WO1994001333A1

WO1994001333A1 - Methods and apparatus for collapsible storage structures

Info

Publication number: WO1994001333A1
Application number: PCT/NZ1993/000043
Authority: WO
Inventors: Brian Clifford Sullivan
Original assignee: Flight Group Limited
Priority date: 1992-07-02
Filing date: 1993-05-20
Publication date: 1994-01-20
Also published as: AU4094693A

Abstract

A collapsible storage structure (1) comprises a base panel (2), side panels (3a-d), a first connecting means (4) for connecting an edge (5) of the side panels (3a-d) to the base panel (2), second connecting means (15a-d) for connecting adjacent edges (16) of the side panels (3a-d) together, wherein each of the first and second connecting means (4, 15a-d) comprise a substantially elongate member having at least one recessed portion (6, 17, a, b) of predetermined section formed therein, the edges (5, 16) of the side panels (3a-d) being formed to a corresponding or complementary predetermined section or shape, whereby the edges (5, 16) are only slidable in and along the longitudinal axis of the recessed portions (6, 17, a, b). A method of forming or assembling a collapsible box structure (1) is also described.

Description

METHODS AND APPARATUS FOR COLLAPSIBLE STORAGE STRUCTURES

TECHNICAL FIELD

This invention relates to apparatus and methods for forming collapsible storage stmctures. The invention may be particularly suitable for forming collapsible boxes or crates that may be repeatedly used for the storage and/or transportation of liquids, goods and/or produce from one place to another. However, it should be understood that it need not be limited to such.

BACKGROUND ART

Wooden boxes or crates are often used for the transportation of goods or produce from one place to another, either within a country or for export to another country. The boxes or crates are generally comprised of a rigid and non-collapsible structure.

On arrival at their destination, and once the goods or produce has been removed, a problem often arises as to how the recipient should dispose of the empty crate(s). Usually, the crates are earmarked to be destroyed, resold or transported back to the sender. However, there are significant disadvantages associated with each of these options.

Firstly, with the growing environmental conscience of most countries, the destruction of the crates is becoming a less desirable option having regard to the wastage factor involved (as well as the cost to the sender who has to purchase replacement crates). Moreover, there are an ever increasing number of countries demanding (and legislating) transportation boxes and crates be recyclable, i.e. reusable. Hence, many countries now (or will soon) require that used crates be either resold, or sent back to the sender.

The main disadvantage associated with reselling the used crates is that the reselling price is generally only a fraction of the production cost or purchase price of the crates. Hence, a sender will have to purchase new crates every time goods or produce are transported. This expense will be passed onto the recipient of the goods, and ultimately therefore the consumer.

Returning the crates to the sender is arguably die best option. However, a disadvantage associated with this option is that the crates are usually bulky and, being non-collapsible, they therefore take up considerable room. Hence, exporters or suppliers of goods or produce may find the freight costs involved in shipping the crates back to themselves prohibitive and/or uneconomic.

In recognition of this, there has recently become available a collapsible crate (the subject of New Zealand Patent Application No. 238460), which has side panels fixable to base and top panels by pushing the side panels into aluminium extrusions fixed to the base and top panels. However, disadvantages associated with this type of crate are: the extrusions are screwed into the top and base panels, and therefore additional tools and fittings such as screws and screw drivers are required; the overall structure is somewhat tight fitting, and often tools such as hammers are required to assemble and disassemble the crate; the extrusions attached to the base portion protrude awkwardly therefrom when the box or crate has been disassembled, and are therefore susceptible to being broken off or otherwise getting in the way; the crates may not be particularly suitable for carrying liquids since the extrusions are provided with sharp portions that may puncture or pinch any liquid lining bags (hence, if liquid bladders are to be transported, sub liners are required to be fitted within the box); the side panels must be of a specific thickness in order to be able to slot into the pre-formed extrusions; the side panels may be unwittingly de-laminated or otherwise deformed when being pushed into the slots of the extrusions.

It is an object of the present invention to address the foregoing problems or at least to provide the public with a useful choice.

