US20040232146A1

US20040232146A1 - Collapsible shipping container

Info

Publication number: US20040232146A1
Application number: US10/441,710
Authority: US
Inventors: John Kessler; Patrick Boomgaard
Original assignee: ENGINEERED MATERIAL HANDLING SYSTEMS Inc
Current assignee: ENGINEERED MATERIAL HANDLING SYSTEMS Inc
Priority date: 2003-05-20
Filing date: 2003-05-20
Publication date: 2004-11-25

Abstract

A collapsible delivery container having hinged legs that fold inwardly to permit the top of the container to collapse toward the bottom of the container. The container is configured to permit it to be collapsed one side at a time. The container includes a handle on each side that extends between the intermediate hinges of the corresponding legs. The handle is configured to be accessible when the container is collapsed, yet out of the way when the container is raised. The container further includes a nesting structure that, among other things, retains the first collapsed side in proper alignment while the second side is collapsed. The nesting structure also provides a force path from the top of the container to base so that the hinges are not required to bear the weight of stacked containers. The container preferably includes a lift assist mechanism that bears some of the weight of the container as it is collapsed and raised.

Description

BACKGROUND OF THE INVENTION

The present invention relates to reusable shipping containers, such as dunnage containers, and more particularly to collapsible reusable shipping containers.

Shipping containers, such as dunnage containers are widely used to deliver parts and products from one location to another. One of the most common uses for shipping containers is to ship parts in bulk from the manufacturer to the purchaser. In these applications, the shipping container is filled by the manufacturer and shipped to the purchaser. The purchaser unloads the parts. In many applications, shipping containers are reusable so that they can be used repeatedly. This is particularly common in applications where durable, high strength containers are required to ship the products, for example, in shipping relatively large components in the automotive industry. When reusable containers are employed, the purchaser must unload the parts and then returns the container to the manufacturer. The purchaser is typically required to store the empty containers for some period of time before returning them to the manufacturer. With conventional shipping containers, the purchaser is required to dedicate a relatively large amount of space to the storage of empty containers before return to the manufacturer. Similarly, the manufacturer is required to dedicate a large amount of storage to empty containers waiting to be filled. Further, a relatively large amount of space in a truck or other delivery vehicle is required to return the containers to the manufacturer.

In an effort to reduce the space occupied by empty shipping containers, for example, during storage and return shipping, a variety of collapsible shipping containers have been developed. Conventional collapsible containers include a base and a top that are interconnected by supports or legs. These supports fold, telescope or can be otherwise manipulated to lower the top onto the base when the container is empty, thereby dramatically reducing the height of the container. Although collapsible containers provide a marked improvement, conventional collapsible containers suffer several drawbacks. Perhaps the most significant drawback is that conventional containers can be difficult to collapse and raise, particularly large, heavy-duty containers. In many applications, the container is designed to receive large, heavy components, such as engine transmission components and other component parts for large consumer goods. To accommodate these types of components, the container must have a large footprint and be manufactured from strong, durable materials, such as thick-wall, steel tubing. With conventional collapsible containers, the user is required to bear the weight of the container, actuate the supports and guide the collapsing top into proper alignment with base. For example, with conventional hinged supports, the weight of the container must be supported while simultaneously moving around the container to separately initiate the folding of each support. Once the supports begin to fold, the top must be supported to provide a controlled lowering of the top. A similar, but reverse, process is required to raise the container. Experience has revealed that this process of manually collapsing and raising the container can require a cooperative effort of two or more people. As a result of the shortcomings of conventional collapsible containers, there is a need for a collapsible shipping container that is more easily raised and collapsed.

SUMMARY OF THE INVENTION

The aforementioned problems are overcome by the present invention wherein a collapsible shipping container is provided with corner supports that are uniquely hinged to permit the container to be collapsed one side at a time. Each corner support preferably includes an offset hinge that permits the support to fold inwardly and downwardly onto itself.

In one embodiment, each corner support includes upper and lower nesting segments that are interfitted when the container is collapsed. The interfitted nesting segments also provide a force path that permits stacking of containers without placing undue load on the hinges.

In another embodiment, the collapsible container includes a pair of handles that facilitate collapse and assemble of the container. Each handle is preferably pivotally mounted between a pair of corner support at or near the hinge location. For example, one handle may be mounted to the left and right supports located at the front of the container while the other is mounted to left and right supports at the rear of the container. This arrangement facilitates separate collapse and assembly of the front and rear of the container. The handles are preferably somewhat U-shaped and configured to permit them to be accessible from the exterior when the container is collapsed and to place them substantially outside of the opening between the supports when the container is assembled.

