GB2598348A

GB2598348A - A folding large container

Info

Publication number: GB2598348A
Application number: GB2013456.5A
Authority: GB
Inventors: Parkinson David
Original assignee: M J Solpac Ltd
Current assignee: M J Solpac Ltd
Priority date: 2020-08-27
Filing date: 2020-08-27
Publication date: 2022-03-02
Also published as: GB202013456D0; WO2022058706A2; WO2022058706A3; EP4204315A2

Abstract

A Folding Large Container (FLC) 10 comprises an outer container body having a footprint area with a base (11, fig. 2) and walls 12 each moveable between an assembled condition in which each wall portion is upstanding and together the wall define a transport volume within the container body and a collapsed condition in which each of the wall portions lies within the footprint area of the base. The container has at least one opposed pair of rigid side support ribs (13, fig. 3). One of each pair is secured to an inner side of respective opposed walls, and each rib includes at least one locating notch (14, fig. 6). At least one pair of elongate rigid component support structures 15 comprises a tongue (16, fig. 12) to be removably received within a notch in a ribs to position the elongate component support structures transversely between the opposed side walls and at least one shaped component-locating opening (17, fig. 8) to locate a component relative to the at least one pair of elongate component support structures.

Description

A FOLDING LARGE CONTAINER

Technical Field of the Invention

The present invention relates generally to the field of reusable returnable packaging systems for component supply. In particular, but not exclusively, the invention concerns plastic Folding Large Containers (FLC) with internal separators.

Background to the Invention

Conventional plastic Folding Large Containers (FLC) utilise textile dunnage separators. Because of the flexibility of textiles (versus solid rigid dividers), a 30% to 40% uplift in pack density can be achieved on the outward leg through better nesting of the parts delivered in the FLC. Once the parts are removed from the packaging, the FLC is folded with the textile separators inside and in its folded state is one third the size. This means for every three trucks that go out, only one is needed to return the empty FLC's.

Unfortunately, textile dunnage is not strong enough for heavy parts such as brake, suspension and engine components for vehicles and most FLC's have a limited weight capacity.

This means heavy components are usually moved in rigid steel stillages with polyurethane dunnage, but as these don't generally fold, the size reduction with the attendant decrease in transport capacity needed to return the empty FLC's cannot he realised, which increases expense and is environmentally damaging through the need to use more vehicles to return the empty PLC's.

Embodiments of the invention seek to at least partially overcome or ameliorate any one or more of the abovementioned disadvantages or provide the consumer with a useful or commercial choice.

Summary of the Invention

According to a first aspect of the invention there is provided a Folding Large Container (FLC) comprising an outer container body having a footprint area with a base and plurality of wall portions each moveable between an assembled condition in which each wall portion is upstanding and together the wall portions define a transport volume within the container body and a collapsed condition in which each of the wall portions lies within the footprint area of the base; at least one opposed pair of elongate rigid side support ribs, one of each respective pair of elongate side support ribs secured to an inner side of respective opposed wall portions, each elongate side support rib including at least one locating notch formed thereinto; and at least one pair of elongate rigid component support structures, each elongate component support structure comprising a tongue to be removably received within a respective notch in the respective elongate side support ribs to position the elongate component support structures transversely between the opposed side walls and at least one shaped component-locating opening to locate a component relative to the at least one pair of elongate component support structures.

Providing a Folding Large Container (PLC) with an internal arrangement including the elongate rigid side support ribs secured to an inner side of opposed walls and the elongate rigid component support structures which are removably located relative to the elongate support ribs allows the internal arrangement to support greater loads when compared to existing Folding Large Containers with textile separators but to still be folded into a collapsed condition for return.

Typically, the elongate rigid component support structures are removably located relative to the elongate support ribs via the tongue which is removably received within a respective notch in the respective elongate side support ribs, supporting the elongate rigid component support structures using a simple abutment, possibly a friction fit, or an interference fit where some deformation of a portion of the tongue is needed to fit the tongue within the notch.

Although the PLC may be made of any material, it will typically be formed of one or more plastic material for light weight but high strength. Different components of the FLC may be made from different plastics.

Preferably, the elongate rigid side support ribs and the elongate rigid component support structures will be made from a high strength plastic such as solid polypropylene. This allows the elongate rigid side support ribs and the elongate rigid component support structures to be CNC machined to shape for example, further reducing cost as the expense of moulds is not incurred.

The PLC will preferably be generally rectangular as this will provide for better packing of multiple PLC's together, although any suitable shape could be used.

The PLC typically comprises an outer container body having a footprint area with a base and plurality of wall portions each moveable between an assembled condition in which each wall portion is upstanding and together the wall portions define a transport volume within the container body and a collapsed condition in which each of the wall portions lies within the footprint area of the base.

The container body will typically be formed of one or more plastic materials but any one or more materials could be used.

The footprint area of the FLC will preferably be defined by the external dimension of the base. This will define a maximum footprint area for the PLC which is preferably the same in the assembled condition and the collapsed condition.