Further aspects and advantages of the present invention will become apparent from the ensuing description which is given by way of example only.

DISCLOSURE OF INVENTION

According to one aspect of the present invention there is provided a collapsible storage structure comprising: (a) a base panel,

(b) side panels,

(c) a first connecting means for connecting an edge of said side panels to said base panel,

(d) a second connecting means for connecting adjacent edges of said side panels together, wherein each of said first and second connecting means comprises a substantially elongate member having at least one recessed portion of predetermined section formed therein, the edges of said side panels being formed to a corresponding or complimentary predetermined section or shape, whereby said edges are only slidable in and along the longitudinal axis of said recessed portions.

According to another aspect of the present invention there is provided a collapsible storage structure substantially as described above wherein said first connecting means is adapted to be fitted along or around the edges and/or peripheral surfaces of said base panel.

According to another aspect of the present invention there is provided a collapsible storage structure substantially as described above wherein said second connecting means is provided with at least two recessed portions having substantially parallel axes. According to another aspect of the present invention there is provided a collapsible storage structure substantially as described above wherein each said second connecting means forms a corner of said collapsible storage structure.

According to another aspect of the present invention there is provided a collapsible storage structure substantially as described above wherein said first and/or said second connecting means are provided with arcuate portions and/or surfaces for providing substantially smooth and rounded corners or surfaces between adjacent panels.

According to another aspect of the present invention there is provided a collapsible storage structure substantially as described above wherein there is further provided a corner connecting member which is able to be fitted to adjacent ends of said first and/or said second connecting means in the region of a corner of said collapsible storage structure, said corner connecting member being provided with arcuate portions and/or surfaces for providing substantially smooth and rounded corners or surfaces in or adjacent to a corner region of said collapsible storage structure.

According to another aspect of the present invention there is provided a collapsible storage structure substantially as described above wherein said recessed portion(s) of said first and/or second connecting means is an elongate channel having a base part and an entry part, said base part being wider than said entry part.

According to another aspect of the present invention there is provided a collapsible storage structure substantially as described above wherein said recessed portion(s) in said first and/or second connecting means is dove-tail shaped.

According to another aspect of the present invention there is provided connecting means for a collapsible storage structure, substantially as described above, comprising an elongate substantially tubular body having two recessed portions substantially at right angles to one another. According to another aspect of the present invention there is provided connecting means for a collapsible storage structure, substantially as described above, comprising an elongate substantially tubular body having two substantially aligned recessed portions.

According to another aspect of the present invention there is provided connecting means for a collapsible storage structure, substantially as described above, comprising an elongate substantially tubular body having a single recess portion and two attachment faces.

According to another aspect of the present invention there is provided a corner connecting member for a collapsible storage structure, substantially as described above. According to another aspect of the present invention there is provided a method of assembling a collapsible box structure substantially as described above, comprising the steps of:

(a) fitting said first connecting means along or around the edges and/or peripheral surfaces of said base panel, (b) sliding the bottom edges of said side panels in and along the longitudinal axes of said recessed portions of said first connecting means,

(c) sliding the second connecting means along the edges of adjacent side panels to be connected, the edges of the adjacent side panels sliding in and along, the longitudinal recessed portions of said second connecting means. According to another aspect of the present invention there is provided a method of assembling a collapsible box structure substantially as described above, said method further including the steps of fitting said corner connecting member into said recessed portions at the ends of said first connecting means, in the region of, or adjacent, a corner of said collapsible storage structure, and subsequently butting the ends of the said second connecting means against or over said corner connecting member.

According to another aspect of the present invention there is provided a method of assembling a collapsible box structure substantially as described above, wherein said method includes steps of attaching or placing a lid on said collapsible storage structure thus formed, and securing said lid to said collapsible storage structure.

Preferably, a collapsible box or crate may be formed from the collapsible storage structure. A collapsible box or crate formed from the collapsible storage structure may be of any suitable size, shape or configuration that is required or desired. For example, the formed box may be a triangle, square, quadrilateral, hexagon, or any other shape as may be required or desired. In a preferred example, the box or crate to be formed may be substantially square. In such a case, the formed box or crate may be approximately 1 cubic metre, this is a convenient size. It may preferably be destined for use in storing and/or re-usably transporting liquids, goods, or produce.

