AU771773B2 - Folding bulk container - Google Patents

Description

Chryslllou Law 99534744 5/52 18/02/2004 16:59 \\server\e\docs\patents\comp\9542auamended.doc Folding Bulk Container Bulk fruit containers are typically containers having a "footprint" the size of a typical pallet which may be used to transport fruit and the like.

Bulk fruit containers may be disposable and made of cardboard or the like or partially or totally reusable. Partially or totally reusable bulk containers have a plastics base and side walls of cardboard or plastics material.

The use of cardboard for bulk containers is becoming less acceptable since the cardboard remains at the destination and is considered waste. The European Union is proposing to require all retail packaging material imported into the EU to be removed to the country of origin. This makes the use of reusable bulk containers Smuch more attractive, if not essential, than previously.

Whilst reusable bulk containers exist, they suffer from lack of durability, rigidity S and poor volumetric efficiency and excessive height when folded.

The present invention, in its various forms, aims to improve the performance of is folding bulk containers in these areas.

Hinge Location and Structure Existing folding bulk containers may suffer from excessive free play in the side walls when being erected. In particular, the side walls may be pivoted more than 900. This can result in damage to the hinge or likewise the end wall. In an attempt to reduce or eliminate this free play the invention provides a folding bulk container including: a base unit including a base and peripheral edge wall extending upwardly from the base, which peripheral edge wall has an outer edge wall surface, an inner edge wall surface and an upper edge wall surface, and

I

COMS ID No: SMBI-00624811 Received by IP Australia: Time 17:12 Date 2004-02-18 18/02/2004 16:59 18/0/204 1:59Chrrs IIlou Law, 99534744 8/52 Wserveritdocs\patents\compss4zauamended.doo at least one side wall pivotably mounted on the base unit for rotation about a fixed axis adjacent the peripheral edge wall and located outside of a space defined by a first plane in which the outer edge wall surface substantially lies and a second plane in which the inner edge wall surface substantially lies the side wall is adapted for movement between an erect position and a folded position, wherein the upper edge wall surface extends upwardly from the outer edge wall surface through to the inner edge wall surface and the side wall includes a complementary surface corresponding to the upper edge wall surface.

Thus, the peripheral edge wall can retard the side wall from pivoting substantially beyond the vertical. Preferably the upper edge wall surface is inclined or arched at about 120 to the horizontal and the complementary surface of the side wall is :similarly inclined.

The geometry of the pivot relative to the bottom of a sidewall is such that when the Side wall is moved through the are from horizontal to vertical, the bottom of the wall locks against the floor of the base thereby discouraging the wall from going beyond 90 degrees. The unique nature of this geometry creates a secondary *~.:prevention of the wall being forced beyond 90 degrees in the form of the recessed l ower bottom of the wall passing through an arc, the centre of which may be a frill 0: 20 40 mm inside the pallet base from the exterior of the peripheral edge wall. This arc a:...:settles on top of the sloped upper edge wall, thereby locating the side wall in the upright position. The pivot axis in the preferred fonns of the invention is about 32 mm from the peripheral edge wall. Prior to this invention known art placed the pivot within the peripheral edge wall.

Durability and Rigidity of the base Some existing base units for bulk containers are injection moulded as a single structure, with the support feet integral with the base. To form the feet with a continuous surface, openings must be left in the upper surface of the base, which 2 COMS ID No: SMBI-00624811 Received by IP Australia: Time 17:12 Date 2004-02-18 18/02/2004 17:00 18/2/0041700ChrvsIIIou Law 99534744 7/52 \\serveare~docs\patents~comp\9542auamended.dac are then closed with press-in inserts. This construction may result in a weak base with insufficient rigidity of the base. The base tends to fail at the junction of the feet, particularly if the base is held in racks and only supported at its edges or corners.

A base unit may be made with separate feet and base which are subsequently welded together. These units are moved by fork lift when loading or unloading trucks or being otherwise moved. The feet are frequently hit either by the tyres of the fork lift or are hit against a solid object, such as the top of a loading dock or the side of a truck. This can shear off. the feet at the weld line.

io Accordingly in an attempt to improve the durability and rigidity of the base of a bulk container, the invention preferably provides a base unit including: base having an underside surface; at least one support mounted to the underside of the cross-sectional base' one of the support and base having at least one male extension extending into a female receptacle in the other of the support and the base, said male extension having a cross-sectional width in a transverse direction and a 0 cross-sectional length in a longitudinal direction, said female receptacle having a cross-sectional width in the transverse direction and a crosssectional length in the longitudinal direction, wherein the cross-sectional width of the male extension and female receptacle extension are substantially the same and the cross-sectional length of the female receptacle is greater than the cross-sectional length of the respective male extension.