The base of the container body will preferably be solid although the base may have one or more openings formed thereinto. Typically, a number of openings will be formed into the base below the floor of the container body (the upper surface of the base in the transport volume) to receive a lifting tine, for example of a forklift or similar.

The base of the container body will preferably be substantially rectangular.

The wall portion provided relative to at least one side of the base is preferably offset vertically from the wall portions provided relative to at least one other side of the base. The wall portions provided relative to one of the pairs of sides of the preferred rectangular base will preferably be offset vertically from the wall portions provided relative to the other of the pairs of sides of the preferred rectangular base. This means that the wall portions can collapse into a flattened position without obstructing the other wall portions when collapsed within the footprint area of the container. For example, a first pair of opposed sides of the base may be provided with a stub wall base extending upwardly from the base and relative to which a side wall portion on that side is mounted.

Typically, the other of the pair of opposed sides of the base are not provided with a stub wall base or may be provided with a stub wall base of lesser height.

The wall portions may be removably mounted relative to the base. For example, the wall portions may be mounted relative to the base such that the wall portions can be detached from the base in order to move to the collapsed condition. Any suitable mounting method could be used for example a tongue and groove assembly in which a tongue is provided on a lower edge of the wall portion to engage with a corresponding groove on an upper part of the base, or vice versa.

The wall portions may be substantially permanently mounted relative to the base. For example, the wall portions may be hinged relative to the base. The hinge arrangement may be such that a linear movement of the wall portion may be required to disengage the wall portion from the base before rotation of the wall portion is possible.

The base generally has a substantially planar upper surface to form an inner bottom wall of the transport volume.

The wall portions are each typically planar, at least on an inner side.

When in the collapsed condition, the wall portions will typically lie substantially horizontally within the footprint area of the base. The wall portions may be angled downwardly (past horizontal) but collapsing the wall portions so that the wall portions are at least horizontal will typically realise the size reduction of the PLC.

When collapsed, the wall portions will preferably be spaced from the inner bottom wall of the container body. This will typically allow the other components (side support ribs and the component support structures) to be located in the collapsed container body between the bottom wall of the container body and the collapsed side walls.

The wall portions may have one or more prepared openings provided therein for the attachment of the side support ribs. The prepared openings may have reinforced surrounds for a more secure mounting.

The internal sides of the wall portions is preferably planar.

Each wall of the container body may be formed from more than one portion. An upper wall portion may be provided which is mounted to a lower wall portion. One or more lower wall portions may be provided, at least one of which mounts the upper wall portion and is in turn mounted relative to another lower wall portion or the base.

The mounting of the wall portions will preferably be such that perpendicular wall portions are offset vertically from one another. In an embodiment in which one or more hinges are used to mount the wall portions relative to one another and/or the base, the hinges of perpendicular wall portions are preferably offset vertically from one another.

When collapsed, two of the wall portions will typically overlie the other two adjacent perpendicular wall portions in a rectangular container. Opposed wall portions will normally lie in the same plane when collapsed.

The FLC will preferably include at least one opposed pair of elongate rigid side support ribs, one of each respective pair of elongate side support ribs secured to an inner side of respective opposed wall portions, each elongate side support rib including at least one locating notch formed thereinto.

Preferably, the elongate rigid side support ribs are secured to opposed wall portions. The elongate rigid side support ribs are typically secured using a robust. securing mechanism such as one or more fasteners such as screws or bolts or plugs or rivets and washers for example.

More than one pair of elongate rigid side support ribs will normally be provided in a container body.

The elongate rigid side support ribs are preferably elongate and linear.

The elongate rigid side support ribs may be horizontally oriented within the container body or vertically oriented. Typically, if the FLC is transporting a single type of component, then all of the elongate rigid side support ribs in the container body will preferably extend in the same direction, but different groups of elongate rigid side support ribs may be provided, spaced through the transport volume.

The elongate rigid side support ribs may be planar or not. Typically, the shape of the elongate rigid side support ribs and the position of the at least one notch is 30 dependent upon whether the elongate rigid side support ribs are oriented horizontally or vertically within the transport volume (which is turn typically dependent upon the component to be transported).

In an embodiment, horizontally oriented elongate rigid side support ribs are typically planar. Horizontally oriented elongate rigid side support ribs will normally have multiple notches. Each elongate rigid side support rib of the pair are preferably aligned to align the notches.

The notches may be in an upper side edge of each horizontally oriented elongate rigid side support rib. At least one pair of elongate rigid side support ribs may have a notch in an upper edge and a lower edge. These notches may be aligned with one 10 another.

A notch may be in one or both lateral side faces of an elongate rigid side support rib. A notch may extend through the thickness of an elongate rigid side support rib.

A notch may be approximately half of the dimension of the elongate rigid side support rib except where a pair of aligned notches are provided in opposite edges in which case the notches may be less than one half of the dimension.

Clearance may be provided between the end(s) of the elongate rigid side support ribs and the perpendicular wall portions of the container body.

In use, the wall portions relative to which the elongate rigid side support ribs are mounted are generally collapsed before the other wall portions.