The base panel of the collapsible storage structure may be provided with runners for supporting the structure above the ground. This also provides access for the forks of a forklift to lift the structure when it is to be loaded, unloaded or otherwise moved. Some or all of the runners may be provided with grooves for receiving and/or retaining strapping that may be used for retaining a lid panel on the formed box. The runners may be joined together (by any suitable means) to provide stability, and to prevent box roll or shear about, or with respect to, the runners. Preferably the runners, and/or joining means for same, may be arranged such that the forks of a forklift have access to the collapsible box structure from each side thereof.

Both the first and second connecting means may preferably comprise an elongate substantially tubular member having at least one recessed portion of predetermined section formed therein. The edges of the side panels may be formed to a corresponding or complimentary predetermined shape or section and may only slide in and along the longitudinal axes of the recessed portions. In this manner, it can be seen that the side panels will not pull out of the connecting means; instead the panels must be slid out of the connecting means.

The first connecting means may preferably be in the form OJ. an extrusion, preferably an aluminium extrusion. The first connecting means may be adapted to be fixable along or around the edge(s) and/or the peripheral surface(s) of the base panel. The extrusion may be fitted to the base panel by any suitable means, and may either b- eleasably attachable thereto, or permanently affixed thereto. The first connecting means may preferably be screwed into the base panel and/or into runners underneath the base panel. Such screws should preferably be long so that the box structure may withstand sideways roll or shear. The recessed portion of the first connecting means may lie in an appropriate configuration whereby side panels may be slid into and along same, and preferably whereby the side panels may be fitted substantially at right angles to the base panel.

The second connecting means may form a comer of the structure, and may preferably be provided with two recessed portions cut therein, substantially at right angles to each other (if a substantially square or rectangular box is to be formed), whereby adjacent edges of two side panels may be connected.

The recessed portions of the first and second connecting means may preferably comprise elongate channels, each having a base part and an entry part, the base part preferably being wider than the entry part. This type of construction allows the side panels to be fitted only to the first and second connecting means by sliding the panel edges in and along the recessed portions. It can also be seen that the side panels may only be removed from the connecting means by sliding, and not by pulling the side panels away from the connecting means.

j&ny suitable arrangement that provides for the base part of the channels to be wider than the entry part of the channels may be used. For example, the base channel may comprise a T-section, and the edges of the side panels may be provided with complimentary section so that they may slot into and be slidable along the T-section. In another embodiment, the recessed portions and edges of the side panels may be connectable in a barb or fish-hook type arrangement. Alternatively, the recessed portions may be in the form of a dove-tail shape or section, and the edges of the side panels may be formed to complimentary shape or section.

It is also envisaged that any other suitable arrangement whereby the base part of the recessed portion or channel is wider than the entry part of the recessed portion or channel may be used as required or as desired. The only requirement is that the side panels should not be able to be pulled away from the connecting means; instead they must be slid along the connecting means to facilitate their removal.

The side panels and base panel may preferably be comprised of any suitable material as required or desired. If comprised of wood, they may be treated to render the panels substantially waterproof or resistant to bugs, if required or desired. The panels may be of any thickness since their edges need only be cut to the predetermined shape or section of the recessed portions in order that they may fit into and slide along same.

The first and/or second connecting means may be provided with portions that provide substantially smooth and rounded comers or surfaces. In this manner, it can be seen that the formed box may be used for carrying liquids in a bag or bladder since there will be no internally extending sharp edges or protrusions that may puncture or interfere with the bag or bladder.

There may also be provided a comer connecting member that may be able to be fitted to adjacent ends of the first and/or second connecting means in the region of a comer of the collapsible storage structure. The comer connecting member may be provided with arcuate portions and/or surfaces for providing substantially smooth and rounded comers or surfaces in or adjacent to a comer region of the collapsible storage structure. The comer connecting member may be of any suitable size, shape and/or configuration as required or desired. The comer connecting member may be comprised of any suitable material, although plastics may be preferred.