Preferably the at least one support is friction welded or press fitted to the base.

Preferably the male extension is circular in cross-section and the female receptacle is an oval in cross-section. Alternatively, the female receptacle is slot shaped in cross-section with straight elongated sides and rounded ends, the rounded ends having a radius adapted to conform substantially and fit within the radius of the 3 COMS ID Na:SMBI-00624811 Received by IP Australia: Time 17:12 Date 2004-02-18 18/02/2004 17:00 1802204 1:0ChrrsiIIou Iaw 99534144 8/52 \\server~e~dacs~patents~owmp s542auameided.dac male extension. However, a square or rectangular extension may be used with a rectangular receptacle or a ny other appropriate shape.

The cross-sectional length of the receptacle needs to be sufficiently large to enable free movement of the male extension in the longitudinal direction during friction welding. This helps withstand lateral and longitudinal impacts.

Most containers have three supports or feet spaced across the width of the base.

These supports are usually of the same width. In preferred forms of the invention, the central support should be increased to nearly double the width of the edge supports (whereas conventional art usually has substantially equal width). This io creates a significantly reduced unsupported span, thereby increasing the rigidity of the base.

Side Wall Construction Existing folding bulk containers have four side walls which move between erect positions and collapsed positions. The base of the container has a peripheral wall running along each edge. In existing containers the peripheral wall extends upwards more than 30mm to 40mm. The side walls, in the erect position, overlap the peripheral wall, so that any load on the side wall is transferred to the base of the container via the peripheral wall. Substantially most of the load is transferred through the hollow corners of the end wall. Most current systems have side walls Mo. 20 which are about 40mm thick and peripheral walls more than half the thickness of the side wall. Further, many existing systems have a lift up/drop down type of pivoting arrangement rather than a true revolving action about a single, fixed axis.

These factors tend to lead to excessive free play in the side walls and, more importantly excess collapsed height.

In most systems the outer surface of the first side walls lies level with the upper edge of the peripheral wall. The side walls lock together in a way which requires one pair of opposed walls to have a female receptacle structure extending out of the general plane of the inner surface of the second side wall. This pair of walls is 4 COMS ID No: SMBI-00624811 Received by IP Australia: Time 17:12 Date 2004-02-18 18/02/2004 17:01 Chryslllou Law 99534744 9/52 \\serveredocs\patents\omp\9542auamended.doc folded on top of the first pair and are mounted higher than the first pair so that this receptacle structure can lie on the horizontal outer surface of the first pair. This leads to excessive folded height.

A preferred aspect of the invention advantageously aims to reduce the height of a folded bulk container by providing a base unit having: an elongate peripheral edge wall, said wall having an inner surface; a side wall pivotably mounted on the base inwardly of the inner wall surface about a revolving axis substantially parallel to the peripheral edge wall; said side wall being movable between an erect position in which it is :i :10 approximately vertical and a folded position in which it is substantially approximately horizontal; said side wall having a first portion having a first outer surface which, when in the erect position, extends generally vertically adjacent to the inner wall surface to at least the highest point of the peripheral edge wall, and when in is the folded position extends generally horizontally below a horizontal plane passing through the said highest point.

The side wall preferably has a second portion with a second outer surface and the peripheral edge wall has an outer surface which is coplanar with the second outer surface when the side wall is in the erect position.

The upper edge wall surface of the peripheral edge wall may be flat or radiused.

Preferably there is an intermediate surface on the side wall extending between the first and second outer surfaces and preferably this intermediate surface is complementary to the top surface of the peripheral edge wall.

In the preferred embodiment the peripheral edge walls only extend upwards by 28mm while the side walls are 40mm thick. The first portion of the side wall, which lies adjacent the peripheral edge wall, is only 28mm thick so that when COMS ID No: SMBI-00624811 Received by IP Australia: Time 17:12 Date 2004-02-18 18/02/2004 17:01 18/0/204 1:01Chrys I Ilou Law 99534744 10/52 %IserveAedocpatents\comp9542auamended.doc folded it lies flush with the upper surface of the peripheral edge wall with the major portion of the side wall above the peripheral edge wall. This step at the edge of the side wall is of sufficient height to receive the female receptacle structure of the second pair of walls, so that the inner surface of the second pair of walls may lie s upon the outer surface of the first pair of side walls. Compared to conventional folding containers this saves a significant amount in folded height 12mm in peripheral edge wall height and 12mm in the mounting of the second pair of walls relative to the first pair.