When the elongate rigid side support ribs are vertically oriented, the elongate rigid side support ribs will typically have a single elongate notch. The notch is typically U-shaped. This configuration may allow one or more component support structure(s) to be inserted into the notch one above another.

The at least one notch is typically rectangular in cross-section. A convergent 25 entryway may be provided on the or each notch The PLC preferably includes at least one pair of elongate rigid component support structures, each elongate component support structure comprising a tongue to be removably received within a respective notch in the respective elongate side support ribs to position the elongate component support structures transversely between the opposed side walls and at least one shaped component-locating opening to locate a component relative to the at least one pair of elongate component support structures.

There will typically be more than one pair of component support structures. The pairs are preferably provided spaced over the width of the transport volume. More than one pair of component support structures may be provided spaced over the height of the transport volume.

Each component support structure is preferably provided with a tongue at each end. A single structure that forms a tongue at each end may be provided or a separate and distinct tongue may be provided. The tongue may be provided at the respective end only. A member or structure may be provided extending over the length of the component support structure and which forms or provides a tongue at each end.

The tongue may be provided as a part of the component support structure or as a separate component and mounted or attached to the component support structure. The tongue may be provided as a part of a reinforcing structure provided relative to a I 5 component support structure.

At least one dimension of the tongue may correspond to the width of the component support structure. At least one dimension of the tongue may be a part of the width of the component support structure.

The tongue is preferably received, at least partially, with a notch on an elongate side support rib. In an embodiment where the component support structure is a unitary structure, a tongue may be provided at both ends of the unitary component support structure to be received in a notch of each of a pair of elongate side support ribs.

Each component support structure may be provided with one or more tongues. Typically, a tongue is provided at each end thereof. At least one component support structure may include an upper tongue and a spaced apart lower tongue. In an embodiment, each bottom component support structure (provided lowermost in the transport volume) is provided with the upper and lower tongues at each end thereof Other component support structures in the transport volume may have a single tongue at each end.

In an embodiment, the tongue is normally a part of the height of the component support structure only. Typically, the tongue may be approximately half of the height of the component support structure. In some embodiments, the tongue may be one third (or less) of the height of the component support structure.

The component support structure may be oriented vertically within the transport volume (the height of the component support structure being greater than the width) or horizontally (the width of the component support structure being greater than the height). The orientation will normally be dependent on the component to be transported and/or whether that component is to be transported in a vertical orientation or a horizontal orientation. The component support structure will normally be oriented perpendicularly to the component(s) and/or the side support ribs. Typically, if the component is laid horizontally in the PLC, then the component support structure is normally oriented vertically. If the component is oriented vertically in the PLC, the component support structure is normally oriented horizontally.

Each component support structure preferably includes at least one shaped component opening. Typically, a number of shaped component openings are provided over the length of each component support structure. The shape of the shaped component opening will depend on the component to be transported. The shape of the shaped component opening will typically correspond to a portion of the external shape of the component to be transported. The shaped component opening may be formed in any way. CNC machining the shaped component opening is particularly preferred but the shaped component opening may be formed using cutting or moulding.

The component openings may be formed as a shaped crenelle between a pair of merlon portions.

Typically, the component will be supported relative to the component support structure by an edge of the shaped component opening. The component may rest at least partially in the shaped component opening. The component may be positively constrained against movement by one or more shaped component openings provided in one or more component support structures.

The shaped component openings on adjacent component support structures may correspond with each other to form a receiving opening for a component or a portion thereof. For example, a pair of shaped component openings on adjacent component support structures may at least partially surround a part of a component to hold the component between the component support structures.

A shaped component opening may interact with an edge of an adjacent component support structure to form a receiving opening for a component or a portion thereof. For example, a shaped component opening may interact with an edge of an adjacent component support structure to at least partially surround a part of a component to hold the component between the component support structures.

The FLC may further comprise a base support member or arrangement. The base support member or arrangement will typically he used in the FLC for components which are to be transported vertically oriented within the FLC.

The base support member or arrangement will typically include a number of openings. The openings will typically be oriented in a regular army so that the FLC can transport a number of components. Each of the openings is preferably shaped and configured to receive one end of a component to be transported therein.

The base support member or arrangement will preferably overlie the bottom wall of the transport volume. The base support member or arrangement may be attached 20 or mounted to the bottom wall of the transport volume.

In an embodiment, the base support member or arrangement may be formed of a resiliently deformable material. The base support member or arrangement may be formed of a rigid material. The periphery of the openings provided in the base support member or arrangement will preferably be slightly deformable in order to positively locate the end of the component which is located therein.

One or more of the component support structures may be attached to one or more other component support structures and/or to wall portion of the container body. Typically, an elongate flexible attachment may be provided. The provision of such an attachment will typically connect the component support structure to another component support structure and/or to a wall portion of the container body in order to prevent loss or theft of the component support structures. The provision of an elongate flexible attachment will allow the component support structures to be relocated within the transport body as needed, particularly before the wall portions are collapsed. Prior to collapsing the wall portions, the component support structures are preferably located in a lower part of the container body and the wall portions collapsed on top of the component support structures. The length of the elongate flexible attachment may be such that partial removal of the component support structure from the transport volume is possible.

