GB2395192A

GB2395192A - Container formed from panels

Info

Publication number: GB2395192A
Application number: GB0317151A
Authority: GB
Inventors: Brian Land
Original assignee: LAND POLYMERS Ltd
Current assignee: LAND POLYMERS Ltd
Priority date: 2002-07-23
Filing date: 2003-07-23
Publication date: 2004-05-19
Also published as: GB0317151D0; GB0217007D0

Abstract

A container 30 includes a plurality of panels 40, 50 arranged to have a first configuration in which the panels 40, 50 form the sides of the container 30 and a second configuration in which the panels 40, 50 may be located within a similar container 30 in the first configuration. The panels 40, 50 preferably have interlocking members 60, 70 having cooperating portions that cause the panels 40, 50 to be brought towards one another as the container 30 is assembled. The container 30 may have an upper collar for cooperating with a second set of panels 40, 50 and a discharge port comprising a sealable aperture may be provided.

Description

23951 92

Container The present invention relates to storage and transportation apparatus, particularly, though not 5 exclusively, to containers and sets of panels for use in constructing containers.

It is known to store and transport large items and bulk quantities of smaller items using pallets. Such pallets lo are generally formed of plastics, though wood and metals may also be used. They generally comprise a base which forms a deck, for supporting a load, and which has an open lattice structure to facilitate lift truck forks.

15 Items which are carried upon such pallets are often boxed and once placed on the pallet they are generally wrapped, for example with a plastics sheet material, to prevent them falling from the pallet. This method of retaining the items on the pallet is not ideal as it provides little 20 protection to the items and results in a large amount of waste packaging material.

An alternative method of retaining the items on the pallet employs wire cages which 'clip' around the pallet to 25 encase the items on the pallet. However, such cages can become deformed over time and can also be cumbersome to use and transport.

It is an aim of the present invention to address at least 30 one problem associated with the prior art whether

discussed herein or otherwise.

According to a first aspect of the present invention a container forming apparatus includes a plurality of panels arranged to have a first configuration in which the panels form the sides of a container and a second configuration 5 in which the panels may be located within a container of the same panels in the first configuration.

In the second configuration, the panels may be separate from each other. In the second configuration, the panels lo may be stacked, for instance on top of each other.

Suitably, the container forming apparatus comprises a set of panels arranged to have a first configuration in which the panels form the sides of a container and a second 15 configuration in which the panels may be located within a container formed from a like set of panels in the first configuration. The set may be capable of being in the first configuration with a plurality of like sets of panels in the second configuration being arranged to be 20 located within said set of panels in the first configuration. Thus, there may be a plurality of sets of panels, each set being capable of being in the first configuration with a plurality of such sets, when in the second configuration, being arranged to be located within 25 a set of panels in the first configuration.

The panels may be arranged to be detachably connected to each other such as by being interlocked with each other when in the first configuration. The panels may include a 30 plurality of first panels and a plurality of second panels with alternate first and second panels being located adjacent to each other around the side of the container when the panels are in the first configuration. The first

panels may be arranged to extend at least partly over the edge of the second panels when in the first configuration.

The first panels may include first interlocking members 5 and the second panels may include second interlocking members, the interlocking members of the second panels being arranged to detachably engage with the interlocking members of the first panels.

lo Preferably, the first interlocking members comprise female interlocking members and the second interlocking members comprise male interlocking members.

Preferably, each panel comprises at least four or more 15 interlocking members, with at least two interlocking members of one panel engaging with at least two interlocking members of an adjacent panel.

Each panel may comprise an inner face arranged, when in 20 the first configuration, to face the inside of the container, an outer face, arranged, to face outwardly of the container, a bottom edge, first and second opposed side edges and a top edge.

25 Preferably, the interlocking members are attached to the inner faces of the panels. Preferably, the interlocking members are mounted to the panels by fixture means. The fixture means may comprise screws, more preferably they comprise nuts and bolts. Preferably, each interlocking 30 member is mounted to a panel by at least two fixture means, more preferably by at least 3 fixture means, for example by 4 fixture means.

Preferably, the fixture means comprise bolts inserted through the panels such that they extend from the outer face thereof. Preferably, the interlocking members comprise apertures arranged to receive and hold nuts such 5 that they cannot rotate relative thereto.

Preferably, the first and/or second interlocking members each comprise a lug extending therefrom and arranged to engage an opening such as a cavity in a panel to which lo said interlocking member is to be secured. The lug may thus retain the interlocking member in position whilst it is secured to the panel by the fixture means.

Preferably, the first panels comprise the interlocking 15 members inset from the side edges thereof. Preferably, said interlocking members are inset by the thickness of a panel member.

Preferably, the second panels comprise the interlocking 20 members inset from the side edges thereof. Preferably, the interlocking members are inset by more than the thickness of a panel member.

Preferably, each panel comprises an interlocking member 25 located substantially towards each corner region or alternatively or additionally at each corner thereof.

Preferably, each panel comprises interlocking members located in the proximity of the bottom edge thereof.