Configuration of the Upper Surface of the Base lo Bulk containers are normally square or rectangular and pallet sizes vary with countries. In some countries the short side of a rectangular pallet does not allow the long side's side walls to fold down without overlapping. This means, the upper of the long side walls does not fold horizontally, which in turn means that the short side walls cannot fold down horizontally, so increasing the folded height of the container.

Accordingly, in another preferred aspect of the invention, there is advantageously a* -provided a base unit for a collapsible bulk container in which side walls are pivotably mounted on the base unit, between erect and folded positions, said base 0unit having an upper surface against which all or part of the inner surface of at least 0. 20 one of the side walls rests when in the folded position, said upper surface and said a.a* inner surface configured to allow the said at least one side wall to pivot more than 9O* between the vertical position and the folded position.

In a preferred embodiment this is achieved by having a V-shaped upper surface.

Preferably the upper surface is bilaterally symmetrical so that it does not matter which side wall is folded down first.

Preferably the lower of the two side walls pivots sufficiently to allow the second side wall to lie horizontally and lower than would otherwise be the ease without this

V.

6 COMS ID No: SMBI-00624811 Received by IP Australia: Time 17:12 Date 2004-02-18 18/2/0041101Chrys IIlou Law 99534744 11/52 18/02/2004 17:01 \\serverhedocspantscwmp\9542auamended.doc Latching Structure In present folding bulk containers, the folding side walls engage with square or rectangular or circular shaped latches. Such configurations require undesirable looseness, since the lower latches travel through a smaller arc than the upper N 5 latches. In many systems the lower latches start to enter their respective female receptacle at about 450 whilst the upper latches enter almost horizontally.

To achieve a rigid design while allowing the side walls to pivot about a fixed axis, the invention preferably provides a folding bulk container having: a base; a. 10 side walls pivotably mounted on the edges of the base for movement between folded positions and erect positions; adjacent pairs of erect side walls engaging each other by a series of engaging male tabs and female receptacles; said male tabs extending from an end wall of a first pair of side walls and engaging in said female receptacles in an inner wall of te other of said pair, 9* 9 said tabs and receptacles extending away from the axes of rotation of the two side walls; said tabs and receptacles having a generally triangular shape, the included 9 angle of the apex of the tab and corresponding receptacle being less than the included angle of the apex of the adjacent tab nearer to the axis.

Preferably, the included angle of the apex of each tab ranges from about adjacent the axis to about 2O' furthest from the axis.

The receptacles near to or adjacent the axis may have a short horizontal lead in.

The included angle of the apex is preferably inversely proportional to the distance of the apex from the axis.

7 COMS ID Na:SMBI-00624811 Received by IP Australia: Time ,1 7:12 Date 2004-02-18 18/02/2004 17:02 Chrys lllou Law 99534744 12/52 \\server\eldocs\patents\comp\9542auamended.doc All tabs preferably have the same dimension across the thickness of the respective side wall.

Peripheral Edge Wall Construction With corrugated cardboard walled containers, the volumetric efficiency is determined in part by the thickness of the peripheral edge walls. Typically these walls are about 24mm or more wide and are formed as an upturned U with parallel side walls about 4mm thick with a gap of about 16mm. Using a blade between the side walls to form the gap requires a blade this thick to allow for proper cooling of the blade thinner blades overheat.

o1 The present invention in a preferred form utilises gas assist to create the actual peripheral wall, which may be reduced to an overall width of only 12mm. Prior to this invention gas had been used to fill voids but never to create an entire wall. On conventional pallet this can lead to a direct increase in internal volume.

Accordingly, in a preferred form the invention advantageously provides an injection moulded plastics base including: an upper surface; an elongate peripheral edge wall extending from the upper surface along or adjacent at least part of the peripheral edge of the base, said peripheral edge wall being gas blown and extending along the length of the wall between inner and outer side walls.

The inner and outer walls of the peripheral edge wall are preferably each about one third the thickness of the peripheral edge wall.