The elongate flexible attachment may be formed in one piece for example as a strap or in more than one piece such as for example a chain. The elongate flexible attachment will typically be securely attached to the component support structure(s) and/or the wall portion. Typically, the elongate flexible attachment is attached to a component support structure at a first end and either a component support structure at a second end and/or a wall portion.

In use, the internal arrangement comprising at least a pair of elongate rigid side support ribs and at least one pair of elongate rigid component support structures will be selected according to the component(s) to be transported. The elongate rigid side support ribs will then typically be attached securely to opposed wall portions of the container body (which are preferably already in the assembled condition) and the component support structures secured relative thereto. One or more components may be located relative to the component support structures in order to complete the FLC for transport. A lid may be provided for the FLC.

The FLC can be transported to the required destination. Once unpacked, the component support structures can then be released from the side support ribs and preferably located in a lower portion of the transport volume. The wall portions with the rigid side support ribs attached thereto are then preferably collapsed on top of the lower portion of the transport volume and the perpendicular wall portions are then typically collapsed on top of the lower collapsed wall portions. The wall portions may then be secured in position.

Collapsing the PLC will typically reduce the height of the PLC by at least one half and preferably towards one third of the height of the PLC in the assembled condition allowing better packing on the return leg of the trip.

The PLC can be reused in the same configuration in the assembled condition or alternatively, the internal arrangement may be changed when the PLC is next used.

The rigid component support structures may be provided with a cushioning portion or layer if desired.

Detailed Description of the Invention

In order that the invention may be more clearly understood one or more 10 embodiments thereof will now be described, by way of example only, with reference to the accompanying drawings, of which: Figure I is an isometric view of a plastic Folding Large Container of a first embodiment configured to transport callipers for vehicles, in an assembled condition.

Figure 2 is an isometric view of the configuration illustrated in Figure 1 in the collapsed condition.

Figure 3 is an isometric view of the configuration illustrated in Figure 1 in a first partially collapsed condition.

Figure 4 is an isometric view of the configuration illustrated in Figure 1 in a second partially collapsed condition.

Figure 5 is an isometric view of the internal arrangement (container body removed) of the configuration illustrated in Figure 1.

Figure 6 is an isometric view of the internal arrangement (container body removed) of the configuration illustrated in Figure 3 Figure 7 is an exploded isometric view of the internal arrangement (container body removed) of the embodiment illustrated in Figure I. Figure 8 is a detailed exploded isometric view of a connecting strap used to connect two elongate rigid component support structures in an embodiment.

Figure 9 is a detailed isometric view of an engagement between an elongate rigid component support structure of an embodiment and an elongate support rib.

Figure 10 is a detailed isometric view of an engagement between an elongate rigid component support structure of another embodiment and an elongate support rib.

Figure 11 is a detailed isometric view of the configuration shown in Figure 8.

Figure 12 is a detailed exploded isometric view of the mounting of an elongate support rib in an embodiment.

Figure 13 is a detailed isometric view of an upper elongate support rib of an embodiment.

Figure 14 is a detailed isometric view of an elongate rigid component support structure of an embodiment.

Figure 15 is a detailed isometric view of an elongate support rib of another embodiment.

Figure 16 is a detailed isometric view of a lower elongate component support structure of an embodiment.

Figure 17 is an isometric view of a plastic Folding Large Container of a first embodiment configured to transport driveshafts for vehicles, in an assembled condition.

Figure 18 is an isometric view of the internal arrangement (container body removed) of the configuration illustrated in Figure 17.

Figure 19 is an exploded isometric view of the internal arrangement (container body removed) of the embodiment illustrated in Figure 17.

Figure 20 is an exploded isometric view of the lower part of the internal arrangement of the configuration illustrated in Figure 19.

Figure 21 is an isometric view of a plastic Folding Large Container of a second embodiment configured to transport thiveshafts for vehicles, in an assembled condition.

Figure 22 is an isometric view of the internal arrangement (container body removed) of the configuration illustrated in Figure 21.

Figure 23 is an exploded isometric view of the internal arrangement (container body removed) of the embodiment illustrated in Figure 21.

Figure 24 is an exploded isometric view of an elongate support rib of the embodiment illustrated in Figure 21.

Figure 25 is an isometric view of a plastic Folding Large Container of an embodiment configured to transport shock absorbers for vehicles, in an assembled condition.

Figure 26 is an isometric view of the internal arrangement (container body removed) of the configuration illustrated in Figure 25.

Figure 27 is an isometric view of the configuration shown in Figure 25 in a first partially collapsed condition.

Figure 28 is an isometric view of the internal arrangement (container body removed) of the configuration illustrated in Figure 28.

Figure 29 is an isometric view of the configuration shown in Figure 25 in a second partially collapsed condition.

Figure 30 is an isometric view of the configuration shown in Figure 25 in the collapsed condition.

Figure 31 is an exploded isometric view of the internal arrangement (container body removed) of the embodiment illustrated in Figure 25.

Figure 32 is an exploded isometric view of an elongate component support structure of the embodiment illustrated in Figure 25.