Preferably, the interlocking members located in the proximity of the bottom edge of the panel (hereinafter

s lower interlocking members) are located above the bottom edge. Preferably, the lower interlocking members are located 5 between 30mm and 50mm above the bottom edge of the panel, more preferably between 38mm and 42mm above the bottom edge of the panel.

When in the first configuration, the panels may be lo arranged to extend at least partially around a pallet with the pallet supporting the container with the lower portion of the pallet being at a lower elevation than the bottom edges of at least one of the panels.

15 Preferably, the lower interlocking members are arranged such that, in use, they abut and rest upon a support such that a part of the panels projects below the level of the upper surface of the support and the assembled set thus encases a part of the support such that the container is 20 substantially retained in position relative to the support. Preferably, the lower interlocking members are arranged such that, in use, they abut and rest upon the deck of a 25 pallet such that a part of the panels projects below the level of the upper surface of said deck. Preferably, the assembled set thus encases a part, preferably the deck, of said pallet such that the container is substantially retained in position relative to the pallet.

Preferably, the panels project below the upper surface of the deck of the pallet such that a fork lift can still get

under the deck of the pallet in order to lift and move said pallet.

Preferably, each panel comprises interlocking members 5 located in the proximity of the top edge thereof.

Preferably, the interlocking members located in the proximity of the top edge of the panel (hereinafter upper interlocking members) are located below the top edge.

Preferably, the top interlocking members are located between 3Omm and 50mm below the top edge of the panel, more preferably between 38mm and 42mm below the top edge of the panel.

Preferably, the upper interlocking members are located below the top edge of the panel by the same amount as the lower interlocking members are located above the bottom edge of the panel. Thus, holes may be drilled in a panel 20 to facilitate the fixing of both the upper and lower interlocking members thereto using the same drilling machine. Preferably, in the first configuration, the aperture 25 defined by the top edges thereof is arranged to receive a pallet. Preferably, the upper interlocking members are arranged such that, in use, they can support a pallet placed upon 30 them. Preferably, the upper interlocking members are arranged, such that, in use, the supported pallet sits upon them such that a part of the panels project above the level of the lowermost part of the base of the supported

pallet such that the assembled set encases a part of said supported pallet to retain it substantially in position relative thereto.

5 Preferably, the panels project above the level of the lowermost point of the base of the supported pallet and below the uppermost level of the supported pallet such that a forklift can still get under the deck of the supported pallet in order to lift and move the supported lo pallet.

Preferably, the supported pallet itself supports a further container with panels in the first configuration as herein referred to.

Alternatively, the container forming apparatus may further comprise a collar arranged to allow a second set of panels in the first configuration to be positioned upon a container formed from a first set of panels.

Preferably, the container forming apparatus is arranged such that the collar fits within a container formed by a set of panels in the first configuration.

25 Preferably, the collar comprises a collar forming apparatus comprising a plurality of strips arranged to have a first configuration in which the strips form said collar and a second configuration in which the strips are separate from one another.

The strips may be arranged to be detachably connected to each other such as by being interlocked with each other when in the first configuration. The collar may include a

plurality of first strips and a plurality of second strips with alternate first and second strips being located adjacent to each other around the collar when the strips are in the first configuration. The first strips may be 5 arranged to extend at least partly over the edge of the second strips when in the first configuration.

The first strips may include first interlocking members and the second strips may include second interlocking 10 members, the interlocking members of the second strips being arranged to detachably engage with the interlocking members of the first strips.

Preferably, each strip comprises two interlocking members 15 with each interlocking member of each strip engaging with an interlocking member of an adjacent strip.

Each strip may comprise an inner face arranged, when in the first configuration, to face the inside of the 20 container, an outer face, arranged, when in the first configuration, to face the inner faces of panels from each of the first and second sets of panels to which it is arranged to lie adjacent, a bottom edge, first and second opposed side edges and a top edge.

Preferably, the interlocking members are attached to the inner faces of the strips. Suitably, the interlocking members of the collar are substantially the same as the interlocking members of the panels as described herein.

Preferably, the collar comprises the same number of strips as there are panels in a set of the panel assembly.

Preferably, the first strips are of such a length that when assembled to form a collar, they can fit within a container against a first panel and extend from one second panel to another. The first strips may suitably have a 5 length substantially equal to the length of a first panel less twice the width of a second panel.

Preferably, the second strips are of such a length that when assembled to form a collar, they can fit within a lo container against a second panel and extend from one first panel to another. The second strips may suitably have a length substantially equal to the length of a second panel less twice the width of a first strip.

15 Preferably, the upper interlocking members of the panels of the container forming apparatus are arranged such that, in use, when a first set of panels is arranged in the first configuration the upper interlocking members thereof can support a collar placed upon them. Suitably, the 20 upper interlocking members and collar are arranged such that, in use, the collar sits upon the interlocking members such that a part of the collar projects above the upper level of the panels.

25 Preferably, the lower interlocking members of the panels of the container forming apparatus are arranged such that, in use, when a second set of panels is arranged in the first configuration the lower interlocking members thereof abut and rest upon the collar such that a part of the 30 panels projects below the upper level of the collar.

