame members, wherein each plate member, each joining member and each frame member is of a plastics material.
24. A packaging case according to any one of claims 1 to 23, comprising a plurality of joining members and frame members, wherein each plate member, each joining member and each frame member is an extruded section.
25 A packaging case according to any one of claims 1 to 23, wherein each plate member is substantially 10 cm wide.
26 A packaging case according to any one of claims 1 to 25, comprising at least one dividing wall panel.
27. A packaging case according to claim 26, wherein the wall panel is formed of a plurality of plate members mutually engaged in a common dividing plane.
28. A packaging case according to claim 27, comprising a base wall panel, a side wall panel and an end wall panel, wherein the dividing wall panel is joined to a base, side or end wall panel by means of a joining member.

29 A packaging case substantially as hereinbefore described with reference to and as illustrated In the accompanying drawings