In a further embodiment, at least one of the supports is providing with a movable locking collar that will selectively lock the support in the extended position to prevent inadvertent collapse of the support. The locking collar is preferably fitted over and slidably movable along the support in a vertical direction. The locking collar preferably includes a locking pin that permits the collar to be secured in place over the hinge where it prevents any substantial folding movement of the hinge.

In yet another embodiment, at least one support is provided with a lift assist mechanism. The lift assist mechanism preferably includes a spring or other resilient device that biases the support in the raised (or unfolded) position. The lift assist works against the weight of the container making it easier to collapse and raise the container.

The present invention provides a simple and inexpensive collapsible container that can be collapsed and assembled one side at a time. This permits operation of the container by a single individual. The handles facilitates controlled and efficient operation by providing a mechanism for controlling movement of the supports at the hinges. The handle is readily accessible when the container is collapsed and does not hinder access to the interior of the container when the container is raised. The nesting segments facilitate collapse of the container one side at a time by providing a mechanism for maintaining proper alignment of the top and the base as each side is separately collapsed. The nesting segments of the supports also provide a strong vertical force path that conveys the weight of the upper portion of the container and any above stacked containers to the ground or other surface upon which the collapsed container is disposed.

These and other objects, advantages, and features of the invention will be readily understood and appreciated by reference to the detailed description of the preferred embodiment and the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a collapsible delivery container in accordance with a preferred embodiment of the present invention; [0011]
FIG. 2 is a is a perspective view of a collapsible delivery container with the dunnage structure removed; [0012]
FIG. 3 is a is a perspective view of a collapsible delivery container with the dunnage structure removed and one side partially collapsed; [0013]
FIG. 4 is a is a perspective view of a collapsible delivery container with the dunnage structure removed and one side fully collapsed; [0014]
FIG. 5 is a is a perspective view of a collapsible delivery container with the dunnage structure removed and the container fully collapsed; [0015]
FIG. 6 is an enlarged view of a portion of a support showing the central hinge and a portion of the handle; [0016]
FIG. 7 is a side elevational view of a portion of a support showing an alternative lift assist; and [0017]
FIG. 8 is a side elevational view of a portion of a collapsed support showing the alternative assist.[0018]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