Preferably, the collar and the interlocking members of the panels are arranged such that the lower edges of the

second set of panels abut the upper edges of the first set of panels.

Suitably, the collar has a height equal to the combined 5 distance of the lower interlocking members of the panels from the lower panel edge and the distance of the upper interlocking members from the upper panel edge.

Suitably, the collar has a height of between 60mm and 10 100mm, more preferably between 78mm and 82mm.

Preferably, the collar comprises the same materials as the panels. Preferably, the collar may be assembled in the same manner as a set of panels.

Preferably, the first and second panels have substantially the same thickness. Preferably, the panels have a thickness of between 6 and 20mm, more preferably between 9 and 15mm, for example between 11 and 13mm. Preferably, 20 the panels are substantially planar. Preferably, the panels have a substantially smooth surface finish.

Suitably, the panels comprise solid, substantially planar, sheets. One or more panels of a container forming 25 apparatus may comprise a discharge port which may comprise a sealable aperture to assist emptying of a container formed from said apparatus. Preferably, only one panel of a set comprises a discharge port.

30 Preferably, a container formed from the container forming apparatus comprises a discharge port which may comprise a sealable aperture of a panel.

Suitably, the discharge port comprises an aperture and a removeable plug. Suitably, the plug is arranged to be removed outwardly of the container. Suitably, the plug and panel are arranged such that the plug can be prevented 5 from passing through the aperture into the container.

Suitably, the panel has abutments mounted thereto to prevent the plug from passing into the container.

Suitably, the plug and panel are arranged such that the lo plug can be secured in a position whereby it seals the aperture. Suitably, the panel has retaining means mounted thereto such that a user can secure the plug over the aperture. The retaining means may comprise pivotally mounted latches.

Suitably, the plug and aperture each have a circular cross section. Suitably, the aperture is formed by cutting a hole in the panel and the plug comprises the part of panel removed by that cut. Suitably, said cut is circular.

Suitably, the discharge port further comprises a securing bar extending through the plug from a panel opposed to that having the aperture.

25 Suitably, the securing bar can carry securing means, for example a wing nut, which can be employed to secure the plug relative thereto.

Suitably, the securing bar is detachably mounted to the 30 panel from which it extends such that it can be detached therefrom to allow the set of panels to be arranged into the second configuration.

Suitably, the securing bar passes through the panel opposed to that having the aperture and can be detached from said opposed panel by pulling it from the side of the outer face of said panel, i.e. away from the aperture, 5 such that it does not prevent the set of panels from being arranged in the second configuration.

Preferably, the panels comprise a plastics material, for example a recycled plastics material. Preferably, the lo panels comprise High Impact Polystyrene (HIPS).

Preferably, the set is arranged such that, in the first configuration, the side edges of one of the first or second pair of panels abut the inner faces of the other of 15 the first or second pair of panels. Preferably, the set is arranged such that, in the first configuration, the side edges of the second panels abut the inner faces of the first panels.

20 Preferably, the first panels have a length equal to or shorter than that of the second panels.

Preferably, the first panels have a length of between 900mm and llOOmm, more preferably of between 980mm and 25 1020mm, for example of about lOOOmm.

Preferably, the second panels have a length of between llOOmm and 1300mm, more preferably of between 1180mm and 1220mm, for example of about 1200mm.

Preferably, the panels have a height equal to or less than the distance separating the opposed second panels in the assembled container.

Thus, when not being employed to form a container, the panels can be stacked within an assembly comprising a container located on a pallet. The panels may be stacked such that their inner and outer faces lie in substantially 5 the same plane as the container base formed by the pallet.

Preferably, the set is arranged such that when assembled with a pallet to form a container said container can hold at least 4 similar sets of panels, more preferably at lo least 5 similar sets, for example 6 similar sets of panels. Preferably, the panels are arranged such that the first and second interlocking members can be brought into 15 engagement when the first and second panels are moved relative to one another to create an assembled set.

Preferably, the set is arranged to be assembled by slotting the panels together. Preferably, the set is 20 arranged to be assembled by positioning the panels such that the first and second interlocking members are aligned and by then moving the panels relative to one another to cause the first and second interlocking members to slide into engagement with one another.

Preferably, the first and second interlocking members are arranged to engage one another when the second panels are moved relative to the first panels in a substantially vertical direction. Preferably, the interlocking members 30 are arranged to draw the panels towards one another as the set is assembled.

Preferably, the set is arranged such that, having been assembled, it can be disassembled by moving the first and second panels relative to one another to bring the first and second interlocking members out of engagement with one 5 another.

The first and second interlocking members may include first cooperating surfaces arranged to cause the first panel to be urged towards the second panel such that its lo inwardly facing surface is urged in the direction of extent of the inwardly facing surface of the second panel as the second interlocking member is moved downwardly relative to the first interlocking member. Alternatively or additionally, the first and second interlocking members 15 may include second cooperating surfaces arranged to urge the first panel such that its inwardly facing surface is urged in a direction perpendicular to the direction of extent of the inwardly facing surface of the second panel as the second interlocking member is moved downwardly 20 relative to the first interlocking member. The first and, alternatively or additionally the second cooperating surface may be provided on cooperating dovetails. The same surface of each interlocking member may comprise both the first and second cooperating surfaces.

