GB2507321A

GB2507321A - Collapsible Transport Container

Info

Publication number: GB2507321A
Application number: GB201219288A
Authority: GB
Inventors: Jeffrey David Cox
Original assignee: RYOBE UK Ltd
Current assignee: RYOBE UK Ltd
Priority date: 2012-10-26
Filing date: 2012-10-26
Publication date: 2014-04-30
Also published as: GB201219288D0

Abstract

A collapsible container 10 for transporting machined parts has a base, which may be rectangular in shape, a plurality of side walls 14, on which handles 16 may be mounted and a plurality of dividers 28, 30, which when the container 10 is in its erect position, 28, 30 may be interlocked. There are a plurality of releasable latches for fastening the base to the side walls, the releasable latches each including a first latch component which may include a living hinge formed integrally with the base, and a second latch component, which may be formed in the surface of a side wall. The first latch component is releasably engagable with the second latch component and may contain an aperture for receiving the second latch component. There are a plurality of a first and second fastening means for releasably fastening adjacent side walls to one another, and for fastening the dividers to the walls and enabling subdivision of the container, the second fastening means are located at spaced positions on the inside of the side walls. The container being movable between a collapsed position and an erect position to allow more containers to be stored in a more efficient manner.

Description

COLLAPSIBLE CONTAINER

The present invention relates to a collapsible container and particularly but not exclusively to a collapsible container for transporting machined parts or the like.

BACKGROUND TO THE INVENTION

In the production of a complex product, such as an engine, it is necessary to obtain parts for the assembly of the product from a wide area. For example, if the assembly of the engine is taking part in central Europc, it may bc that parts need to bc transported to the assembly factory from the UK, the USA, and China. The parts are generally machined parts, are made to high tolerances and are susceptible to damage in transit, It is necessary to pack the parts suitably to prevent damage and also to facilitate handling.

Such parts are packaged in specialist crates for transport. When the parts are delivered to the assembly location and unloaded, the crates are then returned to the originator of the parts for re-use. Delivery of the parts therefore necessitates a vehicle making both an outward journey to deliver the parts, and a return journey to return the crates. This is expensiye and is not environmentally friendly.

In some circumstances it may be more cost-effectivc to use disposablc packaging, so that a return journey is unnecessary. However, this practice is wasteful of materials.

Also, the most common disposable packaging solution is cardboard, which cannot be used for transporting high-tolerance machined parts because of the risk of dust contamination.

It is an object of thc invcntion to providc a coHapsible containcr which is suitaNc for the transport of certain machine parts.

STATEMENT OF INVENTION

According to the present inyention, there is provided a collapsible container comprising: a base; a plurality of side walls; a plurality of dividers; a plurality of releasable latches for fastening the base to the side walls, the releasable latches each including a first latch component and a second latch component, the first latch component being releasably engagable with the second latch component; a plurality of a first fastening means for releasably fastening adjacent side walls to one another; and a plurality of a sccond rclcasablc fastcning mcans providcd at spaccd positions internally of the side walls for fastening the dividers to the walls and enabling subdivision of the container, the container being movable between a collapsed position and an erect position.

The container may be used to transport, in particular, machined parts, though it may also be suitable for transporting other items. The container may be made from plastics, and is rigid and strong enough to provide protection for the parts during transit. The container is reusable many times, and at the end of its life may be recycled.

The container may easily be collapsed once the parts have been unloaded. This allows containers to be transported back to thc source of the machined parts or other items so that they can be reused, without incurring excessive costs in transporting the empty containers.

Each releasable latch may include a living hinge enabling the side walls to be moved from a position in the same plane as the base to a position substantially perpendicular to the base. The living hinge may be provided as part of the first latch component, may extend from a peripheral edge of the base and may be integrally formed with the base. The living hinge allows the container to be folded completely flat. Integrally forming the hinge and the first latch component with the base allows for a smaller number of component parts, reducing manufacturing and tooling costs.

I

Each first latch component may include an aperture for receiving the second latch component, and may be previded with a catch element adjacent an upper edge of the aperture. An aperture with an adjacent catch pmvides a simple to manufacture and easy to use latch, which nonetheless provides for a secure fastening.

Four releasable latches may be provided for connection of each sidewall.

The base may be rectangular in shape. A rectangular shape allows for efficient packing of the erect or collapsed crates.