Configuration of the Side Walls and Feet The stability of a stack of bulk containers may be improved if the stacks are positively locked together to act against creep or slip.

s COMS ID No: SMBI-00624811 Received by IP Australia: Time 17:12 Date 2004-02-18 18/02/2004 17:02 18/2/0041702ChryuIIlou Law 99534744 13/52 \\server~e~docs~patentscompN9542auamended.doc Accordingly, in a preferred form of the invention, there is advantageously provided a folding bulk container wherein: the container includes a pair of side walls pivotably mounted on the base unit for movement between upright erect positions and horizontal folded positions, each of said side walls having an inner side wall surface, an outer side wall surface and an upper side wall surface extending from the outer side wall surface to said inner side wall surface, in an erect position said upper side wall surface has a first side wall potion which extends downwardly and inwardly from the outer side wall surface and a second side wall portion which extends inwardly and upwardly to said inner side wall s urface, and the base unit includes longitudinally extending supports depending downwardly and along or adjacent two opposed side edges of the base unit, each of said supports has a lower support surface including a complementary support portion which extends upwardly and inwardly complementary to said second side wall portion, *Sa whereby a plurality of erect containers may be stacked one on top of another such that the complementary support portion of a first container rests on the upper side wall surface of an adjacent lower container.

Preferably the second portion extends upwardly at about 12' to the horizontal.

These features may also be adapted to cardboard walled containers where a concertina folded corrugated cardboard wall is held inside of the perimeter edge wall with stack locators with a 12 degree inclination.

In the known art the upper surface of the side walls is usually horizontal. Likewise the lower surface of the supports, legs or feet in the known art is usually flat. We acknowledge the known art may have castellated surfaces or ledges to make location more positive. In the above mentioned format the 12 degree downward 9 COMS ID No: SMBI-00624811 Received by IP Australia: Time 17:12 Date 2004-02-18 18/02/2004 17:02 18/2/0041102ChryuIllou Law 99534744 14/52 \\sever~e~docs~paients~con-V\9542auarnended-doc slope towards the exterior of the walls in combination with the downward slope of the outer edges of the supports of a similar 12 degree slope is one preferred aspect of the invention.

The phenomena of pressure induced sliding of bins moulded from polyethylene can cause the walls to bow and upper box to slide into the lower. The geometry of the underside of the supports and the corresponding sloped edge reverses this, and in fact induces the walls inwards, making the stack inherently more stable as the walls are pushed against the locating feet.

The invention shall be better understood from the following non-limiting description of preferred embodiments, in which: Figure l is a plan view of a folding bulk container according to the invention.

Figure 2 is a cross-sectional view taken along line A-A of Figure 1.

Figure 3 is a cross-sectional view of a side wall of Figure 1 in a folded position, erect and part erect positions taken along line B-B of Figure 1.

boo: 15 Figure 4 is a partial cross-sectional view of the container of Figure I with all the side walls folded down.

Figure 5 is a cross-sectional view of the base of the container of Figure I taken :along line C-C. For clarity the side walls and hinge mountings are omitted.

Figure 6 is a side view of one of the supports for the container of Figure 1.

Figure 7 is a plan view of the support of Figure 6.

Figure 8 is an end view of a male side wall of the container of Figure 1.

Figure 9 is an alternate construction of the base of the folding container.

l0 COMS ID No: SMBI-00624811 Received by IP Australia: Time 17:12 Date 2004-02-18 18/02/2004 17:03 ChryslIlou Law 99534744 15/52 \\server\e\docs\patents\comp\9542auamended.doc Referring to the drawings there is shown a folding bulk container 10. The container includes a base 12, a pair of male side walls 14 and a pair of female side walls 16.

The side walls 14, 16 are pivotably mounted on hinges 18, 20 as to be movable between an erect position and a folded position. The hinges 18, 20 are preferably barrel hinges and only allow rotation of the side walls 14, 16 relative to the base 12 there is no slot type arrangement which deliberately allows substantial radial movement of the side walls 14, 16 relative to the hinge line.

The container 10 is designed to fold down to as low a height as possible and to o1 provide a substantially planar upper surface when folded upon which another folded container may be placed. The male walls 14 are designed to be folded down first, between the erect female walls 16 and the female walls 16 are then folded on top of the male walls 14. Accordingly the hinges 20 upon which the female walls 16 are mounted are higher than the hinges 18 of the male walls 14.

To limit movement of the side walls 14, 16 the base 12 is provided with peripheral "edge walls 22, which extend above the height of the respective hinge lines and against which the side walls 14, 16 bear when erected.