Preferably, the first interlocking member comprises a male member having a dovetail shaped projection. Preferably the second interlocking member comprises a female member having a dovetail shaped opening arranged to engage the 30 dovetail shaped projection.

Preferably, the dovetail shaped projection additionally tapers in a second direction. Preferably, the additional

taper is such that the tapered sides of the dovetail projection converge towards one another in a downward direction. 5 Preferably, at least one of the interlocking members of the first panels includes an abutment arranged to be, engaged by a stop of a second interlocking member to limit the relative downwards movement of the second panels relative to the first panels.

The stop may be arranged to be at least partially received by an abutment comprising a recess in the first interlocking member. The stop may comprise a lip extending from an uppermost, in use, part of the male 15 interlocking member and arranged to abut the female interlocking member. The female interlocking member may comprise a recess lying adjacent to the uppermost, in use, part of the female interlocking member and arranged to accommodate the stop of the male interlocking member.

Alternatively, the abutment may be arranged to be at least partially received by a stop comprising a recess in the second interlocking member. The abutment may comprise a lip extending from a lowermost, in use, part of the female 25 interlocking member and arranged to abut the male interlocking member. The male interlocking member may comprise a recess lying adjacent to the lowermost, in use, part of the male interlocking member and arranged to accommodate the abutment of the female interlocking 30 member.

Preferably, the stop and abutment prevent the dovetail shaped projection becoming wedged in the dovetail shaped opening and thus allow for easy disassembly of the set.

5 Preferably, the dovetail shaped opening additionally tapers in a second direction. Preferably, the additional taper is such that the tapered sides of the dovetail opening converge towards one another in a downward direction. The engagement of the dovetail projection in the dovetail opening may hold the first and second interlocking members and consequently the first and second panels in position relative to one another.

The cooperation of the additional tapers of the dovetail taper and dovetail cavity may cause the first and second interlocking members, and consequently the first and second panels, to be drawn towards one another as they are 20 brought into engagement. Thus, the panels may be caused to tightly abut one another.

The container may include four panels.

25 The present invention also includes an assembly comprising a container with panels in a first configuration located on a pallet and an assembly comprising a first container with panels mounted on a pallet, the first container supporting a second pallet with a second container 30 supported on the second pallet and a first container mounted on a pallet with at least one further container with panels in a second configuration located within the first container.

According to a second aspect of the present invention there is further provided a method of using a container comprising assembling a container from a container forming 5 apparatus according to the first aspect of the invention, by connecting panels together to form a container and locating further identical panels as those that form the container within this container.

lo The present invention includes a method of using a container when the container is as herein referred to.

According to a third aspect of the present invention a container forming apparatus comprises a plurality of 15 panels arranged to have a first configuration in which the panels form the sides of a container with at least one first panel including at least one first interlocking member arranged to receive a second interlocking member of a second panel, the first and second interlocking members 20 including cooperating portions that guide the connection of the panels such that, as the second panel is brought downwardly relative to the first panel, an upwardly extending edge of the second panel is caused to move towards an inwardly facing surface of the first panel.

That movement may cause the inwardly facing surface of the first panel to abut the upwardly extending edge of the second panel.

30 The cooperating surfaces may include a surface on the first interlocking member generally facing the first panel extending downwardly towards the first panel. The cooperating surfaces may include a surface on the second

interlocking member facing generally away from the first panel extending downwardly towards the first panel.

The first and second interlocking members may include 5 cooperating surfaces arranged to cause movement of the second panel relative to the first panel in a direction such that the upwardly extending edge of the second panel slides past the inwardly facing surface of the first panel. These cooperating surfaces may include a surface on the first interlocking member generally facing away from the second panel and extending downwardly away from the second panel. These cooperating surfaces may include a surface 15 on the second interlocking member facing generally towards the second panel and extending downwardly away from the second panel.

The cooperating surfaces may include a surface of the 20 interlocking member of the first panel facing generally away from the second panel and extending downwardly at an angle greater than 0 with respect to the general plane of the first panel such as downwardly towards the first panel or downwardly away from the first panel. Where two such 25 surfaces are provided they may extend downwardly towards each other. The cooperating surfaces may include a surface of the second interlocking member facing generally towards the second panel and extending downwardly at an angle greater than 0 with respect of the general plane of 30 the second panel such as downwardly away from the second panel and towards the first panel or downwardly away from the second panel and away from the first panel. Where two

such surfaces are provided they may extend downwardly towards one another.

The present invention also includes a container forming 5 apparatus according to the third aspect when the container is as described in the first aspect with or without that container according to the first aspect including the second configuration. The present invention also includes an assembly as herein referred to comprising a container lo or a first and a further container according to the third aspect of the present invention with or without the or each container including the second configuration.