Each second latch component may be formed in a surface of a side wall, and may include a spring clip. The spring clip may include a slot for engaging with the catch element of the first latch component. An integrally formed spring clip again serves to provide a simple yet secure latching arrangement to fasten the side walls to the base.

The second latch component may extend inwards of the side wall at an angle in the range of 120 to 160 degrees. This range of angles allows the second latch component to fold fairly flat against the side wall, and yet be easily graspable for quickly engaging with the first latch component.

Each side wall may be spaced apart from the base of the container when the side wall is fltstcncd to thc base and thc container sits in thc erect position. Spacing the side wall ftx,m the base allows the side wall to be pivoted outwardly, without fouling the edge of the base. Thus the container may be folded fiat without disassembly.

Each first fastening means may include a male component and a female component.

The male component may be thrmed at one end of each side wall, and the female component may be formed at the other end of each side wall. Providing a male component and a female component, one at either end of each side wall, allows for all four side walls to be identical, keeping manufacturing costs low.

Each second releasable fastening means may project fix,m the inner surface of the side wall, the projection including a slot for receiving an end of a divider. The second rcleasable fastening means may bc a two-pad clip, which resiliently deforms to receive an end ofa divider into a slot between the clips. The two parts ofthe clip may be sprung towards each other to retain the end of the divider in the slot. The end of the divider may include a ridge or thickened portion. When introduced between the clips, the thickened portion at the end of the divider forces the clips apart. The thickened portion passes between the clips, which close around the end of the divider, behind the thickened portion. Alternatively or additionally, apertures may be provided in the ends of the dividers for locating in the slot between the two-part clips of the second fastening means. The apertures allow the clips to completely close, increasing the security of the fastening. Where the clips arc allowed to completely close, this may also reduce wear on thc clips and incrcasc the longevity of the container.

At least one pair of dividers may be provided, the pair of dividers being interlocked by way of opposing slots provided on each divider. Any number of dividers may be provided and may be of two different types, the dividers of a first type being installed within the container perpendicular to the dividers of the second type. The dividers of the first type may have a slot or slots extending from the bottom of the dividers, and the dividers of the second type may have a slot extending from the top of the dividers.

The dividers of the second type are therefore installed first, and the dividers of the first type arc then installed perpendicular to the dividers of the second type, the slotted parts of each type of divider corresponding with the non-slotted parts of the other type of divider.

The dividers may be used to create compartments in the collapsible containers of substantially any size, for storing different items and preventing movement during transit.

According to a second aspect of the invention, there is provided a container system for transporting a plurality of collapsible containers as described above, the container system comprising: a storage container having a base and at least three side walls connected to the base; and a plurality of collapsible containers, as described above, the storage container being sized to contain a first number of collapsible containers in the erect position, and to contain a second number of collapsible containers in the collapsed position.

The second number may be at least five times the first number. This leads to substantial transport savings, since fewer lorries or similar will be required to return the empty containers once parts have been delivered.

DESCRIPTION OF THE DRAWINGS

For a better understanding of the present invention, and to show more clearly how it may be carried into effect, reference will now be made, by way of example only, to the accompanying drawings, in which: Figure 1 shows a perspective view of an assembled collapsible container including base, side walls, dividers and handles, ready for use; Figure 2a shows a plan view from above of the base of the collapsible container of Figure 1; Figure 2b shows a handle for attachment to a side wall of the collapsible container of Figure 1; Figures 2c and 2d show opposing side walls of the collapsible container of Figure 1; Figures 2c and 2f show interlocking dividing walls or dividers of the collapsible container of Figure 1; Figure 3 shows a cross sectional view through a side wall and the base of the collapsible container of Figure 1; Figure 4 shows a plan view from above of a comer of the collapsible container of Figure 1; Figure 5 shows a perspective internal view of the latching arrangement of the base to aside wall of the collapsible container of Figure 1; Figure 6a shows a plurality of the collapsible container of Figure 1, palletised for transit; Figure 6b shows a plurality of the collapsible container of Figure 1, collapsed and palletised for return transit; Figurc 7a shows a plan vicw from abovc of a second cmbodimcnt of a collapsible container, suitable for use in place of the container of Figure 1 in the system of Figure 6a; Figure 7b shows a close-up perspective view of a clip, forming part of the container of Figure 7a Figure 8a shows a side view of a divider, fbrming a component part of the container of Figure 7a Figure 8b shows a close-up perspective view of a formation forming part of the divider of Figure 8a Figure 9a shows a close-up perspective view of the clip of Figure 7b engaged in the formation of Figure 8b; Figure 9b shows a plan view from above of the clip of Figure 7b engaged in the tbrmation of Figure 8b; and Figure 10 shows a close-up perspective view of a divider engaged in a side wall of the container of Figure 7a.