0. The peripheral edge walls 22 are about 12mm thick and about 28mm high and in a the preferred embodiment have upper surfaces 24 which slope downwards from the 20 inner surface 26 toward the outer surface 28 at about 12°. Each peripheral edge wall 22 is formed of an inverted U-shape with a void 29. This void 29 is not formed by a blade but by gas assist during moulding and is, preferably, fully enclosed, which is not possible with conventional moulding. The walls of the peripheral edge wall 22 are each about 4mm thick and the void 29 is about 4mm thick.

The major portion 30 of each of the side walls 14, 16 nominally has a maximum thickness of about 40mm but the minor portion 32 adjacent the peripheral edge wall 11 COMS ID No: SMBI-00624811 Received by IP Australia: Time 17:12 Date 2004-02-18 18/02/2004 17:03 Chryslllou Law 99534744 16/52 \\serverle\docs\patents\comp\9542auamended.doc 22 is thinner. The hinge 18, 20 is preferably placed in this minor portion 32 as low as possible and as close to the inner surface 26 as possible.

The horizontal distance of the outer surface 34 of the minor portion 32 from the hinge 18, 20 is preferably less than the height of the uppermost point of the peripheral edge wall 22 above the axis. Thus when the side wall 14, 16 is folded down, the outer surface 34 of the minor portion 32 does not lie above the peripheral edge wall 22.

In the preferred embodiment, the peripheral edge wall 22 extends about 28mm above the hinge line and the minor portion 32 of the side wall 14, 16 is about 28mm thick. The transition surface 33 from the minor portion 32 to the major portion is angled at about 120 so as to complement the upper surface 24 of the peripheral edge wall 22. When erect, this surface 33 bears on the upper surface 24 of the peripheral edge wall 22 and prevents over rotation.

o** The base 35 of the side wall 14, 16 is also configured so that attempted over rotation beyond 90° will cause it to bear on the floor of the base 12.

The male side walls 14 have tabs 40 extending from their ends 42 which engage in 0 *i female receptacles 44 provided on the inner surface 46 of the female side walls 16.

a The female walls 16 are erected first and the male walls 14 pivoted to engage the a female walls 16. Thus the male tabs 40 must clear the inner surface 46 of the 20 female walls 16, ie, the structure for female receptacles 44 must extend inwardly of the inner surface 46 of the female walls 16. The provision of the lower height minor portion 32 on the male side walls 14 allows the female side walls 16 to fold down with the female receptacle structure 44 located in this lower portion 32 and the major part 30 of the female wall 16 resting on major portion 30 on the male wall 14. The female receptacle structure 44 extends approximately 12mm from the general plane of the female walls 16. By providing a 12mm recess at the edge of the male side walls 14, this allows the hinge 20 of the female walls 16 to be 12 COMS ID No: SMBI-00624811 Received by IP Australia: Time 17:12 Date 2004-02-18 18/02/2004 17:03 18/2/0041103Chrysillou Law 99534144 17/52 \erveo~cs~atentscompk9542auamended.doc lowered by a corresponding 12mm, so reducing the folded height of the container The bulk container 10 is normally pallet sized with exterior dimensions of 1200mm by 1000.mm with side walls 14, 16 extending upwards about 600mm. Thus, nonnally, on the short side, even allowing for the thickness of the peripheral edge walls 22, there is clearance between the two folded male walls 14. However, for containers 10 wit a smaller short side or taller side walls, this clearance will cease to exist and the two walls will overlap. Referring to Figure 9, to accommodate this, the upper surface of the base may be formed of two downwards sloping surfaces ic 52. If the surfaces 52 slope downwards sufficiently, the lower of the two male side walls 14 will be angled downwards so that the second side wall lies horizontally, so allowing the second set of female side walls 16 to fold down to a true horizontal position. Alternatively, if the female pair of walls 16 have recessed inner surfaces, the surface may only need to slope downwards a small amount, resulting in the upper one of the male walls 14 still extending upward a small amount but still allowing the second pair of walls to lie horizontally.

The bulk containers 10 of the invention wre intended to be manipulated by fork lifts and accordingly are provided with two outer structures and one central structure.

"604%These structures extend parallel to the long side of the base 12 and are spaced along the short side. The lower surface of the structures is provided with two longitudinal a '0 recesses, which thus define fork receiving longitudinal slots and two longitudinal outer supports 53 and one longitudinal central support 54. The central support 54 is about twice the width of the outer supports 53.