If a collapsible box of considerable size or length is to be formed, aligned side panels may be required to be joined. There may therefore be provided a third (mid section) connecting means, provided with two substantially aligned recessed portions for connecting the edges of the side panels to be joined in alignment. The recessed portions of the third connecting means may preferably be of the same or similar shape and configuration as the recessed portions described above for the first and second connecting means.

It is also envisaged that there may be provided other connecting means with one or more recessed portions, substantially as described above. For example, there may be provided connecting means with four recessed portions arranged in a configuration whereby four side panels may be connected substantially at right angles to each other about the connecting means.

We believe the advantages of our invention to be as follows, however it should be appreciated that all such advantages may not be realised on all embodiments of the invention, and the following list if therefore given by way of example only, as being indicative of potential advantages of the present invention. Furthermore, it is not intended that the advantages of the present invention be restricted to those of the list which follows: -

1. The collapsible box structure may be used for re-usably transporting goods or produce from one place to another. After reaching its destination, the box structure may be disassembled and shipped back to the sender - the disassembled box structure taking up only a fraction of the space of an empty assembled box structure, thereby minimising freight costs to the sender.

2. Once the first connecting means (and runners) are fitted to the base panel no other tools or fittings are needed to assemble or disassemble the collapsible box structure. Furthermore, the box structure may be assembled and disassembled readily and easily and without the use of undue force.

3. The design of the recessed portions of the connecting means and the edges of the side panels allows for variations in plywood thickness; i.e. the edges of the side panels need only be pre-formed into an appropriate shape or section in order to be fixable in, and slidable along the recessed portions of the connecting means. 4. Since the side panels cannot be pushed into or pulled out of the recessed portions of the connecting means, the edges of the side panels may not accidentally be de- laminated or otherwise deformed as may occur if they were to be pushed into or pulled out of a tight fitting slotted recess.

5. The arcuate portions of the connecting means, and the inclusion of the comer connecting member, allow for liquid bladders to be carried within the collapsible box structure as there are no sharp edges or protrusions which may interfere with or puncture the bladder.

6. Apart from forming the edges of the side panels to slot into the recessed portions of the connecting means, no other preparations or deformations of the side panels are required prior to fitting.

7. The first connecting means is preferably of a shape or configuration which will not be a hindrance when collapsing, assembling or shipping the collapsed box structure.

Further aspects of the present invention will become apparent from the ensuing description which is given by way of example only and with reference to the accompanying drawings in which:

BRIEF DESCRIPTION OF DRAWINGS

Fig 1: is a perspective view of one possible embodiment of a collapsible storage structure;

Fig 2: is a schematic plan view of the embodiment shown in Fig 1 ;

Fig 3: is a cross section through the region marked "A" in Fig 1 ;

Figs 4a-c: show schematically a part of the collapsible box of Figs 1 & 2 with the addition of a third (mid section) connecting means;

Fig 5: is an inside comer view of the collapsible box of Fig 1 , and

Fig 6: is a perspective view of the comer connecting member of in Fig 5.

Having regard to the drawings, there is shown a collapsible storage structure generally indicated by arrow 1. The collapsible storage structure 1 is in the form of a substantially square collapsible box, and is one cubic metre in volume. The collapsible box 1 comprises a base panel 2 and side panels 3a-d. There is also provided a first connecting means 4 in the form of elongate substantially tubular extrusions for connecting the bottom edges 5 (only 1 shown in Fig 3) of the side panels 3a-d to the base panel 2. The first connecting means 4 is provided with a single recessed portion 6 and two attachment faces 7,8 for engaging with the peripheral surface 9 and edge 10 of the base panel 2 respectively. The attachment faces 7,8 of the first connecting means 4 are attached to the base panel 2 by the use of screws 11,12 respectively.

The recessed portion 6 of the first connecting means 4 is in the form of an elongate channel having a base part 13 and an entry part 14, the base part 13 being wider than the entry part 14.