DESCRIPTION OF PREFERRED EMBODIMENT(S)

Referring firstly to Figure 1, a collapsible container is indicated generally at 10. The container comprises a base 12, four side walls 14, and intersecting dividers of a first type 28 and a second type 30. A handle 16 is provided at the centre of the top edge of each side wall 14, for lifting the container.

As seen best in Figure 2a, a first latch component 18 extends from the periphery of the base 12. Four first latch components 18 are provided on each of the four sides of the base. The first latch components 18 are integrally formed with the base.

The first latch component includes a living hinge 32 where it joins to the base 12.

The living hinge allows the first latch component to pivot from a collapsed position in the same plane as the base 12, as seen in Figure 2a, to an erect position substantially perpendicular with the base 12, as seen in Figure 3 and Figure 5.

A rectangular aperture 40 is provided through the first latch component 18. An upper ridge 34 is provided adjacent to the rectangular aperture 40, above the aperture and on the inner side when in the erect position and as viewed in Figure 5. A lower ridge 36 is provided adjacent to the rectangular aperture 40, below the aperture. An outer ridge 38 is provided adjacent to and above the aperture on the outer side of the first latch component 18.

A plurality of second latch components 20 is provided in the inside surface of the side walls 14. Four second latch components 20 are provided on each of the four side walls 14, in positions corresponding with the first latch components 18 on the base.

The second latch component 20 comprises a spring clip, formed inteally with the side wall. The spring clip 20 extends inwardly of the side wall 14 and upwardly at an angle of approximately 140 degrees from the vertical. The spring clip 20 is resiliently flexible, and has a substantially inward facing lower surface 44 and a substantially outward facing upper surface 42. Two ridges 46, 48 extend from the upper surface 42, and run horizontally from one side of the second latch component 20 to the other.

A portion of the second latch component 20 near the upper ridge 48 is curved outwardly towards the side wall, but can be bent inwardly. The second latch component is made flt,m a resilient material so that the second latch component 20 will spring back into shape after being defonned. The upper ridge 48 is at an acute angle to the upper surfitce 46 of the second latch component 20, extending towards the lower ridge 46 as it extends outwardly of the second latch component 20. In this way, the slot 50 between the ridges can be extended and contracted by deforming the second latch component 20.

When the container lOis assembled, a side wall 14 is placed adjacent the base 12 so that the first latch components 18 on the base correspond with the second latch components 20 on the side wall 14. Thc spring clip 20 of the second latch component is introduced through the aperture 40 of the first latch component 18, as shown best in Figure 3. The upper ridge 34 and the outer ridge 38 of the first latch component 18 sit in the slot 50 of the second latch component 20. The second latch component 20 is deformed slightly so that upper ridge 34 can pass upper ridge 48, into the slot 50. The second latch component 20 then springs back, effectively gripping the upper ridge 34 and outer ridge 38 of the first latch component 18 between the upper and lower ridges 46,48 of the second latch component 20.

hi Figure 3, it can be seen that there is a horizontal space between the edge of the base 12 and the bottom of the side wall 14. This allows the side wall, when connected to the base 12, to be fold,ed outwardly, without fouling the edge of the base. Thus the container may be folded flat.

Referring now to Figure 4, a male wall fastener 22 is provided at one end of each side wall 14. The male wall fastener is formed as a ridge running down the end of the side wall 14. Behind the ridge, further towards the centre of the wall, three spaced apertures 52 are provided. At the other end of the side wall 14, female wall flisteners 24 are provided to correspond with the male wall fasteners 22. The female wall fasteners 24 comprise a clip for receiving the male wall fasteners 22. The ridge part of the male wall fastener is received within the clip, with the apertures 52 of the male wall fastener allowing the clip of the female wall fastener 24 to pass around behind the ridge.

Referring now to Figure 5, fasteners for dividers are shown at 26. Multiple fasteners 26 are provided, spaced at equal intervals on the internal surface of each side wall 14, as seen clearly in Figure 2. The fasteners 26 comprise two-part clips, with a slot between the two parts of the clip. The clips may be deformed to enlarge the width of the slot, and resiliently spring back to reduce the width again. As seen in Figures 2e and 2f, dividers 28, 30 have a ridge at either end, and apertures behind the ridge in a similar arrangement to the male wall fastener 22. The ends of the dividers 28, 30 may therefore be snapped into the fasteners 26.