A collapsible delivery container according to a preferred embodiment of the present invention is shown in FIG. 1 and generally designated [0019] 10. The container 10 generally includes a base 12 and a top 14 that are interconnected by folding supports 16 a-b, preferably located in the four corners of the container 10. The folding supports 16 a-b permit the container to be collapsed when empty, thereby saving space during storage and return shipment. The container 10 includes handles 52 and 54 that facilitate collapse of the container 10 one side at a time. The present invention is described in connection with a generally rectangular delivery container configured to ship relatively large and heavy components. The present invention is, however, well suited for use in other application and may be fitted with a variety of alternative dunnage structures or with no dunnage structure at all.
As noted above, the [0020] container 10 includes a base 12, which generally forms the bottom of the container 10, and a top 14, which generally closes the upper end of the container 10. In the illustrated embodiment, the base 12 includes a peripheral frame generally following the footprint of the container. The base 12 is preferably dimensioned to correspond in size and shape with a conventional pallet. Referring to FIG. 2, the base 12 includes four cross members 20 a-d arranged in a generally rectangular configuration. In the illustrated embodiment, the cross members 20 a-d are interconnected with and extend between the supports 16 a-d (described below). The cross members 20 a-d are preferably connected to the lower nesting sections 28 a-d of the supports 16 a-d a sufficient distance from the bottom end of the supports 16 a-d to permit the forks of a fork lift to pass beneath the cross members 20 a-d. A plate 22 a-d extends beneath each cross member 20 a-d, preferably in alignment with the bottom of the supports 16 a-d and in parallel relationship. Accordingly, the plates 22 a-d cooperate with the bottom ends of the supports 16 a-d to form the bottom of the container 10. The illustrated base construction is merely exemplary, and one skilled in the art will readily appreciate that the base 12 may include a wide variety of alternative constructions.
The top [0021] 14 is mounted upon the supports 16 a-d to generally form the top of the container 10. In the illustrated embodiment, the top 14 includes a peripheral frame generally matching the size and shape of the base 12. Referring to FIG. 2, the top 14 includes four cross members 21 a-d arranged in a generally rectangular configuration. The cross members 21 a-d are mounted between the four upper nesting sections 26 a-d of the supports 16 a-d, for example, by welding. As with the base 12, the illustrated top construction is merely exemplary, and one skilled in the art will readily appreciate that the top 14 may include a wide variety of alternative constructions.
The [0022] base 12 and top 14 may, as in the illustrated embodiment, include mounting structure to permit the installation of a dunnage structure. For example, the base 12 and top 14 may each include a plurality of parallel rods 24 adapted to receive and hold a flexible dunnage structure 200. The rods 24 are illustrated in FIG. 2. The dunnage structure 200 may be a conventional flexible bag-type structure that includes a plurality of pockets 202 adapted to received and separately support the products to be shipped. The size, shape and configuration of the pockets 202 may vary from application to application. Flexible dunnage structure is preferred in many embodiments because it can be collapsed and raised automatically with the container 10. Although rigid dunnage structure may be used, it may be necessary to remove rigid structure before the container can be collapsed and then reinsert the rigid structure when the container is raised. The collapsible delivery container may be provided with any of a wide variety of alternative dunnage structures, including without limitation hanging pouches, racks and bags. In some applications, the container may include no dunnage structure, and hence no dunnage mounting structure is necessary. In some applications it may be desirable to provide the container with a full or partial floor (not shown) or ceiling (not shown) that is supported by the corresponding cross members. If desired, the floor and ceiling may be solid, such as sheet or plate metal, or may be perforated, such as expanded metal.
The [0023] base 12 and top 14 are interconnected by folding supports 16 a-d that permit the container 10 to collapse when desired. The container 10 of the illustrated embodiment includes four supports 16 a-d, one located in each corner of the container 10. The supports 16 a-d extend in a generally vertical orientation and are interconnected with the base 12 and the top 14. As noted above, the supported 16 a-d are articulated to permit collapse of the container 10. To provide this function, each support 16 a-d includes a plurality of hinged sections. More specifically, each support 16 a-d generally includes a lower nesting section 28 a-d interconnected with the base 14, a lower folding section 38 a-d hingedly secured to the lower nesting section 28 a-d at a lower hinge 72 a-d, an upper folding section 36 a-d hingedly secured to the lower folding section 28 a-d at a central hinge 74 a-d and an upper nesting section 26 a-d that is interconnected with the top 14 and hingedly secured to the upper folding section 36 a-d at an upper hinge 76 a-d. The various support sections 26 a-d, 28 a-d, 36 a-d and 38 a-d of the illustrated embodiment are manufactured from tubular steel. The materials from which the container is manufactured may, however, vary from application to application depending on various factors, including the desired strength, price point, weight and intended use of the container. In the illustrated embodiment, the lower, central and upper hinges are configured to provide offset hinge locations so that the folding sections 36 a-d and 38 a-d fold flat onto one another when the container 10 is collapsed. The lower hinge 72 a-d includes a pair of hinge plates 86 a-b that are affixed to the corresponding lower folding section 38 a-d, a hinge sleeve 88 that is affixed to the lower nesting section 28 a-d and a hinge pin 90 that pivotally interconnected the hinge plates 86 a-d and the hinge sleeve 88 a-d (See FIG. 3). The hinge pin 90 may be a conventional bolt that passes through the hinge plates 86 a-d and the hinge sleeve 88 a-d, and that is secured by a lock nut. The central hinge 74 a-d includes a first hinge plate 92 a affixed to the lower folding section 38 a-d and a second hinge plate 94 b affixed to the upper folding section 36 a-d (See FIGS. 3 and 6). The hinge plates 92 a-b are pivotally interconnected by the handles 52 and 54 as described in more detail below. The upper hinge 76 a-d includes a pair of hinge plates 96 a-b that are affixed to the upper folding section 36 a-d, a hinge sleeve 98 that is affixed to the upper nesting section 26 a-d and a hinge pin 100 that pivotally interconnected the hinge plates 96 a-d and the hinge sleeve 98 a-d. Like hinge pin 90, hinge pin 100 may be a conventional bolt that passes through the hinge plates 96 a-b and the hinge sleeve 98, and that is secured by a lock nut. It should be noted that the structure of the lower, central and upper hinges may vary from application to application. For example, in certain applications, the hinges of the preferred embodiment may be replaced by conventional piano hinges or other similar hinging mechanisms.