There is also provided second connecting means 15a-d for connecting adjacent edges 16 of the side panels 3a-d together. The second connecting means 15a-d comprise elongate substantially tubular extrusions, each extrusion having two recessed portions 17a,b positioned substantially at right angles to one another. Each second connecting means 15a-d forms a comer of the collapsible box 1. Each recessed portion 17a,b of the second connecting means 15a-d comprises an elongate channel having base parts 18a,b and entry parts 19a,b, the base parts 18a,b being wider than the entry parts 19a,b.

The recessed portions 6,17a,b of the first and second connecting means 4,15a-d are dove-tail shaped in cross-section.

The arrangement or configuration of the recessed portions 6, 17a,b of the first and second connecting means 4,15a-d only allow for the edges 5,16 of the side panels 3a-d to be slidable in and along the first and second connecting means 4, 15a-d respectively. In this way, it can be seen that the side panels 3a-d will not pull out of the first and second connecting means 4,15a-d; instead the panels 3a-d must be slid out.

The first and second connecting means 4,15a-d are aluminium extrusions. The base panel 2 and side panels 3a-d are comprised of laminated plywood.

The angle 20 of the recessed portions 6,17a,b of the first and second connecting means 4,15a-d is 60°. This angle is preferable as it appears to provide the greatest resistance to the side panels 3a-d being pulled from the first and second connecting means 4,15a-d whilst not compromising the strength of the connection between the panels 3a-d and the first and second connecting means 4,15a-d. Generally, an angle of between 50° to 85° will be sufficient.

The first and second connecting means 4,15a-d are each provided with arcuate portions 21,22a-d. These portions 21,22a-d provide for smooth, rounded comers and surfaces within the box structure 1, and the box structure 1 may therefore be utilised for carrying liquids in a bag or bladder since there are no internally extending sharp edges or protrusions that may puncture or pinch the bag or bladder.

The base panel 2 is provided with a number of runners 23 for supporting the collapsible box 1 above the ground. It can be seen from Fig 1 that the arrangement of the runners 23 provides access, for the forks of a forklift, from all four sides of the collapsible box 1. The runners 4 are held in place by screws 11 (only one shown - in Fig 3) which pass through the first connecting means 4 and the base panel 2. The screws 11 are quite long to minimise sideways movement or shear of the collapsible box 1. The runners 23 are comprise of wood. The runners 23 are provided with grooves 24 to locate and retain strapping which may pass around the box to secure a lid thereupon (lid not shown).

Having regard to Figs 4a-c there is provided a third (mid section) connecting means 25. The third connecting means 25 comprises an elongate substantially tubular extrusion having two aligned recessed portions 26a,b. The recessed portions 26a,b are of the same size, shape and configuration as the recessed portions 6,17a,b of the first and second connecting means 4,15a-d.

The third connecting means 25 provides stability by joining aligned panels 3e,f when a collapsible box structure of considerable length or size is to be formed, and/or comprises more than one panel along each side. The third connecting means 25 is an aluminium extrusion.

Having regard to Figs 5 and 6, there is shown a comer connecting member 27 that is able to be fitted to adjacent ends of the first and second connecting means 4,15a-d. The comer connecting member 27 is provided with two protrusions 28a,b for slotting into the recessed portions 6 of adjacent first connecting means 4. The comer connecting member 27 is also provided with an arcuate portion 29 which buts the bottom end 30 of the second connecting means 15b. The comer connecting member 27 provides for a smooth and rounded comer of the collapsible box 1. Again, this allows for the collapsible box 1 to carry liquids in a bag or bladder.

The collapsible box 1 is assembled in the following manner.