Figure 33 is an isometric view of a base component of the embodiment illustrated in Figure 25.

Figure 34 is an isometric view of the elongate component support structure of the embodiment illustrated in Figure 32.

Figure 35 is an isometric view of an elongate support rib of the embodiment illustrated in Figure 25.

Figure 36 is a detailed exploded isometric view of the elongate support rib of the embodiment illustrated in Figure 25 showing an attachment mechanism.

Figure 37 is a detailed isometric view of the engagement between the elongate component support structure and the elongate support rib of the embodiment illustrated in Figure 25.

Figure 38 is a detailed isometric view of a strap attachment and the elongate component support structure of the embodiment illustrated in Figure 25.

With reference to the accompanying figures, a Folding Large Container (FLC) 10 is provided. The FLC 10 shown in the Figures is shown with a number of internal arrangements. In all embodiments, the FLC 10 comprises an outer container body having a footprint area, with a base 11 and plurality of wall portions 12, each wall portion 12 moveable between an assembled condition (shown in Figures 1, 17, 21 and 25 for example) in which each wall portion 12 is upstanding and together the wall portions 12 define an internal transport volume within the container body and a collapsed condition (shown in Figures 2 and 30 for example) in which each of the wall portions 12 lies within the footprint area of the base 11.

Although different configurations are illustrated, the FLC 10 illustrated includes a number of opposed pairs of elongate rigid side support ribs 13, one of each respective pair of elongate side support ribs 13 secured to an inner side of respective opposed wall portions 12, each elongate side support rib 13 including at least one locating notch 14 formed thereinto. The FLC 10 illustrated also includes a number of pairs of elongate rigid component support structures 15, each elongate component support structure 15 comprising a tongue 16 to be removably received within a respective locating notch 14 in the respective elongate side support ribs 13 to position the elongate component support structures 15 transversely between the opposed wall portions 12. Each elongate component support structure 15 also includes a number of shaped, component-locating opening 17 to locate a component relative to the elongate component support structures 15.

As shown, the elongate rigid component support structures 15 are removably located relative to the elongate support ribs 13 via the tongue 16, which is removably received within a mspective notch 14 in the mspective elongate side support ribs 13, supporting the elongate rigid component support structures 15 using a simple abutment, possibly a friction fit, or an interference fit where some deformation of a portion of the tongue 16 is needed to fit the tongue 16 within the notch 14.

Although the FLC 10 may be made of any material, it will typically be formed of plastic for light weight but high strength. Different components of the FLC may be made from different plastics. For example, the container body may be made of one plastic and the internal components (the elongate rigid side support ribs 13 and the elongate rigid component support structures 15) may be made from a high strength plastic such as solid polypropylene. This allows the elongate rigid side support ribs and the elongate rigid component support structures to be CNC machined to shape for example, further reducing cost as the expense of moulds is not incurred.

The FLC 10 illustrated is generally rectangular as this will typically provide for better packing (and stacking) of multiple FLC's together.

The footprint area of the FLC 10 will preferably be defined by the external dimension of the base 11. This will define a maximum footprint area for the FLC 10 which is preferably the same in the assembled condition and the collapsed condition.

The base 11 of the container body will normally be solid, but have one or more openings formed thereinto. Typically, a number of openings 18 will be formed into the base 11 below the floor of the container body (the upper surface of the base in the transport volume) to receive a lifting tine, for example of a forklift or similar.

As illustrated best in the Figures showing the collapsed condition (Figures 2 and 30 for example), the wall portions 12 provided relative to one of the pairs of sides of the base 11 are preferably offset vertically from the wall portions 12 provided relative to the other of the pairs of sides of the base 11. This means that the wall portions 12 can collapse into a flattened position without obstructing the other wall portions when collapsed within the footprint area of the FLC 10. As shown in Figure 2 for example, a first pair of opposed sides of the base 11 are provided with a stub wall base 19 extending upwardly and relative to which a side wall portion 12 on that side of the PLC, is mounted. Typically, the other of the pair of opposed sides of the base 11 are not provided with a stub wall base 19 or may be provided with a stub wall base of lesser height.

The wall portions 12 of the illustrated embodiments are substantially permanently mounted relative to the base 11. The wall portions 12 are hinged relative to the base 11 to allow folding inwardly into the collapsed condition.

The base II generally has a substantially planar upper surface to form an inner bottom wall of the transport volume. One or more base support members 20 or arrangements, such as that illustrated in Figures 18, 26 and 33 for example, maybe used in the PLC for components which are to be transported vertically oriented within the PLC.

The base support member or arrangement will typically include a number of openings 21. The openings 21 will typically be provided in a regular array so that the PLC 10 can transport a number of components. Each of the openings 21 is preferably shaped and configured to receive one end of a component to be transported therein.

The base support member or arrangement will preferably overlie the bottom wall of the transport volume. The base support member or arrangement may be attached or mounted to the bottom wall of the transport volume.

In the embodiment illustrated in Figures 26 to 31 and 33, the base support member is unitary and formed of a resiliently deformable material, such as a high-density foam. The openings 21 are formed directly into the base support member 20.