To permit stacking of containers, the top end of each [0024] support 16 a-d is configured to nest with the bottom end of another support 16 a-d. The nesting may be achieved by providing the top end of each upper nesting section 26 a-d with a protrusion 30 and the bottom end of each lower nesting section 28 a-d with a recess (not visible) adapted to receive the protrusion 30. In a preferred embodiment, the nesting sections 26 a-d and 28 a-d are also configured to nest when the container is collapsed. As perhaps best shown in FIG. 3, the bottom end of each upper nesting section 26 a-d includes a protrusion 31 and the upper end of each lower nesting section 28 a-d defines a recess 33 adapted to receive the protrusion 31. When the container 10 is collapsed the protrusion 31 and recess 33 nest to help maintain proper alignment between the top 14 and bottom 12 (See FIGS. 4 and 5). The protrusions and recesses can be replaced by other nesting structure as desired.
Each [0025] support 16 a-d may also be fitted with a locking sleeve 120 that is selectively movable over one of the hinges to prevent the hinge from opening, and consequently, the support from folding. For purposes of disclosure, a locking sleeve 120 is shown in FIG. 3 over support 16 c. Although only illustrated over support 16 c, a separate locking sleeve 120 is preferably mounted over each support 16 a-d. In the illustrated embodiment, the locking sleeve 120 is a generally tubular segment that is fitted over and slidably movable along the support 16 c. The locking sleeve 120 is loosely fitted over the lower folding section 38 c so that it may slide down over the lower hinge 72 to prevent collapse of the support 16 c. The locking sleeve 120 preferably moves into the locked position automatically by gravity as the lower folding section 38 c reaches the raised position. The container 10 preferably includes a retaining pin 121 for securing the locking sleeve 120 in a raised position when it is desired to collapse the container 10. The locking sleeve 120 is shown in the raised position in phantom lines in FIG. 3. The retaining pin 121 is preferably fitted through holes in the locking sleeve 120 and corresponding holes in the lower folding section 38 a-d. The locking sleeve may alternatively be secured using other conventional mechanisms, such as a spring-loaded pin or by a friction fit. The illustrated locking sleeve 120 is merely exemplary, and the size, shape and configuration of the locking sleeve 120 may vary from application to application.
As an additional or alternative locking mechanism, one or more of the [0026] supports 16 a-d may include a locking pin 122 that locks one or more of the hinges in the raised position. For purposes of disclosure, a locking pin 122 is shown mounted to a central hinge 74 b in FIG. 7. Although only illustrated in central hinge 74 b, a separate locking pin 122 is preferably installed in each central hinge 74 a-d. In the illustrated embodiment, the locking pin 122 is fitted into the central hinge 74 to lock the central hinge 74 in the raised position. More specifically, the hinge plates 92 a-b and upper folding sections 36 a-d define locking pin holes (not shown) that are aligned when the support is raised. To lock the central hinge 74, the support 16 c is moved into the fully raised position, thereby bring the locking pin holes into alignment. The locking pin 122 is then fitted through the holes 132 to lock the sleeve in place. The locking sleeve 120 and locking pin 122 are exemplary locking mechanisms, and may be replaced by other locking mechanisms.
In the illustrated embodiment, the four [0027] supports 16 a-d extend between the upper and lower extremes of the container 10. As shown, the upper and lower nesting sections 26 a-d, 28 a-d extend through the corners of the top 14 and base 12. In this way, the supports 16 a-d directly engage the ground or other surface on which the container is placed, while at the same time directly supporting any above stacked containers. Alternatively, the upper and lower nesting sections 26 a-d, 28 a-d of each support can be eliminated, and the upper and lower folding sections can be hingedly secured directly to the top and bottom. In this alternative embodiment (not shown), the top and base are configured to provide a structural framework having mounting locations at or near the corners for the upper and lower folding sections of the supports.
The [0028] container 10 preferably includes a pair of handles that facilitate collapse of the container 10 one side at a time. In the illustrated embodiment, each handle is connected to two adjacent legs so that both legs can be controlled by a single handle. This permits an individual to simultaneously control the folding of two legs and consequently the collapse of one side of the container. In this embodiment, the container 10 is configured so that the front and rear of the container 10 collapse separately. Accordingly, handle 52 is connected to the left and right supports, namely supports 16 a-b, at the front of the container and handle 54 is connected to the left and right supports at the rear of the container 10, namely supports 16 c-d. Alternatively, the container 10 may be configured to permit the left and right sides of the container to collapse separately, for example, by connecting one handle to the front and rear supports on the right side of the container and the other handle to the front and rear supports on the left side of the container. Referring now to FIGS. 2 and 5, the handles 52, 54 are configured so that they are accessible when the container is collapsed or raised, yet do not significantly extend into the opening between the supports so that they do not interfere with access to dunnage structure or components packaged in the container. In the illustrated embodiment, the handles 52, 54 are generally U-shaped and each includes a cross member 56 extending between a pair of extension portions 58 and 60. The extension portions 58 and 60 are configured to mount to the supports at or near the central hinge location. More specifically, each extension portion 58, 60 terminates in a mounting axle 62 (perhaps best shown in broken line in FIG. 6) that is fitted through the hinge plates 64 on the corresponding support. To reduce components, the mounting axle 62 also functions as an axle for the corresponding central hinge 74 a-d. A tubular spacing sleeve 66 is fitted over the mounting axle 62. The outside diameter of the sleeve 66 is preferably greater than the diameter of the corresponding holes in the hinge plates 64. The length of the sleeve 66 corresponds to the spacing between the hinge plates 64 so that it maintains the spacing between the hinge plates 64 and hence the alignment between the upper and lower folding sections. The end of each axle 62 is preferably threaded to receive a lock nut 70 that secures the axle 62 in place. The axle 62 can be secured using other techniques, for example, by flaring, peening, enlarging or otherwise changing the shaping the end of the axle 62 so that it is not readily removed from the hinge plates 64. Alternatively, the handle 52, 54 may be separate from the central hinge, for example, by mounting to the supports adjacent to the central hinge. In this alternative embodiment (not shown), the central hinge may include a hinge pin or other conventional hinge mechanism in place of the axle 62.
