WO2003008275A2

WO2003008275A2 - Collapsible container

Info

Publication number: WO2003008275A2
Application number: PCT/GB2002/003310
Authority: WO
Inventors: Stephen Thomas Mcaleavy; Derek Hughes
Original assignee: Arena Vm Limited
Priority date: 2001-07-19
Filing date: 2002-07-19
Publication date: 2003-01-30
Also published as: AU2002313531A1; WO2003008275A3

Abstract

A container having a base and a plurality of walls, at least one of the walls comprising a flat sheet folded over along at least one edge to form a continuous bead or lip which acts to stiffen the wall along that respective edge.

Description

COLLAPSIBLE CONTAINER

This invention relates to collapsible bulk containers, particularly, but not exclusively, adapted for the transport of components such as blocks, bricks and the like, and for the transport of liquid and particulate material in flexible liners or receptacles, suitably of plastics.

Collapsible bulk containers are known comprising a base, two side walls, two end walls, and optionally, a lid. The walls may be detachably mounted on the base by means which allow the containers to be collapsed or dismantled for secure and low cost empty return. Such containers will hereinafter be referred to as "containers of the kind set forth" .

In certain containers of the kind set forth the walls comprise skeletal frames of box section covered with or enclosed by infill panels. The infill panels are fixedly secured to the frames, for example by use of a suitable adhesive or by welding.. Cross contamination may take place in containers utilising walls of this kind as a result of debris caught between the skeletal frame and the infill panel.

According to a first aspect of the invention there is provided a container having a base and a plurality of walls, at least one of the walls comprising a flat sheet folded over along at least one edge to form a continuous bead or lip which acts to stiffen the wall along that respective edge.

This provides a container that is strong and stiff. As the bead is formed from the same sheet of metal as the wall and is, in fact, integral with it the container is considerably easier to fabricate notably as there is much less welding included than in a container of the prior art as described above. Of course, all of the panels may have at least one edge so deformed. At least one of the walls may additionally have at least one edge which is deformed into a half hinge.

This provides for part of a hinge mechanism that, again, is formed from part of the same sheet as the wall. Once more this calls for less separate parts, and so less welding, than with a separate hinge.

At least one of the or each of the walls having at least one half hinge formed thereon may be hingeably connected to the base by means of a hinge comprising in part, the or a half hinge formed on the wall. The or each hinge may further comprise a rod or pin passed between overlapping portions of the or each half hinge and a corresponding half hinge provided on the base. This provides a simple yet convenient method of fastening the base and walls together.

The base may comprise a flat sheet deformed at the edges to form one or more corresponding half hinges. This provides for a base having similar convenience of manufacture as the walls.

Optionally, at least one wall may comprise a plurality of separate sheets which are hingeably connected together by means of a hinge comprising two half hinges, each half hinge being formed from a deformed edge of one of the sheets. This engenders increased flexibility in handling the contents of the container, as access will become easier than with a container lacking this feature.

The or each half hinge may be of square cross section. In fact, the or each bead may be of square cross section. Advantageously, this provides especially strong walls for the container. In an alternative, one or more of the beads and/or the half hinges may be of circular or semi-circular cross section.

At least one of the walls may be stiffened by a diamond fold in the respective sheet.

A lid may be provided. The lid may comprise at least one panel, the or each panel being hingeably mounted on the end of one of the walls distal from the base. There may be a plurality of lid panels at least two of which have co-operating ends. There may be, in fact, two lid panels.

This provides for providing a container which entirely encompasses its contents .

At least one wall may be hingeably connected to the base such that the or each relevant wall is collapsible onto the base.

Accordingly, the container may be collapsible such that it takes up less space when being stored empty.

In a preferred embodiment, at least one pair of adjacent walls may be releasably connected together by means of releasable catches. The catches may comprise hooks on one part co-operating with pins on the other. The catches may act through holes punched or cut through at least one of the walls.

The walls may be connected to the base such that the or each bead and any half hinges project outwardly. In a preferred embodiment there may be four walls surrounding a substantially rectangular base.

Furthermore, the container may have a side pair of walls positioned at opposite sides of the rectangular base each having a side deformed into a half hinge by means of which each side wall is hingeably connected to the base and three remaining sides deformed into a continuous bead, and a pair of ends walls positioned at opposite sides of the rectangular base adjacent to the side walls, each end wall having a first side deformed into a half hinge by means of which each end wall is hingeably connected to the base, a second side opposite to the first side deformed into a further half hinge by means of which a panel of the lid is hingeably connected to each of the end walls and two remaining sides deformed into a continuous bead. This combination provides a container which is simply to make, flexible in storage and convenient for a user.

According to a second aspect of the invention, there is provided a wall for the container of the first aspect, comprising a sheet of metal folded over at at least one edge to form a continuous bead or lip which acts to stiffen the wall along that respective edge.

This provides a strong stiff wall for the container of the first aspect which is easily interchangeable.