In the embodiment illustrated in Figures 18 to 20, the base support arrangement is two part, with an upper layer 22 and a lower layer 23. The lower layer 23 is preferably more rigid than the upper layer 22, and is provided with openings which are larger than 30 those in the upper layer 22. The openings in the upper layer 22 are aligned with those in the lower layer 23. In this configuration, the lower layer 23 provides additional support for the components and the upper layer 22 grips the ends of the components to be transported.

The wall portions 12 are each typically planar, at least on an inner side as shown.

When in the collapsed condition, the wall portions 12 will typically lie substantially horizontally within the footprint area of the base as shown in Figure 2 for example.

When collapsed, the wall portions 12 will preferably be spaced from the inner bottom wall of the container body. This will typically allow the other components (the component support structures 15) to be located in the collapsed container body between the bottom wall of the container body and the collapsed side wall portions 12.

As illustrated in Figures 3 and 4 for example, the wall portions 12 may have one or more prepared openings 24 provided therein for the attachment of the side support ribs 13. The prepared openings 24 may have reinforced surrounds for a more secure 15 mounting When collapsed, two of the wall portions 12 will typically overlie the other two adjacent perpendicular wall portions 12 in a rectangular container as illustrated in Figures 2 and 30 for example. Opposed wall portions 12 will normally lie in the same plane when collapsed.

Preferably, the elongate rigid side support ribs 13 are secured to opposed wall portions 12. The elongate rigid side support ribs 13 are typically secured using a robust. securing mechanism such as one or more threaded fasteners such as screws or bolts for example but the illustrated mechanism is a plug 31 inserted through the wall portion with an enlarged head and a complementary washer 32 or similar which is then fixed on the inside of the container. As rebate 33 is provided in the rib for the plug and washer.

As shown in the Figures, more than one pair of elongate rigid side support ribs 13 will normally be provided in a container body. The number of pairs provided will generally depend on the components to be transported and/or the orientation of the ribs 30 13.

The elongate rigid side support ribs 13 are preferably elongate and linear.

The elongate rigid side support ribs may be horizontally oriented within the container body or vertically oriented (shown in Figures 21 to 24). Typically, if the PLC 10 is transporting a single type of component, then all of the elongate rigid side support ribs 13 in the container body will preferably extend in the same direction, but multiple groups of elongate rigid side support ribs 13 may be provided, spaced through the transport volume as shown.

Typically, the shape of the elongate rigid side support ribs 13 and the position of the at least one notch is dependent upon whether the elongate rigid side support ribs 13 are oriented horizontally or vertically within the transport volume (which is turn typically dependent upon the component to be transported).

As shown in all the embodiments except those illustrated in Figures 21 to 24, horizontally oriented elongate rigid side support ribs 13 are typically planar. Horizontally oriented elongate rigid side support ribs will normally have multiple notches 14 spaced over their length. Each elongate rigid side support rib 13 of the pair are preferably aligned to align the respective notches 14.

The notches 14 of the horizontally oriented elongate rigid side support rib may be in an upper side edge of each horizontally oriented elongate rigid side support rib 13 as shown in Figures 12 and 13 for example.

The lowermost pair of elongate rigid side support ribs may have an upper notch in an upper edge and a lower notch 26 in a lower edge as shown in Figure 15. These notches may be aligned with one another. This allows use of a different tongue configuration on the lower component support structures 15, as shown in Figures 10 and 16 in particular.

Typically, for ribs 13 other than the lowermost ribs, each notch 14 may be approximately half of the dimension of the elongate rigid side support rib. For the lowermost ribs where a pair of aligned notches 25, 26 are provided in upper and lower edges respectively, the notches may be less than one half of the dimension as shown in Figures 10 and 15.

In use, the wall portions 12 relative to which the elongate rigid side support ribs 13 are mounted are generally collapsed before the other wall portions.

When the elongate rigid side support ribs 13 are vertically oriented as shown in the embodiment of Figures 21 to 24, the elongate rigid side support ribs 13 will typically have a single elongate notch 14. The notch 14 is typically U-shaped. This configuration may allow the component support structures 15 to be inserted into the notch one above another as shown in Figure 22 for example.

Each notch is typically rectangular in cross-section. An arcuate or convergent entryway 27 may be provided on each notch 14.

As shown, there will typically be more than one pair of component support structures 15 located relative to each pair of elongate support ribs 13. The pairs are preferably provided spaced over the width of the transport volume. More than one pair of component support structures may be provided spaced over the height of the transport volume as shown in Figure 22. Although a pair of component support structures IS can support a component, one or more intermediate of component support structures 15 may be provided relative to each pair to provide additional support.

Each component support structure 15 is preferably provided with a tongue 16 at each end. A single structure that forms a tongue at each end may be provided such as that shown in Figure 12 as an example. The tongue may be provided at the respective 20 end only as shown in Figure 12.

An elongate member 28, such as that shown in Figure 32, may be provided extending over the length of the component support structure 15 and which forms or provides a tongue at each end to be received in the notch 14 as shown in Figure 37.