The [0029] extension portions 58 and 60 of each handle 52, 54 preferably include an intermediate bend 72 that provides additional control over collapse and raising of the upper folding sections. The intermediate bend 72 extends through the vertical plane defined by the movement of the folding sections. As a result, when the handles 52 are 54 are manipulated properly by the user, the intermediate bends 72 can be brought into contact with the corresponding upper folding sections 36 a-d (See Arrow A, FIG. 3). When collapsing the container 10, the bends 72 can thus be used as a brake to slow or stop collapse of the container 10. When raising the container 10, the bends 72 can also be used to lift the upper folding sections. This can be particularly helpful in providing an initial boost when raising the container. The shape and location of the bend 72 may vary from application to application. The bend may also be replaced by other structure extending into the vertical plane of the supports, for example, by a leg or other protrusion (not shown) extending into the vertical plane from each extension portion 58, 60.
With large containers, the [0030] supports 16 a-d are preferably provided with a lift assist that biases the supports toward the raised (or unfolded) position or otherwise bears at least a portion of the weight of the collapsing portions of the container 10. The lift assist can be provided by a variety of mechanisms. In the illustrated embodiment, the list assist includes an extension spring 110, such as a coil spring, fitted within each support 16 a-d. For purposes of disclosure, an extension spring 110 lift assist is illustrated in broken lines in support 16 a of FIGS. 2 and 3. Although only illustrated in support 16 a, a separate extension spring 110 or other lift assist is preferably installed on or within each support 16 a-d. As shown, the extension spring 110 is affixed at one end to the lower folding section 38 a and at the other end to the upper folding section 36 a. The extension spring 110 is preferably affixed to the upper folding section 36 a-d by a cable 112 or other similar component so that the extension spring 110 is not itself visible when the central hinge 74 a-d is opened. The extension spring 110 is preferably mounted so that it is under tension regardless of the position of the supports 16 a-d. In use, opening of the central hinge 74 a-d causes the distance between opposite ends of the lift assist to increase, thereby stretching the extension spring 100 and applying an increased biasing force to the support 16 a-d. As a result, the extension spring 110 has the effect of lessening the apparent weight of the top 104 making it easier to control collapsing and raising of the container. The extension spring can be replaced by other lift assist devices, including both internal and external devices. For example, the lift assist may alternatively include other elastic or resilient components, such as an alternative extension spring, a compression spring, a bungee chord, a rubber strap, a torsion spring, a bendable rod or a gas-assist cylinder. These alternative lift assist mechanism may be disposed within the tube or mounted to the exterior of the tube as required. In some applications, the lift assist may be mounted between the top and the base rather than directly to the supports, for example, a gas assist cylinder (not shown) may be mounted between the top and base. In some applications, it may be desirable to incorporate the lift assist into the hinges, for example, by replace the hinges described above with spring-loaded hinges.
An alternative lift assist is shown in FIGS. 7 and 8. In this alternative embodiment, a pair of conventional compression springs [0031] 10 a-b′ are disposed within one or more of the supports 16 a-d to bias the corresponding support 16 a-d toward the raised position. As shown, a first compression spring 110 a′ is mounted within the upper folding section 36 a and a second compression spring 110 b′ is mounted within the lower folding sections 38 a. Each compression spring 110 a-b′ includes a fixed end 111 that is fixedly mounted to the support 16 and a free end 113 that extends freely into the support 16 in a direction away from the central hinge 74. A cable 112′ or other flexible element is mounted between the free ends 113 of the two compression springs 110 a-b′. The cable 112′ preferably extends from the free ends 113 through the center of each compression spring 110 a-b′. In this embodiment, the cable 112′ is connected to the free ends 113 of each spring 110 a-b′ by a washer 150 and a stop sleeve 152. The washer 150 preferably includes an outer diameter that is greater than the inner diameter of the compression springs 110 a-b′ to prevent the washer 150 from being pulled into the center of the springs 110 a-b′. The stop sleeve 152 is preferably crimped or otherwise secured to the cable 112′ to lock the washer 150 in place. The cable 112′ may be secured to the compression springs 110 a-b′ using alternative techniques and apparatus. As the support 16 is collapsed, the central hinge 74 swings open, thereby increasing the effective distance between the free ends 113 of the two compression springs 110 a-b′. Because the cable 112′ is secured between the springs 110 a-b′ at a fixed length, the collapsing action causes the cable 112′ to compress the two compression springs 110 a-b′. This compression biases the support 16 in the raised (or unfolded) position, thereby bearing at least a portion of the weight of the collapsing portions of the container 10. Although this embodiment is described with two compression springs 110 a-b′ (one in each folding section), the lift assist may alternatively include only a single compression spring located in one of the two folding sections. In this “one-spring” alternative, one end of the cable is secured to the free end of the compression spring and the other end is secured to the folding section that does not include the compression spring. When the support 16 is collapsed, the single compression spring is compressed to provide the desired lift assist. The precise characteristics of the compression springs, cable and other elements of the alternative lift assist will vary from application to application depending primarily on the weight of the container and the desired amount of list assist.
