WO2003055755A2

WO2003055755A2 - Crates

Info

Publication number: WO2003055755A2
Application number: PCT/GB2002/005912
Authority: WO
Inventors: David Choon Sen Lam
Original assignee: David Choon Sen Lam
Priority date: 2001-12-21
Filing date: 2002-12-23
Publication date: 2003-07-10
Also published as: GB0130661D0; WO2003055755A3; AU2002358912A1

Abstract

A collapsible crate (1) comprises a base (11) and opposite shorter (14,15) and longer side walls (16,17) and is arranged to carry a heavy load when in the erect condition and to be substantially flat for storage when in the collapsible condition.

Description

CRATES

This invention relates to crates, and more specifically, to re-usable crates in which goods may be transported, for example in sea going containers.

There is a need for a crate which can be used to transport relatively heavy goods, which can be packed to a high density in standardised large shipping containers and which can be collapsed to reduce space for transporting or storage when empty.

A first aspect of the invention provides a collapsible crate for transporting goods, the crate comprising a base having feet, and having corner posts and a pair of opposed longer side walls and a pair of shorter end walls, each side wall comprising a pair of hinged panels mounted between hinged corner posts, the panels and posts being mutually rotatable about their hinges to allow collapse of the walls into an area defined by the base.

A more specific aspect of the invention provides a collapsible crate for transporting goods comprising a base, hinged corner posts, opposed side walls upstanding therefrom, the opposed side walls comprising a pair of panels attached together by hinge means, and end walls which are removable from the base to allow the hinged posts and the side walls to mutually rotate about the hinge means and collapse into an area defined by the base.

It is a more specific object of the invention to provide a crate having a frame structure which can be folded to a horizontal condition and occupy the area of the base element, but which can be assembled to a rigid condition to accept a high vertical load.

According to this invention the corner posts of the crate have hinged or knee joints which are folded to allow the crate to be collapsed to a flat condition. The crate includes between the longer sidewalls, a locking pin arrangement and the posts so that the crate can contain the high load. In use, pins from the longer sidewalls and the end walls engage each corner post.

The crate is preferably stackable in both the erected and collapsed conditions.

Each post preferably has an extension portion which, in the erected condition of the crate, extends above each of the sidewalls for engagement in the underside of the immediately above crate. Typically, the extension is a pin at the end of the post to be received in the foot of the superimposed crate.

The base may be provided with means for receiving the forks of a fork-lift truck.

In another aspect the invention provides a collapsible crate comprising a generally rectangular base having a foot at each corner; the crate having opposite short walls and opposite longer walls, a pivotable post at each corner, the two opposite shorter sidewalls being secured to the adjacent posts; the two longer sidewalls being connected to the adjacent posts by releasable connections at the top of the walls and at about mid-height.

Preferably, the post comprises a fixed based post portion to which an upper post length is pivotally connected.

Preferably, each post has an upstanding pin in its upper end to fit into a recess of the foot of a superimposed crate and to hold the crates in a column or stack.

Preferably the longer sidewalls have at their vertical sides bolts or the like for reception in the posts to lock the assembly together. The invention will now be described, by way of example only, and with reference to the accompanying diagrammatic drawings, in which:

Figure 1 is an isometric view of one embodiment of a crate according to the invention;

Figure 2 is an isometric view of the crate of Figure 1 showing an open side flap;

Figure 3 is an isometric view of the crate of Figure 1 in a partially collapsed state;

Figure 4 is an isometric view of the crate of Figure 1 in a fully collapsed state;

Figure 5 is an isometric view of the crate of Figure 1 in a partially disassembled state;

Figure 6A is an isometric view of an end panel of the crate of Figure 1;

Figure 6B is an isometric view of an edge detail of the crate of Figure 1 ;

Figure 7 is an isometric view of the underside of the crate of Figure 1 ;

Figure 8 is an isometric view of a bank of crate of Figure 1 ;

Figure 9 shows a detail of the hinged connection of a corner post;

Figure 10 shows the hinge assembly in exploded condition;

Figure 11 shows different views of the latch; Figure 12 shows different views of the locking pin;

Figure 13 shows an exploded view on the top of a corner post;

Figure 14 is a perspective view of another crate of the invention;

Figure 15A to E show details of the crate of Figure 14;

Figures 16A and 16B are perspective views of the crate of Figure 14 in two positions;

Figures 17A to 17E show different stages of collapsing a single crate to a flat condition;

Figure 18 is a perspective view of a stack of collapsed crates.

A crate 1 of the invention has two pairs of opposed side walls 2, 3 and a generally rectangular base 4. The base 4 comprises a frame on which a floor panel may be fitted. The base 4 has hollow feet portions 7 at each corner. The inner volume of each box is preferably 1.55 to 1.6 m³.