The present invention also includes a method of assembling 15 a container comprising causing interlocking portions of adjacent panels to engage each other by relative downwards movement of a second panel towards a first panel whereby the outwardly facing upwardly extending edge of the second panel is drawn towards the inwardly facing surface 20 of the first panel.

The method may comprise the engagement by that movement causing relative sliding movement of the inwardly facing surface of the second panel past the outwardly facing 25 upwardly extending edge of the first panel.

The present invention also includes a method of assembling a container as herein referred to.

30 The present invention includes any combination of the herein referred to features or limitations.

An embodiment of the invention will now be described by way of example with reference to the accompanying drawings in which: s Figure 1 is a plan view of an assembled set of panels; Figure 2 is a perspective view of a container comprising an assembled set of panels; lo Figure 3 is a perspective view of a first panel; Figure 4 is a perspective view of a second panel; Figure 5 is a plan view showing hidden detail of assembled 15 panels comprising interlocked interlocking members according to a first embodiment; Figure 6 is a side view showing hidden detail of the interlocked interlocking members of Figure 5; Figure 7 is another side view showing hidden detail of the interlocked interlocking members of Figure 5; Figure 8 is a cross section along line A-A of Figure 2; 25 andFigure 9 is a cross section along line A-A of Figure 2 but showing an additional container stacked upon the container of Figure 2.

Figure 10 is a cross section along line A-A of Figure 2 but showing an additional set of panels for assembling a container stacked within the container of Figure 2.

Figure 11 is a plan view of an alternative embodiment of a first interlocking member mounted to a panel.

5 Figure 12 is a bottom view of the interlocking member of Figure 11.

Figure 13 is a side end view of the interlocking member of Figure 11.

Figure 14 is a side view of an alternative embodiment of a second interlocking member mounted to a panel.

Figure IS is a plan view of the interlocking member of 15 Figure 14.

Figure 16 is a bottom view of the interlocking member of Figure 14.

20 Figure 17 is a perspective view of a part of a container comprising an assembled set of panels and having a discharge port.

Figure 18 is a perspective view of a container comprising 25 an assembled set of panels and having a discharge port.

Figure 19 is a perspective view of a part of a container comprising an assembled set of panels and having an open discharge port.

Figure 20 is a perspective view of a container comprising an assembled set of panels and having a collar.

Figure 21 is a perspective view of a container comprising an assembled first set of panels and a collar and showing a second assembled set of panels (shown in part) being positioned over the collar.

Figure 22 is a perspective view of a part of a "double depth" container comprising assembled first and second sets of panels and a collar.

AS best illustrated by Figures 1 and 2 a set of panels 1 for producing an assembly 10 which can be used with a pallet 20 to form a container 30, which can hold one or more stacked sets 1 of panels, comprises a pair of first panels 40 and a pair of second panels 50.

Each of the first panels 40 comprises four interlocking female members 60, mounted to the internal face 41 thereof. As best shown by Figure 3, the female interlocking members 60A-D are mounted to the panel 40 at 20 points inset from the side edges 42, 43 and top and bottom edges 44, 45 of the panel 40. The female interlocking members 60A, 60D mounted adjacent the first side edge 42 are identical and the female interlocking members GOB, 60C mounted adjacent the second side edge 43 are identical.

25 The two lower female interlocking members 60C, 60D are mirror images of one another as are the two upper female interlocking members 60A, GOB. Each female interlocking member 60A-D comprises a dovetail shaped cavity 61 orientated such that it extends in substantially the same 30 plane as the side edges 42, 43 of the panel 40.

Each of the second panels 50 comprises four male interlocking members 70 mounted to the internal face 51

thereof. As best shown by Figure 4 the male interlocking members 70A-D are mounted to the panel 50 at points inset from the side edges 52, 53 and top and bottom edges 54, 55 of the panel 50. The male interlocking members 70A-D are 5 identical to one another. Each male interlocking member 70A-D comprises a dovetail shaped projection 71 orientated such that it extends in substantially the same plane as the internal face 51 of the panel 50.

10 AS best illustrated by Figure 1 the set of panels can be assembled such that the female interlocking members 60A-D of a first panel inter- engage with male interlocking members 70A-D of two adjacent second panels 50 and vice versa. When the set of panels is arranged to form the assembly 10 the side edges 52, 53 of the second panels 50 abut the internal faces 41 of the first panels 40.

20 The male interlocking members 70A-D and female interlocking members 60A-D are arranged to cooperate such that adjoining first and second panels 40, 50 can be slid into engagement with one another by movement in a substantially vertical plane.

The dovetail projections 71 of the male interlocking members 70A-D and the dovetail cavities 61 of the female interlocking members 60A-D each comprise an additional taper. The tapered sides 72, 73 of the dovetail 30 projection 71 additionally taper in a downward direction in a convergent manner. The tapered sides 62, 63 of the dovetail cavity 61 additionally taper in a downward direction in a convergent manner.