As noted above, the [0032] container 10 is raised during loading and shipment of products, and can be collapsed to save space once the container 10 is empty. The container 10 is specially configured to permit a single individual to easily raise and collapse the container one side at a time. The process of raising and collapsing the container one side at a time will now be described in some detail. Either side of the container 10 can be raised/collapsed first. For purposes of this disclosure, the process will be described by first raising the front of the container and then the rear of the container. The collapsing process will be described in reverse. To raise the front of the container, the individual manipulates handle 52. As noted above, the handle 52 is connected to the central hinges 74 of the corresponding supports 16 a-b so that manipulation of the handle 52 provides direct control over the movement of the central hinges 74. By lifting upwardly on the handle 52, the user causes the intermediate bends 72 to engage the upper folding sections 36 a-b, thereby provides an initial boost to the lifting process. It should be noted that the lift assist 109 provides a force that assists in lifting the container 10 as described above. As a result, the individual is not required to lift the entire weight of the components to be raised at the front of the container 10. By pulling outwardly and upwardly on the handle 52 the central hinges 74 are lifted and drawn outwardly, thereby causing the supports 16 a-b to unfold, which in turn raises the front of the top 14. During this motion, the nesting engagement between the top 14 and base 12 at the rear of the container 10 helps to prevent the top 14 from shifting undesirably. Once the supports 16 a-b are fully unfolded, a locking sleeve 120 is secured in place over the lower hinge 72 of preferably at least one of the supports 16 a-b. As noted above, the locking sleeve 120 preferably drops down over the lower hinge 72 automatically by gravity as the supports 16 a-b reach the fully raised position. Additionally, the central hinge 74 of preferably at least one of the supports 16 a-b is locked used a locking pin 122. In the illustrated embodiment, the locking sleeve 120 will maintain the front of the container 10 in the raised position, thereby facilitating installation of the locking pins 122. To further ease the locking process, the supports 16 a-d may be configured to unfold to a position that is slightly over-center. As a result, the weight of the top 14 will tend to hold the central hinges 74 open and the supports 16 a-d in the raised position. Once locked in the raised position, the user allows the handle 52 to swing down against the container 10 into a resting position (See FIG. 1). Because of its unique configuration, the handle 52 does not extend substantially into the space between the supports 16 a-b and therefore will not inhibit access to the interior of the container 10. If desired, a strap, clasp, latch (not shown) or other mechanism can be provided to retain the handle 52 in the resting position. The individual next raises the rear of the container 10 by unfolding supports 16 c-d through manipulation of handle 54. Again, the handle 54 may be lifted to provide an initial boost to the unfolding process. The handle 54 can then be drawn outwardly and upwardly until the supports 16 c-d are fully unfolded. As when lifting the front of the container, the lift assist 109 bears some of the weight of the portions of the container 10 to be raised making it easier to lift the rear of the container. Once raised, a locking sleeve 120 is secured in place over the lower hinge 74 of at least one of the two supports 16 c-d. The central hinge 74 of preferably at least one of the supports 16 c-d is locked by a locking pin 122. With the illustrated embodiment, the process of raising the container 10 automatically opens the flexible dunnage structure 200 that is mounted between the top 14 and base 12. As a result, the raised container 10 is ready to receive products. Loaded containers 10 are easily moved using a fork lift or other similar machinery, and can be stacked one on top of the other with the protrusions 30 of one container nesting with the recesses of the other.
After the [0033] container 10 has been emptied, the container 10 is easily collapsed so that it requires less space for shipping and storage. The container 10 is collapsed in essentially the reverse of the process described above. In short, the locking pin(s) 122 of the rear supports 16 c-d are removed and the locking sleeve(s) 120 are moved into the unlocked position so that the lower hinges 72 and central hinges 74 can move. The handle 54 is then pushed inwardly causing the upper and lower folding sections 36 c-d and 38 c-d to fold inwardly. The process continues until the top 14 is brought into contact with the base 14, and more specifically, until the protrusions 31 are nested within the recesses 33. This nesting interaction will help to maintain proper alignment between the top 14 and base 14 as the opposite side of the container 10 is collapsed. During the collapsing process, the lift assist 109 will bear a portion of the weight of the container 10 reducing the weight that must be supported by the user. The front of the container 10 is next collapsed through essentially the same process: the locking pin(s) 122 are removed from the front supports 16 a-d; the locking sleeve(s) 120 are moved to the unlocked position; and the handle 52 is manipulated to cause the supports 16 a-b to collapse at central hinges 74. As the container 10 is collapsed, the flexible dunnage structure also collapses folding onto itself so that it is contained within the collapsed container 10 ready for expansion when the container 10 is again raised. Collapsed containers 10 are easily moved using a fork lift other similar machinery. Like the raised containers, the collapsed containers can be stacked one atop the other with the protrusions 30 of one container nesting with the recesses 32 of the other. If desired, the container 10 may include bungee straps (not shown) or other retaining devices to secure the container 10 in the collapsed position.
The above description is that of a preferred embodiment of the invention. Various alterations and changes can be made without departing from the spirit and broader aspects of the invention as defined in the appended claims, which are to be interpreted in accordance with the principles of patent law including the doctrine of equivalents. Any reference to claim elements in the singular, for example, using the articles “a,” “an,” “the” or “said,” is not to be construed as limiting the element to the singular. [0034]