At least one of the remaining edges may be deformed into half hinges. Indeed, all the edges of the wall may be deformed into beads or half hinges. There may be two of each, or one hinged and three beaded edges.

This provides for hingeably mounting the walls on a container. The or each bead may be of box section. Also, the or each half hinge may be of box section. Preferably the box section may be a square box section. This provides for particularly strong half hinges and beads.

The wall may be stiffened by a diamond fold across the sheet.

The use of a square hinge is particularly advantageous as it provides for a strong yet simple to manufacture hinge. Therefore, according to a third aspect of the invention there is provided a panel comprising a flat sheet having a half hinge of square cross-section folded into at least one edge.

There may also be provided a hinged arrangement of panels comprising at least two such panels. They may be connected by means of a hinge comprising overlapping portions of the or a half hinge from each panel with a pin or rod passed between those overlapping portions.

The method of manufacture of- the container or walls of the first two aspects of the invention lends itself to computer controlled manufacture, as the walls and possibly the base are made from flat sheets and then folded and otherwise deformed as necessary. Therefore, according to a fourth aspect of the invention there is provided a data carrier carrying instructions to make, under computer control, a wall according to the first or second aspects of the invention.

According to the fifth aspect of the invention a wall for a container of the kind set forth comprises a sheet of metal which is folded at each of a pair of opposed edges to form a continuous bead or lip which acts to stiffen the wall along that respective edge. The wall may be formed from a single sheet folded over at one pair of opposite edges to form continuous beads, with the remaining edges being deformed into half hinge arrangements.

When assembled onto a base to constitute a container of the kind set forth the beads and the half hinge arrangements project outwardly, and each wall is hingedly connected to the base at its lower edge. Since a substantially continuous surface is defined by the panels, cross contamination is unlikely to occur since there are no regions in which debris can be caught.

Conveniently end hinge arrangement is of substantially square outline with a hinge pin or rod seated in an elastomeric, suitably rubber, seating. This end part has the advantage that the inside of the container has no gaps at the hinging areas, just flat surfaces.

Walls constructed in this way are relatively easy and cheap to fabricate since only a folding operation on a suitable folding machine is required in order to form beads along the edges, with a punch and folding operation being required to produce the half hinge arrangements .

The walls may be stiffened by diagonal folds across each sheet suitably of a diamond configuration.

In a container of the kind set forth at least one wall may comprise two separate panels which are hingedly connected together at adjacent edges, for example by a bottom fold in the side wall. The beads are suitably adapted to engage each other and a pin or rod may be passed between overlapping portions constructed by the half hinge arrangements. This enables the container to be provided with a "drop-down" front, which may also be removable. When the container is provided with a lid, such a lid may be constructed from two similar panels. Each lid panel is hingedly connected to an adjacent end wall of the container with the lid panels co-operating with each other at their inner ends.

Preferably the two lid panels are of different sizes. This provides a greater or smaller access to the container.

Each of the two end walls and the two side walls is hingedly connected to the base so that, in the collapsed position the end walls, side walls, and lid can be folded down onto the base in superimposed positions.

When the container is erected the side and end panels are releasably connected together at least at their upper ends by means of releasable catches .

One embodiment of our invention is illustrated in the accompanying drawings in which :-

Figure 1 is a perspective view of a collapsible bulk container in an erected position;

Figure 2 is a section on an enlarged scale through the edge of an end wall;

Figure 3 shows an edge of the container;

Figure 4 is a perspective view of the container with the lid folded back and the front wall partially open; and Figure 5 is a perspective view of the container in a collapsed position.

The collapsible bulk container 1 illustrated in the accompanying drawings comprises a base 2, a pair of opposed side walls 3 and 4, and a pair of opposed end walls 5 and 6, all upstanding from the base. Each wall is hingedly connected at its lower end to the base and a lid 7 for closing the other end of the container comprises two separate pieces 8 and 9 each hingedly connected at its outer end to the upper end of a respective one of the end walls 5 and 6.

The side wall 4 and each end wall 5 and 6 is constituted by a panel comprising a sheet 10 of metal formed at one pair of outer edges with beads 11, each as shown in detail in Figure 2 of the accompanying drawings. The beads 11 may be of rectangular, substantially square cross-section, or of semi-circular outline. Each of the other edges of the panel is deformed into a half hinge arrangement, preferably of square cross -section. Irrespective of the configuration the beads and hinge arrangements constitute an integral frame providing rigidity to the wall.

The side wall 3 comprises two panels 12 and 13, each hinged together at adjacent edges by a hinge pin or rod.

Each panel 8, 9 constituting the lid 7 is also formed in a similar manner with each edge of the panel provided with similar half hinge arrangement. The outer ends of the panel are hingedly connected to the upper ends of the end walls 5 and 6.

The lower edges of each of the wall 3, 4 and 5 and 6 are hingedly connected to the base by hinges and, as illustrated in Figure 1, all the walls and the lid 7 are arranged with the beads 11 and the half hinge arrangements projecting in an outwards direction. This ensures that all the internal walls constituting the container are smooth to ensure that the contents of the container and any flexible liner will not be damaged during transit.