The dividers are of a first type 28 and a second type 30. The dividers of the first type and the second type 28, 30 are substantially identical, except that the dividers of the first type 28 include a plurality of vertical slots 29 at spaced intervals along the divider, which extend from the bottom of the divider to a point approximately half way to the top of the divider. The dividers of the second type 30, on the other hand, have vertical slots 31 in corresponding locations, but extending from the top of the divider 30 to a point approximately half way to the bottom of the divider, as installed and as viewed in Figures 2e and 2f. The dividers of the second type 30 may therefore be fitted into the container 10, snapping into the fastenings 26 on the side walls 14.

The dividers of the second type should all be installed in the same direction, that is, parallel to each other. Dividers of the first type 28 may then be fitted perpendicular to the dividers of the second type 30. The slots of the dividers of the first and second types 28, 30 interleave so that the dividers do not obstruct each other. The interleaving slots also serve to enhance the security of the dividers, so that they are unlikely to come loose in transit.

Any number of dividers 28, 30, constrained only by the number of available fastenings 26, may be used to separate the container into different sized compartments for transporting different types of parts. Tn Figure 1, the maximum number of dividers 28, 30 possible in this embodiment is shown, but equally a smaller number could be used if larger compartments are required. It is not necessary to install any dividers at all, if one large compartment is required.

In Figure 2b, a handle 16 is shown. The handle snaps onto the top edge of side walls 14, one handle at the centre of each side wall. The fastening on the handle is similar to the fastening on the end of the dividers, comprising a ridge at the bottom edge of the handle and three spaced apertures behind the ridge.

Refening now to Figures 7 to 9, a second embodiment of the collapsible container is shown generally at 1 Oa. The second embodiment 1 Oa is similar to the first embodiment 10, except that clips 54a are provided for fixing dividers 30a to the base 12a. The clips 54a are provided on the base 12a of the container lOa, each clip being on the line between the two opposing fastenings 26a on the side walls 14a. Two clips 54a are provided between each pair of two opposing fastenings 26a, with the exception of the fastenings 26a at the centre of the side walls 14a, which have only one clip between the opposing central fastenings. The anangement of clips 54a is in the shape of a cross, as shown in Figure 7a.

Figure 7b shows a close-up view of a clip 54a. Each clip 54a is formed as two identical protrusions, mirroring each other. The protrusions are resiliently deformable, so that the clip may be forced open by introducing an object between the protrusions, and will then close around the object. The space between the protrusions of the clip 54a is nanow close to the base 12a, and narrow at the top end of the clip, furthest from the base 12a, with a wider portion between the two nanow portions.

Figure 8a shows a divider 30a which is identical to divider 30, save for formations 56a for engaging with clips 54a. Formations 56a are provided spaced along the bottom edge of divider 30a, at positions corresponding to vertical slots 31a.

Figure 8b shows a close-up view of the formation 56a. The formation 56a comprises a central protrusion 58a, which is tapered so that it is narrow at the bottom edge of the divider 30a as installed and as viewed in Figure 8a, and wider close to its top edge.

The top edge of the formation 56a is only very slightly tapered, having a top ledge which is nearly horizontal. Two substantially rectangular stops protrude from the surface of the divider 30a, at either side of the central protrusion SSa. The formation 56a is minored on either side of the divider 30a, so that each formation comprises in total four rectangular stops and two central protrusions.

In use, as shown in Figures 9a and 9b, divider 30a is clipped into clip 54a. Divider 28 is installed perpendicular to divider 30a, as in the first embodiment. Clipping the dividers 30a into the base 12a prevents uimecessary bending of the base 12a, since the base 12a is supported by the side walls 14 via the dividers 30a. Stops 60a prevent unwanted horizontal movement of the dividers 30a with respect to the base 12a, and reduce the likelihood that dividers will become loose.

Referring now to Figure 10, a close up view of divider 30a where it corresponds with clip 26a on side wall 14a is shown. The edge of the divider 30a is similar to the edge of divider 30 in thc first embodiment, savc that a stop 62a is includcd abovc apcrturc 52a. A similar stop (not shown) is provided below the aperture closest to the base 14a of the container lOa. The stops 62a prevent vertical movement of the divider 30a when installed, and prevent separation of the divider 30a from side wall 14a when container 10 is loaded with heavy components.