Claims

The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows:

1. A collapsible shipping container comprising:

a base;

a top;

a plurality of supports mounted between said base and said top, each of said supports including a top hinge, a bottom hinge and an intermediate hinge permitting each of said supports to fold inwardly and thereby permitting said container to be selectively movable between a raised position and a collapsed position; and

a handle movably mounted to at least one of said supports adjacent said intermediate hinge, said handle being accessible from an exterior of said container when said container is in said collapsed position.

2. The collapsible shipping container of claim 1 wherein said handle is mounted between at least two of said supports.

3. The collapsible shipping container of claim 1 wherein said handle is generally U-shaped having a first end connected to a first of said supports and a second end connected to a second of said supports.

4. The collapsible shipping container of claim 1 wherein at least one of said supports travels through a plane as the container moves between said raised position and said collapsed position, said handle including a portion extending into said plane, whereby said portion is capable of engaging at least one of said supports as the container moves between said raised position and said collapsed position.

5. The collapsible shipping container of claim 3 wherein an opening is defined between said first support and said second support, said opening being substantially unimpeded by said handle.

6. The collapsible shipping container of claim 1 wherein said handle includes a first extension portion connected to a first of said supports, a second extension portion connected to a second of said supports and a cross member interconnecting said first extension portion and said second extension portion, wherein when said handle is in said raised position said first extension portion extends substantially along said first support, said second extension portion extends substantially along said second support and said cross member extends substantially along one of said top and said base, whereby said handle does not substantially impede access to an interior of said container through a space between said first support and said second support.

7. The collapsible shipping container of claim 6 wherein at least one of said supports includes a lift assist means for biasing at least one of said supports toward a raised position.

8. The collapsible shipping container of claim 6 further including a lift assist mechanism bearing at least a portion of the weight of the container as the container is moved between said raised position and said collapsed position.

9. The collapsible container of claim 8 wherein at least one of said top and said bottom includes a nesting protrusion, the other of said top and said bottom including a nesting recess, whereby said nesting protrusion and said nesting recess nest when together said container is in said collapsed position.

10. The collapsible shipping container of claim 7 wherein said list assist means includes at least one of an extension spring, a torsion spring and a gas assist cylinder.

11. The collapsible shipping container of claim 1 further comprising a locking sleeve movably fitted over at least one of said supports.

12. A collapsible shipping container comprising:

a base;

a top;

a plurality of supports mounted between said base and said top, each of said supports including a top hinge, a bottom hinge and an intermediate hinge permitting each of said supports to fold inwardly and thereby permitting said container to be selectively movable between a raised position and a collapsed position;

a nesting means for nesting said top and said bottom when said container is moved into said collapsed position.

13. The collapsible container of claim 12 wherein said nesting means include an upper nesting section connected to said top and a lower nesting section mounted to said base.