The tongue may be provided as a part of the component support structure as shown in Figure 12 or as a separate component 28 mounted or attached to the component support structure 15 as shown in Figure 32.

The tongue 16 is preferably received, at least partially, with a notch 14 on an elongate side support rib 13. In an embodiment where the component support structure 15 is a unitary member such as that shown in Figures 14 and 16, a tongue 16 may be provided at both ends of the unitary component support structure 15 to be received in a notch 14 of each of a pair of elongate side support ribs 13.

Each component support structure 15 may be provided with one or more tongues. Typically, a tongue is provided at each end thereof. In the embodiment shown in Figure 10 and 16, a component support structure 15 may include an upper tongue and a spaced apart lower tongue. This may be preferred for the bottom or lowermost component support structures 15 (provided lowermost in the transport volume). Other component support structures in the transport volume may have a single tongue at each end.

The component support structure may be oriented vertically within the transport volume (the height of the component support structure being greater than the width) which is illustrated in Figures 1 60 16 and 21 to 24 or horizontally (the width of the component support structure being greater than the height). illustrated in Figures 17 to 20 and 25 to 38. The orientation will normally be dependent on the component to be transported and/or whether that component is to be transported in a vertical orientation or a horizontal orientation.

The component support structures 15 will normally be oriented perpendicularly to the component(s) and/or the side support ribs 13. Typically, if the component is laid horizontally in the FLC 10, then the component support structures IS are normally oriented vertically. If the component is oriented vertically in the PLC 10, the component support structures 15 are normally oriented horizontally. This presents a longer axis of the component support structure perpendicularly to the length of the component (edge on) which is likely to increase the security of the abutment with the component.

Each component support structure 15 illustrated includes a number of shaped component openings 17 over the length of each component support structure 15. The shape of the shaped component opening 17 will depend on the component to be transported. The shape of the shaped component opening 17 will typically correspond to a portion of the external shape of the component to be transported. The shaped component opening may be formed in any way. CNC machining the shaped component opening 17 is particularly preferred but the shaped component opening may be formed using cutting or moulding.

Typically, the component will be supported relative to the component support structure 15 by an edge of the shaped component opening 17. The component may rest at least partially in the shaped component opening 17. The component may be positively constrained against movement by one or more shaped component openings 17 provided in one or more component support structures 15.

The shaped component openings 17 on adjacent component support structures 15 may correspond with each other to form a receiving opening for a component or a portion thereof such as is illustrated in Figures 25 to 38. In this embodiment, a pair of shaped component openings 17 on adjacent component support structures 15 at least partially surround a part of a component to hold the component between the component support structures 15.

A shaped component opening 17 may interact with an edge of an adjacent component support structure 15 to form a receiving opening for a component or a portion thereof such as is illustrated in Figures 17 to 20. hi this embodiment, a shaped component opening 17 interacts with an edge of an adjacent component support structure 15 to at least partially surround a part of a component to hold the component between the component support structures 15.

For horizontally extending component support structures 15, such as those illustrated in Figures 1 to 16, the component openings may be formed as a shaped 20 crenelle between a pair of merlon portions 29.

As show in some of the illustrated embodiments, one or more of the component support structures 15 may be attached to one or more other component support structures 15 and/or to wall portion 12of the container body. Typically, an elongate flexible attachment such as a strap 30 may be provided. The provision of such an attachment will typically connect the component support structure 15 to another component support structure 15 and/or to a wall portion 12 of the container body in order to prevent loss or theft of the component support structures 15. The provision of an elongate flexible attachment such as the strap 30 illustrated, will allow the component support structures 15 to be relocated within the transport body as needed, particularly before the wall portions 12 are collapsed. Prior to collapsing the wall portions, the component support structures 15 are preferably located in a lower part of the container body as shown in Figure 27 for example, and the wall portions collapsed on top of the component support structures 15 as shown in Figures 29 and 30. The length of the elongate flexible attachment may be such that partial removal of the component support structure 15 from the transport volume is possible.

The elongate flexible strap 30 is securely attached to the component support structure(s) 15 and/or the wall portion 12. Typically, the elongate flexible attachment is attached to a component support structure at a first end and either a component support structure at a second end and/or a wall portion. Intermediate attachments of the strap 30 to other component support structure(s) 15 may be provided as shown in Figure 11.

In use, the internal arrangement comprising at least a pair of elongate rigid side support ribs 13 and at least one pair of elongate rigid component support structures 15 will be selected according to the component(s) to be transported. The elongate rigid side support ribs 13 will then typically be attached securely to opposed wall portions 12 of the container body (which are preferably already in the assembled condition) and the component support structures 15 secured relative thereto. One or more components may be located relative to the component support structures 15 in order to complete the FLC 10 for transport. A lid may be provided for the FLC 10. The FLC 10 can be transported to the required destination.

Once unpacked, the component support structures 15 can then be released from the side support ribs 13 and preferably located in a lower portion of the transport volume. The wall portions 12 with the rigid side support ribs 13 attached thereto are then preferably collapsed on top of the lower portion of the transport volume and the perpendicular wall portions are then typically collapsed on top of the lower collapsed wall portions 12. The wall portions 12 may then be secured in position.