Firstly, the first connecting means 4 are attached along and around the peripheral surfaces 9 and edges 10 of the base panel 2. At the same time, the comer connecting members 27 are fitted to adjacent ends of the first connecting means 4. The runners 23 are also attached to the underside of the base panel 2 at this time. The bottom edge 5 of the side panels 3a-d are then slid along their respective first connecting means 4. The second connecting means 15a-d are then slid down and along adjacent edges 16 of the side panels 3a-d. Apart from the attachment of the first connecting means 4 and the runners 23, no nailing or screwing is required to form the collapsible box structure 1. A lid (not shown) may then be placed on the formed collapsible box structure 1 (preferably after appropπate goods, produce or liquid bladder has been placed within the box stracture 1) and tied down by straps, the straps being located and retained by the grooves 24 of the runners 23.

Aspects of the present invention have been described by way of example only and it should be appreciated that modifications and additions may be made thereto without departing from the spirit or scope thereof, as defined in the append. .-. claims.

Claims

THE CLAIMS DEFINING THE INVENTION ARE:

1. A collapsible storage structure comprising:

(a) a base panel,

(b) side panels,

2. A collapsible storage stracture as claimed in claim 1 wherein said first connecting means is adapted to be fixable along or around the edges and/or peripheral surfaces of said base panel.

3. A collapsible storage structure as claimed in claim 1 or claim 2 wherein said second connecting means is provided with at least two recessed portions having substantially parallel axes.

4. A collapsible storage stracture as claimed in any one of claims 1 to 3 wherein each said second connecting means forms a comer of said collapsible storage stracture.

5. A collapsible storage stracture as claimed in any one of claims 1 to 4 wherein said first and/or said second connecting means are provided with arcuate portions and/or surfaces for providing substantially smooth and rounded comers or surfaces between adjacent panels.

6. A collapsible storage structure as claimed in any one of claims 1 to 5 wherein there is further provided a comer connecting member which is able to be fitted to adjacent ends of said first and/or said second connecting means in the region of a comer of said collapsible storage structure, said comer connecting member being provided with arcuate portions and/or surfaces for providing substantially smooth and rounded corners or surfaces in or adjacent to a comer region of said collapsible storage stracture.

7. A collapsible storage stracture as claimed in any one of claims 1 to 6 wherein said recessed portion(s) of said first and/or second connecting means is an elongate channel having a base part and an entry part, said base part being wider than said entry part.

8. A collapsible storage structure as claimed in claim 7 wherein said recessed portion(s) in said first and/or second connecting means is dove-tail shaped.

9. Connecting means for a collapsible storage stractur as claimed in any one of claims 1 to 8, comprising an elongate substantially tubular I ...ay having two recessed portions substantially at right angles to one another, substantially as described with reference to Fig. 4a and 4c of the accompanying drawings.

10. Connecting means for a collapsible container as claimed in any one of claims 1 to 8 comprising an elongate substantially tubular body having two subst? ally aligned recessed portions, substantially as described with reference to Fig 4b of the accompanying drawings.

11. Connecting means f a collapsible container as claimed in any one of claims 1 to 8 comprising an elongate substantially t\ ular body having a single recess portion and two attachment faces substantially as described with reference to Fig. 3 of the accompanying drawings.

12. A comer connecting member for a collapsible container as claimed in anyone of claims 1 to 8 substantially as described with reference to Fig 6 of the accompanying drawings.

13. A method of assembling a collapsible box stracture as claimed in any one c

1 to 8 comprising the steps of:

(a) fitting said first connecting means along or around the edges and/or peripheral surfaces of said base panel,

(b) sliding the bottom edges of said side panels in and along the longitudinal axes of said recessed portions of said first connecting means,

(c) sliding the second connecting means along the edges of adjacent side panels to be connected, the edges of the adjacent side panels sliding in and along the longitudinal recessed portions of said second connecting means.

14. A method of assembling a collapsible box stracture as claimed in claim 13, said method further including the steps of fitting said comer connecting member into said recessed portions at the ends of said first connecting means, in the region of or adjacent a comer of said collapsible storage stracture, and subsequently butting the ends of the said second connecting means against or over said comer connecting member.

15. A method of assembling a collapsible box structure as claimed in claim 13 or claim 14 said method including steps of attaching or placing a lid on said collapsible storage structure thus formed, and securing said lid to said collapsible storage structure.

16. A collapsible box structure as described herein with reference to the accompanying drawings.