Referring now to Figures 6a and 6b, a container storage system is indicated generally at 100. The container storage system comprises a large container 110, having a base and three side walls. The container may be placed on a pallet. The large container is sized to receive many collapsible containers 10 in the erect position. In the Figure, 24 containers in the erect position are shown. When the collapsible containers 10 are collapsed, the space occupied is substantially reduced. In this embodiment, approximately five times as many collapsed containers 10 than erect containers may be stored in the large container 110.

The collapsible container 10, and the container storage system 100 of which it forms a part, allows for the safe transportation of sensitive parts. Once the parts have been delivered, the containers 10 may be returned to the source at low cost. This is cost effective compared with the alternatives of returning containers without collapsing them first, or of using disposable containers which arc not reused.

Claims

CLAIMS1. A collapsible container comprising: a base; a plurality of side walls; a plurality of dividers; a plurality of releasable latches for fastening the base to the side walls, the releasable latches each including a first latch component and a second latch component, the first latch component being relcasably cngagablc with the second latch component; a plurality of a first fastening means for releasably fastening adjacent side walls to one another; and a plurality of a second releasable fastening means provided at spaced positions internally of the side walls for fastening the dividers to the walls and enabling subdivision of the container, the container being movable between a collapsed position and an erect position.
2. A collapsible container as claimed in claim 1, in which each releasable latch includes a living hinge enabling the side walls to be moved from a position in the same plane as the base to a position substantially perpendicular to the base.
3. A collapsible container as claimed in claim 2, in which the living hinge is provided as part of the first latch component.
4. A collapsible container as claimed in any of the preceding claims, in which each first latch component extends from a peripheral edge of the base.
5. A collapsible contained as claimed in any of the preceding claims, in which each first latch component is integrally formed with the base.
6. A collapsible container as claimed in any of the preceding claims, in which each first latch component includes an aperture for receiving the second latch componcnt.
7. A collapsible containcr as claimed in claim 6, in which each first latch component is provided with a catch element adjacent an upper edge of the aperture.
8. A collapsible container as claimed in any preceding claim, in which four releasable latches are provided fbr connection of each sidewall.
9. A collapsible container as claimed in any preceding claim, in which the base is rectangular or square in shapc.
10. A collapsible container as claimed in any preceding claim, in which each second latch component is formed in a surface of a side wall.
11. A collapsible container as claimed in any preceding claim, in which the second latch component includes a spring clip.
12. A collapsible container as claimed in claim 11 when dependent on claim 7, in which the spring clip includes a slot for engaging with the catch element of the first latch component.
13. A collapsible container as claimed in claim 10, in which each second latch component extends inwards of the side wall at an angle in the range of 120 to degrees.
14. A collapsible container as claimed in any preceding claim, in which each side wall is spaced apart from the base of the container when the side wall is fastened to the base and the container is in the erect position.
15. A collapsible container as claimed in any preceding claim, in which each first fastening means includes a male component and a female component.
16. A collapsible container as claimed in claim 15, in which the male component of the first fastening means is tbrmed at one end of each side wall, and the female component of the first fastening means is formed at the other end of each side wall.
17. A collapsible container as claimed in any preceding claim, in which each second releasable fastening means projects from the inner surface of the side wall, the projection including a slot for receiving an end of a divider.
18. A collapsible container as claimed in claim 17, in which the second releasable fastening means are two-part clips, which resiliently deform to receive an end of a divider into thc slot bctwccn thc clips, and which arc sprung towards each other to retain the end of the divider in the slot.
19. A collapsible container as claimed in claim 18, in which apertures are provided in the ends of the dividers for locating in the slot between the two-part clips of the second fastening means.
20. A collapsible container as claimed in any preceding claim, in which there is provided at least one pair of dividers, the pair of dividers being interlocked by way of an opposing slot provided on each divider.
21. A container system for transporting a plurality of collapsible containers as claimed in claim 1, the container system comprising: a storage container having a base and at least three side walls connected to the base; and a plurality of collapsible containers, the storage container being sized to contain a first number of collapsible containers in the erect position, and to contain a second number of collapsible containers in the collapsed position.
22. A container system as claimed in claim 21, in which the second number is at least five times the first number.
23. A collapsible container substantially as described herein with reference to and as illustrated in Figures ito 5 of the accompanying drawings.
24. A container system substantially as described herein with reference to and as illustrated in Figures 6a and 6b of the accompanying drawings.