The longer side walls 2 are hinged at or about their longitudinal mid-points 5, to define upper and lower panel sections 9, 10 which are held between posts 11. These are hinged at a point near the base 4. A short extension 12 is present at the upper end of each post 11. A hole 14 is present in the lower panel section 10. The shorter side walls 3 are rigid panels having outside cross braces 13. Frame members 6 interconnect the longer side walls 2. The upper edge of each side wall 2 has a resiliently urged locking pin 8, which engages an aperture in the frame member 6. The locking pin 8 is urged into an extended position to engage the aperture, thereby retaining the side wall 2 in an upright condition. The pin is made of high tensile steel.

The locking pin 8 may be forced out of engagement with the aperture, allowing the upper panel 9 of side wall 2 to rotate about its hinged mid-point 5 for the discharge or loading of goods from or to the interior of the crate 1.

As show in Figures 3 and 4, to collapse the crate 1 , the side walls 3 are removed and the panels 9, 10 are rotated with respect to one another about their mid-points 5. The lower panels 10 are retained at their lowermost edges by engagement with the posts 11 and the upper panels 9 are retained at their uppermost edges by respective locking pins 8.

The panels 9, 10 of each side wall 2, are brought into an overlying relationship, as shown in Figure 4, whereupon the crate 1 is in a fully collapsed state. The collapsed crate 1 may be stacked on top of one another with each extension portion 12 engaging a suitably shaped recess (17, Figure 7) provided in each foot portion 7. The collapsed container will have a maximum height of 230 mm;

Figure 5 shows the side walls 2 interconnected with members 6 being removed from the base 4. Such removal ensures that the base 4 can be used a standard pallet. The lowermost panels 10 are either simply held within an upstanding perimeter of the base 4 or are connected to the base 4 through a resiliently urged locking device;

Figure 6A shows a side panel 3 with a brace support disposed horizontally. Figure 6B shows the locking pin arrangement at the lower corner.

Figure 7 shows the forks 100 of a fork-lift truck (not shown) extending through apertures 14 in the feet portion 7.

Figure 8 shows a 2 x 2 x 4 stack of sixteen crates 1. Such a stack is of suitable dimensions to fit into a standardised shipping container.

Figure 9 to 13 show details of the hinges, post, locking pin and latch components.

In use, a crate 1 is filled with goods, and is then moved by a fork-lift truck, pallet truck or similar, to a shipping location. The filled crates 1 may be stacked within a shipping container, for long or short distance transportation, as is shown in Figure 8 or may be simply placed onto a lorry, into the hold of a ship and so on. The crates 1 can be stacked up to five high with each holding up to approximately 1.4 tons of goods. The crate when locked rigidly can take a top load of approximately 11 tons.

Upon arrival at their destination, the goods may be removed from the interior of the crates 1 via their open tops or by opening the 'drop-flap' panel 9 as is shown in Figure 2. Once the contents have been discharged, the crate may be re-filled with goods or may be collapsed, as shown in Figure 4, for storage or for transport back to their point of origin or another location.

In the embodiment for Figures 14 to 18, the crate 10 comprises a base 11 having a foot 12 depending from each corner of the base 11. The foot portion 12 extends from the corner a short distance along the longer side of the base 11 and is shaped to receive the forks of a fork lift truck, not shown. At each corner, the base 11 has a post P1 made up of a short upright pillar 13 which is permanently fixed on the base 11. Above each pillar 13 is a post P2 which is generally L-shaped in section. The crate has two shorter sidewalls 14, 15 and two opposite longer sidewalls 16, 17.

About halfway up each post P2, above its side near a longer sidewall, there is a recess 18 to receive an extension portion 19 extending from each end of the longer sidewalls 16, 17, a detail of one of which being shown in Figure 15A. The recess 18 has a curved wall 18A which corresponds in shape to the facing wall 19A of the extension portion 19A. In use, the extension portion 19 (and hence the longer side walls 16, 17) is secured to the post P2 (and hence shorter sidewalls 14, 15) by a screw 100 which extends through aligned apertures18B and 19B in the recess 18 and extension portion respectively. The aperture 18B in the recess is tapped to ensure that the screw 100 is securable, whilst the aperture 19B in the extension portion 19 is countersunk to ensure that no portion of the screw 100 protrudes from the plane of the crate.

At the top of each post P2 there is an upright pin 20 shaped for reception in the underside of the foot 12 of a superimposed crate. Each shorter sidewall 14, 15 is connected to a leg of the

L-shaped post P2 by one or more grub screws 101. f

The upper edge of the longer sidewall 16, 17 has a square pin extension 21 and this is abuttable against an upper portion 22 of the facing side of the post P2 below the lower end of the vertical pin 20. The upper portion 22 may be rebated with respect to the rest of the post P2. The opposed faces of the extension 21 and upper portion 22 of the post P2 carry, respectively, a locating spigot 30 (Figure 15C) and a blind aperture in which the spigot 30 is receivable. A partially tapped countersunk aperture 33 extends through the extension portion 21 which, when a sidewall 16, 17 is in its vertical position, is aligned with a tapped aperture 34 extending through the post P2. A screw 101 is used to retain the extension portion 21 (and hence the upper portion of a longer sidewall 16, 17) in abutting engagement with the post P2.