Collapsing the FLC 10 will typically reduce the height of the FLC 10 by at least one half and preferably towards one third of the height of the FLC in the assembled condition allowing better packing on the return leg of the trip. The FLC 10 can be reused in the same configuration in the assembled condition or alternatively, the internal arrangement may be changed when the FLC 10 is next used.

The one or more embodiments are described above by way of example only. Many variations are possible without departing from the scope of protection afforded by the appended claims.

Claims

CLAIMSI. A Folding Large Container (FLC) comprising: an outer container body having a footprint area with a base and plurality of wall portions each moveable between an assembled condition in which each wall portion is upstanding and together the wall portions define a transport volume within the container body and a collapsed condition in which each of the wall portions lies within the footprint area of the base; at least one opposed pair of elongate rigid side support ribs, one of each respective pair of elongate side support ribs secured to an inner side of respective opposed wall portions, each elongate side support rib including at least one locating notch formed thereinto; and 2. 3. 4.at least one pair of elongate rigid component support structures, each elongate component support structure comprising a tongue to be removably received within a respective notch in the respective elongate side support ribs to position the elongate component support structures transversely between the opposed side walls and at least one shaped component-locating opening to locate a component relative to the at least one pair of elongate component support structures.
A Folding Large Container as claimed in claim I wherein the elongate rigid component support structures are removably located relative to the elongate support ribs via the tongue which is removably received within a respective notch in the respective elongate side support ribs.
A Folding Large Container as claimed in claim 1 or claim 2 wherein the elongate rigid side support iibs and the elongate rigid component support structures are CNC machined to shape.
A Folding Large Container as claimed in any one of the preceding claims wherein the footprint area is defined by an external dimension of the base and remains unchanged between the assembled condition and the collapsed condition.
5. A Folding Large Container as claimed in any one of the preceding claims wherein the wall portion provided relative to at least one side of the base is offset vertically from the wall portions provided relative to at least one other side of the base.
6. A Folding Large Container as claimed in any one of the preceding claims wherein the wall portions are hinged relative to the base to rotate inwardly when moved to the collapsed condition.
7. A Folding Large Container as claimed in any one of the preceding claims wherein when in the collapsed condition, the wall portions lie substantially horizontally within the footprint area of the base.
8. A Folding Large Container as claimed in any one of the preceding claims wherein when collapsed, the wall portions are spaced from an inner bottom wall of the container body.
9. A Folding Large Container as claimed in any one of the preceding claims wherein more than one pair of elongate rigid side support ribs is provided in a container body.
10. A Folding Large Container as claimed in any one of the preceding claims wherein at least some of the elongate rigid side support ribs are horizontally oriented within the container body.
11. A Folding Large Container as claimed in claim 10 wherein the horizontally oriented elongate rigid side support ribs have multiple notches with each elongate rigid side support rib of a pair aligned to align the respective notches.
12. A Folding Large Container as claimed in claim 11 wherein the multiple notches are in an upper side edge of at least some of the horizontally oriented elongate rigid side support rib.
13. A Folding Large Container as claimed in claim 11 or 12 wherein at least one pair of elongate rigid side support ribs have an upper notch in an upper edge and a lower notch in a lower edge aligned with one another.
14. A Folding Large Container as claimed in any one of the preceding claims wherein at least some of the elongate rigid side support ribs are vertically oriented within the container body.
15. A Folding Large Container as claimed in claim 14 wherein the elongate rigid side support ribs have a single elongate notch.
16. A Folding Large Container as claimed in any one of the preceding claims wherein the at least one notch is rectangular in cross-section.
17. A Folding Large Container as claimed in any one of the preceding claims wherein each component support structure is provided with a tongue at each end.
18. A Folding Large Container as claimed in any one of the preceding claims wherein the component support structure is a unitary member and the tongue is form thereinto at each end.
19. A Folding Large Container as claimed in any one of claims 1 to 17 wherein at.least one member is attached to the component support structure to provide the tongue.
20. A Folding Large Container as claimed in any one of the preceding claims wherein the tongue is received, at least partially, with the notch on an elongate side support rib.
21. A Folding Large Container as claimed in any one of the preceding claims wherein the component support structures are oriented vertically within the transport. volume
22. A Folding Large Container as claimed in any one of claims 1 to 20 wherein the component support structures are oriented horizontally within the transport volume.
23. A Folding Large Container as claimed in any one of the preceding claims wherein a number of shaped component openings are provided over the length of each component support structure.
24. A Folding Large Container as claimed in any one of the preceding claims wherein the component is supported relative to the component support structure by an edge of the shaped component opening.
25. A Folding Large Container as claimed in any one of the preceding claims further comprising a base support member or arrangement including a number of openings shaped and configured to receive one end of a component to be transported therein.
26. A Folding Large Container as claimed in any one of the preceding claims further comprising an elongate flexible attachment assembly is provided to attach one or more of the component support structures to one or more other component support structures and/or to a wall portion of the container body and to allow movement of the one or more of the component support structures relative to the container body.