Thus, both the dovetail projection 71 and dovetail cavity 61 are, in effect, dovetailed in two planes. The dovetails in the first plane, best illustrated by Figure 5 5, are arranged to retain the panels 40, 50 in position relative to one another. The dovetails in the second plane, best illustrated by Figure 6, are arranged to guide the interlocking members 60, 70 into engagement with one another and draw them into closer engagement with one lo another as they are slid relative to one another into their assembled positions. The additional taper thus allows the panels 40, 50 to be drawn into close abutment with one another with the upper edges of the panels being at the same level and this the lower edges being at the 15 same level.

The male interlocking members 70 each comprise a lip 74 extending from the upper edge thereof, arranged to prevent the dovetail projection 71 being inserted too far into the 20 dovetail cavity 61 such that it becomes jammed therein.

The female interlocking members 60 each comprise a recess 64, at their upper edge, arranged to receive the lips 74 of the male interlocking member 70 such that the upper faces of the male and female interlocking members 60, 70 25 sit flush with one another.

Each female interlocking member 60 is secured to a first panel 40 by four bolts 80 and nuts 81. The panel 40 and female interlocking member 60 each comprise apertures 30 through which the bolt is arranged to extend. The female interlocking member 60 further comprises cavities 65 arranged to retain the nuts 81 such that they cannot rotate relative thereto. In addition, the female

interlocking member 60, comprises a lug 66 projecting therefrom and arranged to be inserted in a corresponding aperture in the panel 40 to locate it in position relative thereto. The female interlocking member 60, containing 5 nuts 81 in the cavities 65 thereof may thus be positioned against a panel 40 such that its lug 66 engages a cavity in the panel. Bolts 80 may then be passed through aligned apertures in the panel 40 and female member 60, into engagement with the nuts 81. The bolts 80 can then be lo rotated to secure the nuts 81 thereto and consequently the panel 40 and female member 50 to one another.

Each male interlocking member 70 is secured to a second panel 50 by four bolts 81 and nuts 83. The panel 50 and 15 male interlocking member 70 each comprise apertures through which the bolt is arranged to extend. The male interlocking member 70 further comprises cavities 75 arranged to retain the nuts 83 such that they cannot rotate relative thereto. In addition, the male 20 interlocking member 70 comprises a lug 76 projecting therefrom and arranged to be inserted in a corresponding aperture in the panel 50 to locate it in position relative thereto. The male interlocking member 70 containing nuts 83 in the cavities 75 thereof may thus be positioned 25 against a panel 50 such that apertures in the panel 50 and male member 70 are aligned. Bolts 82 may be passed through aligned apertures into engagement with the nuts 83. The bolts 82 can then be rotated to secure the nuts 83 thereto and consequently the panel 50 and male member 30 60 to one another.

In use, the first and second panels 40, 50 of the set 1 are slotted together to form an assembly 10, the assembly

having the form of an open-ended box. The assembly can be positioned over a pallet 20 having a flat upwardly facing deck 21 such that the pallet 20 forms the base of a container 30. The lower faces of the lower interlocking 5 member 60CD, 70CD abut the deck 21 of the pallet such that the panels 40, 50 surround the deck 21 and encase part of the pallet 20 to retain the assembly 10 in position relative thereto while still allowing a forklift access under the deck 21 of the pallet such that it can lift the lo container 30.

The assembly can be disassembled when desired by first lifting a second panel 50 to bring its male interlocking member 70 out of engagement with the adjacent first panels 15 40 female interlocking members 60 and by then similarly separating the remaining panels.

As best illustrated by Figure 9 a second container 130 comprising an assembly 110 of first and second panels 140, 20 150 can be stacked upon the first container 30.

The base 122 of the second pallet 120 is supported upon the upper interlocking members (only the female interlocking members 60A,B are shown) of the first 25 container 30 such that the panels 40,50 thereof surround the base 122 and encase part of the second pallet 120 to retain the second pallet 120 in position relative thereto.

The upper interlocking members are arranged such that the second pallet 120 is encased such that a forklift can get 30 access under the deck 121 of the second pallet 120 in order to lift it on and off the first container 30. The weight of the second container 130 is supported by the upper interlocking members of the first container 30 and

transferred via the panels 40,50 and the lower interlocking members (only the female interlocking members 60C,D are shown) to the first pallet 20 and consequently via the base 21 thereof, to the surface (not shown) upon 5 which it is supported.

As best illustrated by Figure 10 when the set 1 is not assembled it can be stacked within a container 30 formed with an assembly 10 of similar panels. To facilitate this lo the first panels 40 are shorter in length than the second panels 50 and the first and second panels 40, 50 are shorter in height than the distance separating the opposed second panels 50 in an assembly of panels 10.

15 Figures 11, 12 and 13 illustrate an alternative embodiment of a female interlocking member 160 to that depicted in Figures 5, 6 and 7. Figures 14, 15 and 16 illustrate an alternative embodiment of a male interlocking member 170 to that depicted in Figures 5, 6 and 7, for use in 20 conjunction with the female interlocking member 160 shown in Figures 11, 12 and 13. The female interlocking member 160 and male interlocking member 170 of the second embodiment are substantially identical to those of the first embodiment and like parts are numbered accordingly.