14. The collapsible container of claim 12 wherein said nesting means includes an upper nesting section connected to said top in vertical alignment with one of said supports and a lower nesting section mounted to said base in vertical alignment with one of said supports.

15. The collapsible container of claim 12 wherein said container includes a plurality of corners, said plurality of supports including a separate support disposed substantially in each of said corners, said nesting means including a plurality of upper nesting sections and a plurality of lower nesting sections, one of said upper nesting sections and one of said lower nesting sections being vertically aligned with a corresponding one of said supports.

16. The collapsible container of claim 15 further comprising a handle mounted to at least one of said supports adjacent said intermediate hinge, said handle being accessible from an exterior of said container when said container is in said collapsed position.

17. The collapsible container of claim 15 wherein said handle is generally U-shaped having a first end connected to a first of said supports and a second end connected to a second of said supports.

18. The collapsible container of claim 16 further including a lift assist mechanism.

19. A collapsible container, comprising:

a base;

a top;

a plurality of supports mounted between said base and said top, each of said supports being hinged to permit each of said supports to fold inwardly, thereby permitting said container to be selectively movable between a raised position and a collapsed position; and

a lift assist means for bearing a portion of the weight of the container when the container is moved between said raised position and said collapsed position.

20. The collapsible container of claim 19 wherein said lift assist means includes a lift assist device mounted to at least one of said supports.

21. The collapsible container of claim 19 where said lift assist means includes a lift assist device mounted to each of said supports.

22. The collapsible container of claim 20 wherein at least one of said supports includes a first section hingedly secured to a second section, said lift assist device includes an extension spring mounted between said first section and said second section.

23. The collapsible container of claim 20 wherein at least one of said supports includes a first section hingedly secured to a second section, said lift assist device includes a torsion spring mounted between said first section and said second section.

24. The collapsible container of claim 20 wherein said lift assist device includes a gas assist cylinder mounted between at least one of said supports and at least one of said top and said base.

25. The collapsible container of claim 22 wherein said at least one support defines an internal void, said extension spring being disposed within said internal void.

26. The collapsible container of claim 20 wherein each of said supports includes an intermediate hinge; and

further comprising a handle mounted to at least one of said supports adjacent said intermediate hinge, said handle being accessible from an exterior of said container when said container is in said collapsed position.

27. The collapsible container of claim 26 wherein said handle is generally U-shaped having a first end connected to a first of said supports and a second end connected to a second of said supports.

28. The collapsible container of claim 27 wherein said top includes an upper nesting portion and said base includes a lower nesting portion, said upper nesting portion interfitting with said lower nesting portion when said container is in said collapsed position.

29. A collapsible delivery container having a first side and a second side, the container adapted to be raised and collapsed one side at a time, comprising:

a base;

a top;

a first pair of hinged supports extending between said base and said top on a first side of said container;

a second pair of hinged supports extending between said base and said top on a second side of said container, said second pair of supports being actuatable independently of said first pair of supports;

a first handle mounted to each support in said first pair of hinged supports, whereby said first handle facilitates simultaneous folding and unfolding of both supports of said first pair of supports; and

a second handle mounted to each support in said second pair of hinged supports, whereby said second handle facilitates simultaneous folding and unfolding of both supports of said second pair of supports.

30. The container of claim 29 wherein said first handle is U-shaped having a first end connected to one of said supports of said first pair of supports and a second end connected to the other of said supports of said first pair of supports.

31. The container of claim 30 wherein each of said support of said first pair of supports includes an intermediate hinge, said first end of said handle being mounted proximate to said intermediate hinge of one of said supports of said first pair of supports, said second end of said handle being mounted proximate to said intermediate hinge of the other of said supports of said first pair of supports.

32. The container of claim 31 wherein said handle is accessible from an exterior of said container when said container is in said collapsed position.

33. The container of claim 29 wherein said top includes a first upper nesting portion on said first side of said container and a second upper nesting portion on said second side of said container, said base includes a first lower nesting portion on said first side of said container and a second lower nesting portion on said second side of said container, said first upper nesting portion interfitting with said first lower nesting portion when said first side of said container is in said collapsed position, said second upper nesting portion interfitting with said second lower nesting portion when said second side of said container is in said collapsed position.

34. The container of claim 29 further comprising a lift assist means for bearing a portion of the weight of the container when the container is moved between said raised position and said collapsed position.

35. The container of claim 29 further comprising a first lift assist device mounted to said first side of said container and a second lift assist device mounted to said second side of said container.

36. The container of claim 35 where said first lift assist device includes at least one of an extension spring, a torsion spring and a gas assist cylinder.