Each hinge arrangement is of substantially square outline with a hinge pin or rod of metal or nylon seated in a rubber seating.

When the container is in the erected position illustrated in Figure 1, the end wall and side walls are locked together at mating co-operating faces by means of manually operable releasable locking mechanisms 15 as illustrated in Figure 3. The locking mechanism 15 is provided at the upper ends of the walls. A similar locking mechanism is provided between each end wall and the panel 12 of the front wall. These mechanisms retain the panel 12 in the closed position when upper panel 13 is hinged downwardly or "dropped down" as illustrated in Figure 4. Alternatively the whole front wall can be removed from the container to allow fork truck access.

When the container is to be collapsed the side walls 3 and 4 are hinged inwardly onto the base with the wall 3 superimposed upon the wall 4. Thereafter the end wall 5 is superimposed upon the wall 3 and, finally, the wall 6 is folded over onto the wall 5 with the panel 9 supported upon it.

Our container is relatively cheap and simple to produce in as much as each of the walls and lid panels can each be produced from a single sheet of metal by a simple folding operation or deforming operation with a minimum of welding. End wall may be additionally stiffened by the provision of a diamond fold across each sheet.

Claims

1. A container having a base and a plurality of walls, at least one of the walls comprising a flat sheet folded over at at least one edge to form a continuous bead or lip which acts to stiffen the wall along that respective edge.

2. A container according to Claim 1 in which at least one of the walls has at least one edge which is deformed into a half hinge.

3. A container according to Claim 2 in which at least one of the or each walls having at least one half hinge formed thereon is hingeably connected to the base by means of a hinge comprising, in part, the or a half hinge formed on the wall.

4. A container according to Claim 3 in which the or each hinge further comprises a rod or pin passed between overlapping portions of the or each half hinge and a corresponding half hinge associated with the base.

5. A container according to Claim 4 in which the base comprises a flat sheet deformed at the edges to form the corresponding half hinge.

6. A container according to any one of Claims 3 to 5 in which at least one wall comprises a plurality of separate sheets which are hingeably connected together by means of a hinge comprising two half hinges, each half hinge being formed from a deformed edge of one of the sheets .

7. A container according to any one of Claims 2 to 6 in which the or each half hinge is of square cross section.

8. A container according to any previous claim in which the or each bead is of square cross section.

9. A container according to any previous claim in which at least one of the walls is stiffened by a diamond fold in the or each sheet.

10. A container according to any previous claim in which the container is provided with a lid comprising at least one panel, the or each panel hingeably mounted on the end of one of the walls distal from the base.

11. A container according to Claim 10 in which there are a plurality of lid panels, at least two of which have co-operating ends.

12. A container according to any previous claim in which at least one wall is hingeably connected to the base such that the or each relevant wall is collapsible onto the base.

13. A container according to Claim 12 in which a plurality of the walls are collapsible onto the base such that, in a collapsed state, the collapsed walls are folded down onto the base in superimposed portions .

14: A container according to any previous claim in which at least one pair of adjacent walls are releasably connected together by means of releasable catches.

15. A container according to any previous claim in which the walls are connected to the base such that the or each bead and any half hinges project outwardly.

16. A container according to any previous claim in which there are four walls surrounding a substantially rectangular base.

17. A container according to Claim 16 in which there are a side pair of walls positioned at opposite sides of the rectangular base each having a side deformed into a half hinge by means of which each side wall is hingeably connected to the base and three remaining sides deformed into a continuous bead, and a pair of end walls positioned at opposite sides of the rectangular base adjacent to the side walls, each end wall having a first side deformed into a half hinge by means of which each end wall is hingeably connected to the base, a second side opposite to the first side deformed into a further half hinge by means of which a panel of the lid is hingeably connected to each of the end walls and two remaining sides deformed into a continuous bead.

18. A wall for the container of any previous claim comprising a sheet of metal folded over at at least one edge to form a continuous bead or lip which acts to stiffen the wall along that respective edge.

19. A wall according to Claim 18 in which at least one of the remaining edges are deformed into half hinges .

20. A wall according to Claim 19 in which all edges of the wall are either deformed into a bead or a half hinge.

21. A wall according to any one of Claims 18 to 20 in which at least one of the or each bead and any half hinge are of box section.

22. A wall according to Claim 21 in which the box section is a square box section.

23. A wall according to any one of Claims 18 to 22 stiffened by a diamond fold across the sheet.

24. A panel comprising a flat sheet having a half hinge of square cross-section folded into at least one edge.

25. A hinged arrangement of panels comprising at least two panels according to Claim 24 connected by means of a hinge comprising overlapping portions of the or a half hinge from each panel with a pin or rod passed between those overlapping portions.

26. A data carrier carrying instructions to make, under computer control, a wall of any one of Claims 1 to 23.