As shown in Figure 15D, a corrugated or cranked member 40 is located internally of the post P2 at an upper end thereof. The member 40 helps to bear weight due to its location and inherent resilience. By bearing some of the weight when crates are stacked on top, the load exerted on the screw 102 and locating spigot 30 is reduced. In this way, when one crate is stacked upon another, the load is transmitted through the post P2 downwardly and the extension 21 at each longer sidewall does not have to bear all of the weight but it does act to help strengthen and add rigidity to the structure. By this system, the loaded crates can be stacked very high and up to 16 loaded units can be stacked in a 20-foot sea or road going container.

Each shorter wall 14, 15 is fixed to the respective posts by the grub screws 101 and has a cross brace 23 at about mid height.

Each longer wall is in two panels A & B, one above the other which are hinged at the level of a mid bar 29, so that, as shown in Figure 16A, the upper half 16A may be lowered to allow access to the contents and as shown in Figure 16B, the lower portion 16B may be lowered to ease removal of goods or loading of goods. Figure 15A shows a portion of the hinge connection 50 between upper and lower panels A and B. A simple hinge mechanism 50 is provided with a pair (or more) of recesses along the upper edge of the lower panel B into which a correspondingly shaped extension (not shown) from the lower edge of the upper panel A extends. The recess 51 is provided with a pair of apertures 52 through which the hinge pin (not shown) extends to secure the extension in the hinge 50. The recess 51 has a rearward wall 53 to prevent pivotal motion of the upper panel A past the vertical. Similarly, shaped and configured hinges are found on the lower edge of the bottom panel B. 208 empty crates can be packed into a 40-foot container, with 13 units in each stack.

Each crate measures length x width x height

internal top rim 1437 x 1.105 mm extremely top rim 1465 x 1155 x 1083 mm internal bottom rim 1437 x 1090 internal height 1000.

Because each crate or box is designed to tight tolerances, it is possible to lodge 16 loaded crates in a 20-foot container with a carry volume of 1.5731 m³.

The crate may be collapsed so that one empty crate may be stacked upon another. As shown in the sequence of Figure 17, one shorter sidewall is hinged forwardly followed by the other and then each longer sidewall and the end result is a generally flat structure having at each corner the depending feet 12 and short upright posts PL As shown in Figure 18 these may be stacked to say, 13 high and the stacks may be loaded in a 40-foot container. Up to 208 flat crates may be returned in such a container in this way.

The invention is characterised by the fact that the crate is made of a metal box having a generally rectangular base and the corners of which have depending feet and short upright posts. The sidewalls may be hinged in whole or in part for collapsing to provide a stackable crate. The sidewalls incorporate a locking bolt arranged to support the pin by which one crate may be stacked upon another when loaded.

Claims

1. A collapsible crate for transporting goods, the crate comprising a base having feet, and having corner posts and a pair of opposed longer side walls and a pair of shorter end walls, each side wall comprising a pair of hinged panels mounted between hinged corner posts, the panels and posts being mutually rotatable about their hinges to allow collapse of the walls into an area defined by the base.

2. A collapsible crate for transporting goods comprising a base, hinged corner posts, opposed side walls upstanding therefrom, the opposed side walls comprising a pair of panels attached together by hinge means, and end walls which are removable from the base to allow the hinged posts and the side walls to mutually rotate about the hinge means and collapse into an area defined by the base.

3. A crate according to Claim 1 or 2, the corner posts of the crate have hinged or knee joints which are folded to allow the crate to be collapsed to a flat condition.

4. A crate according to Claim 1 , 2 or 3, including between the longer sidewalls, a locking pin arrangement and the posts.

5. A crate according to any preceding Claim, wherein each post has an extension portion which extends above each of the sidewalls for engagement in the underside of an immediate above crate.

6. A collapsible crate comprising a generally rectangular base having a foot at each corner; the crate having opposite short walls and opposite longer walls, a pivotable post at each corner, the two opposite shorter sidewalls being secured to the adjacent posts; the two longer sidewalls being connected to the adjacent posts by releasable connections at the top of the walls and at about mid-height.

7. A crate according to Claim 6, wherein each post comprises a fixed based post portion to which an upper post length is pivotally connected.

8. A crate according to Claim 6 or 7, wherein the longer sidewalls have at their vertical sides bolts or the like for reception in the posts to lock the longer sidewalls to the posts.