Rather than the male interlocking member 170 comprising a lip and the female interlocking member 160 comprising a recess, arranged to receive the lip, the female interlocking member 160 comprises a lip 67 extending from 30 the lower edge thereof into the dovetail cavity 61. The lip 67 is arranged to prevent the dovetail projection 71 being inserted too far into the dovetail cavity 61 such that it becomes jammed therein. The male interlocking

member 170 comprises a recess 77 arranged to receive the lip 77 of the female interlocking member. The female and male interlocking members 160, 170 may thus cooperate such that their upper and lower faces sit flush with one 5 another.

The female interlocking member 160 comprises a cavity 68A in the top face thereof and cavities 68B and 68C in the bottom face thereof. Cavities 68A and 68B are separated lo from one another by a part of the interlocking member 160 forming a wall therebetween. The male interlocking member 170 also comprises a cavity 78 in a side face thereof.

The cavities 68A, GOB, 68C and 78 serve to reduce the amount of materials required to produce the interlocking 15 members without significantly affecting the strength thereof. As illustrated by Figures 17 to 19 a container 30 formed from the assembly 10 of the invention can be provided with 20 a discharge port 200.

The discharge port comprises an aperture 210 formed in one of the first panels 40 of the set of panels 1 and a plug 220 arranged to releasably seal the aperture 210. The 25 plug 220 and aperture 210 are arranged such that the plug 220 is removed outwardly of the container 30 to open the port 200. The first panel 10 having the aperture 210 is provided with four abutments 211 comprising washers 212 secured to the panel 40 by bolts 213. The abutments 211 30 are arranged to project beyond the edge 214 of the panel 40 defining the periphery of the aperture 210 such that the plug 220 can be engaged thereby and thus prevented

from entering through the aperture 210 into the container 30. The first panel 40 is further provided with four latches 5 215 comprising bent washers 216 secured to the panel 40 by bolts 213.

The washers 216 are arranged to pivot relative to the bolts 213 such that the latches 215 can move between a lo retaining position 215A and a release position 215B. In the retaining position the latches 215 project beyond the edge 214 of the panel 40 defining the periphery of the aperture 210. Thus, they hold the plug 270 in position relative to the panel 40 such that the aperture 210 is 15 substantially sealed. In the release position the latches suitably do not project beyond the edge 214. Thus, in this position the latches allow the plug to be removed from the aperture 210 and thus for the discharge port 200 to be opened.

The container 30 further comprises an elongate securing bar 230 mounted to the other of the first panels 40. The securing bar 230 passes through an aperture in said other first panel and has a nut 231 at a first end 232 thereof 25 arranged to abut the outer face of the panel 40. The securing bar 230 is arranged to be detachable from the panel 40 such that the assembly 30 can be disassembled and the panels stacked.

30 The second end 233 of the securing bar 230 passes through an aperture in the plug 220 when the plug 220 is positioned to seal the aperture 210 and a washer 234 and wing nut 235 are secured to the second end 233 of the

securing bar such that the plug 220 is releasably secured in place.

As illustrated by Figures 19 to 22 a container 30 formed 5 from a first assembly 10 of the invention can be provided with a collar 300 to allow a second assembly 110 of the invention to be positioned directly upon the container 30 formed from a first set of panels 1 such that a "double depth" container (shown near completion of assembly in lo Figure 21) is formed.

The collar 300 is in essence a miniature version of the assembly 10. The collar 300 comprises a collar forming assembly comprising a pair of first strips 310 and a pair 15 of second strips 320.

Each of the first strips 310 comprises two interlocking female members 311 and each of the second strips 320 comprises two interlocking male members 321.

The interlocking members 311, 321 are substantially identical to the interlocking members 60, 70 of the panels 40, 50 of the assembly 10. Thus, the collar 300 may be disassembled for convenient transport when not required to 25 form a "double depth" container.

The first and second strips 310, 320 have lengths such that the assembled collar 300 fits within the first assembly 10 and sits upon the upper interlocking members 30 of the first assembly 10 (only one interlocking member 60 shown).

The collar 300 is arranged such that a second assembly 110 can then be located over and around the collar (as shown in Figure 21) to form a "double depth" container. As shown by Figure 22 the strips 310, 320 of the collar 300 5 are of such a height that whilst the lower edge 301 of the collar sits upon the upper interlocking members of the first assembly, the upper edge 302 of the collar has the lower interlocking members (only one 60' shown) of the second assembly resting thereupon.

The collar 300 suitably also has such a height that the lower edges 145, 155 of the panels 140, 155 of the second assembly 110 abut the upper edges 44, 54 of the panels 40, 50 of the first assembly 10 when the "double depth" 15 container is formed.

Accordingly, the collar 300 is arranged to retain the second assembly 110 upon the first assembly 10 and suitably to share the weight of the second assembly 110 20 between the panel edges 44, 55 and the upper interlocking members of the first assembly 10 to allow a "double depth" container to be employed.

The present invention thus provides a set of panels for 25 use in construction of containers which may provide greater utility than known methods for retaining items upon a pallet. The set may be durable, economic to produce and may beneficially be stored within a container comprising a similar set when not in use.

Any or all parts of the container or pallet may be made from reprocessed plastics such as high impact polystyrene.

As the set is made from a plastics material it may be

suitable for use in applications where a hygienic container is required. Thus, if a plastics pallet, preferably having no cavities, is employed to form the base of a container comprising a set of panels in 5 accordance with the invention, then a fully hygienic container may be produced.

The reader's attention is directed to all papers and documents which are filed concurrently with or previous to lo this specification in connection with this application and

which are open to public inspection with this specification, and the contents of all such papers and

documents are incorporated herein by reference.

15 All of the features disclosed in this specification

(including any accompanying claims, abstract and drawings), and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features 20 and/or steps are mutually exclusive.

Each feature disclosed in this specification (including

any accompanying claims, abstract and drawings), may be replaced by alternative features serving the same, 25 equivalent or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features.

30 The invention is not restricted to the details of the foregoing embodiment(s). The invention extends to any novel one, or any novel combination, of the features disclosed in this specification (including any

accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed.

Claims

1. A container forming apparatus characterized in that it includes a plurality of panels arranged to have a first 5 configuration in which the panels form the sides of a container and a second configuration in which the panels can be located within a container of the same panels in the first configuration.

lo

2. A container forming apparatus according to claim 1, wherein in the second configuration the panels are separate from each other.

3. A container forming apparatus according to claim 1 or 15 2, wherein the container forming apparatus comprises a set of panels arranged to have the first configuration in which the panels form the sides of a container and the second configuration in which the panels can be located within a container formed from a like set of panels in the 20 first configuration and wherein the set is capable of being in the first configuration with a plurality of like sets of panels in the second configuration being arranged to be located within said set of panels in the first configuration.

4. A container forming apparatus according to any preceding claim, wherein the panels are arranged to be detachably connected to each other such as by being interlocked with each other when in the first 30 configuration.

5. A container forming apparatus according to claim 4, wherein the panels include a plurality of first panels and

a plurality of second panels with alternate first and second panels being located adjacent to each other around the side of the container when the panels are in the first configuration and wherein the first panels include first s interlocking members and the second panels include second interlocking members, the interlocking members of the second panels being arranged to detachably engage with the interlocking members of the first panels.

lo

6. A container forming apparatus according to claim 4 or 5, wherein each panel comprises at least four or more interlocking members, with at least two interlocking members of one panel engaging with at least two interlocking members of an adjacent panel.

7. A container forming apparatus according to any of claims 4 to 6 wherein each panel comprises interlocking members located in the proximity of the bottom edge of the panel (lower interlocking members) and which are located 20 above the bottom edge.

8. A container forming apparatus according to claim 7, wherein the lower interlocking members are arranged such that, in use, they abut and rest upon a support such that 25 a part of the panels projects below the level of the upper surface of the support and the assembled set thus encases a part of the support such that the container is substantially retained in position relative to the support.

9. A container forming apparatus according to any of claims 4 to 8, wherein each panel comprises interlocking members located in the proximity of the top edge of the

panel (upper interlocking members) and which are located below the top edge.

10. A container forming apparatus according to claim 9, 5 wherein the upper interlocking members are arranged such that, in use, they can support a pallet placed upon them and such that, in use, the supported pallet sits upon them such that a part of the panels project above the level of the lowermost part of the base of the supported pallet lo such that the assembled set encases a part of said supported pallet to retain it substantially in position relative thereto.

11. A container forming apparatus according to any 15 preceding claim, wherein the container forming apparatus further comprises a collar arranged to allow a second set of panels in the first configuration to be positioned upon a container formed from a first set of panels.

20

12. A container forming apparatus according to any preceding claim, wherein one or more panels of a container forming apparatus comprises a discharge port comprising a sealable aperture to assist emptying of a container formed from said apparatus.

13. A method of using a container comprising assembling a container from a container forming apparatus according to any preceding claim by connecting panels together to form a container and locating further identical panels as those 30 that form the container within this container.

14. A container forming apparatus characterized in that it comprises a plurality of panels arranged to have a first

configuration in which the panels form the sides of a container with at least one first panel including at least one first interlocking member arranged to receive a second interlocking member of a second panel, the first and 5 second interlocking members including cooperating portions that guide the connection of the panels such that, as the second panel is brought downwardly relative to the first panel, an upwardly extending edge of the second panel is caused to move towards an inwardly facing surface of the lo first panel.

15. A container forming apparatus according to claim 13 and further comprising the features of any of claims 1 to 12.

16. A method of assembling a container according to claim 14 or 15 and comprising causing interlocking portions of adjacent panels to engage each other by relative downwards movement of a second panel towards a first panel whereby 20 the outwardly facing upwardly extending edge of the second panel is drawn towards the inwardly facing surface of the first panel.

17. A container forming apparatus substantially as herein 25 described with reference to the accompanying drawings.