The supports 53, 54 are manufactured separately from the base 12 and are friction welded or press-fitted to the base. The base 12 is formed with a series. of downward extending ribs 60 which correspond to ribs 62 on the supports. The ribs 62 are welded together so providing a large welded surface. In nonmal use the supports 53, 54 wre subject to many inadvertent impacts. For instance, the containers 10 may not be raised sufficiently and the supports 53, 54 of the lowest 13 COMS ID No: SMBI-00624811 Received by IP Australia: Time 17:12 Date 2004-02-18 18/02/2004 17:04 18/2/0041704ChrysilIlou Law 99534744 18/52 container 10 may bit the edge of a loading dock or truck. Similarly, the forks of the fork lift may not align with the fork receiving slots and hit the supports 53, 54. This places great stresses on the welds. To improve the durability of the structure the supports 53, 54 are provided with a series of pegs or bosses 64 and the lower s surface of the base is provided with -corresponding holes 66. The pegs 64 are preferably circular in cross-section but this is not essential. The use of pegs 64 and boles 66 would normally prevent the use of vibration welding, since such welding requires relative movement of the two parts being welded. To overcome this each hole 66 is not circular in cross-section but is oval, so allowing relative motion in ia one direction but not in the other the width of the oval corresponding to the diameter of the peg 64. The. oval is arranged with its lengthwise direction parallel to the length of each support 53, 54. Thus any impacts, which are normally parallel to the longitudinal supports 53, 54 will be partially transferred between the supports 53, 54 and the base 12 'via the hole 66 peg 64 arrangement.

is It will be noted the central support 54 is approximately twice the width of the outer supports 53, which increases the strength of the unit when it is only supported by its outer supports 53.

As mentioned earlier, the male walls 14 engage the female walls 16 with triangular tabs which are received in triangular shaped recesses in the inner surface 46 of the *.20 female walls 16. The male walls 14 each rotate about their hinge axis and so the lowermost tab/recess combination will commence engagement before the upper-most and (inherently) when the angle of the male wall 14 to the female wall 16 is greater. Typically the lower combination may commence engagement at 450 rotation whilst the upper combination commences engagement at almost 2s rotation.

The use of different angled triangular tabs successfully deals with the problems of different angles of engagement. By using different angles, the tabs 40 in fact engage (overlap) the walls at about the same angle of rotation and provide a roughly similar amount of overlap from the bottom latch to the top latch, so 14 COMS ID No: SMBI-00624811 Received by IP Australia: Time 17:12 Date 2004-02-18 Chrvslllou Law 99534744 19/52 18/02/2004 17:05 \\server\e\docspatents\comp\9542auamended.doc improving the rigidity of the engagement. In the preferred embodiment there are provided six tabs, with the lowest tab, 40a having an included angle of about 800 and the upper tab 40f having an included angle of about 200. The included angles and tabs 40b to 40e lie between these two extremes. The two lower tabs 40a and 40b have horizontal lead-ins 43 to enable the tabs 40a, 40b to be placed closer to each other than otherwise.

A final aspect of the invention relates to the stacking capability of the bulk container 10. The top of the side walls 14, 16 are provided with a step 70 which has an outer side surface 72 and a base surface 74. The outer surface 72 is inclined outwardly in the upwards direction and the base surface is inclined upwardly at about 120 inwardly. The perimeter edge of the supports 53 are provided with a recess or groove 76 which is complementary to the base surface 74 and about .1 14mm wide.

This ensures that the supports 53 of containers in a stack mate securely with the side walls 14, 16 of the container 10 below. Further, the slope of the lower surface 74 causes the side walls 14, 16 to lock against the supports 53. The downward weight of the upper container 10 will tend to cause the lower surface to move inwards, but such movement is prevented by the outer surface 72 bearing on the support 53, whilst outward movement of the side wall 14 is resisted by the need to 20 raise the container(s) 10 for this to happen. The outwardly extending outer surface 72 aids in placing the pallets in a stack.

The recess 76 on the lower surface of the supports 53 has the same effect with cardboard walls as with moulded side walls 14, 16, even when the top surfaces of the cardboard walls are horizontal. The recess 76 will tend to force the cardboard walls inwards, so improving the stability of the stack and preventing the side walls 14, 16 bowing outwards.

COMS ID No: SMBI-00624811 Received by IP Australia: Time 17:12 Date 2004-02-18 18/02/2004 17:05 Chryslllou Law 99534744 20/52 \server\e\docs'patents\comp\9542auamended.doc It will be appreciated by those skilled in the art that many modifications and variations may be made to the embodiments described herein without departing from the spirit or scope of the invention.

0* 0 00 0* *0 0 **00 01 16 COMS ID No: SMBI-00624811 Received by IP Australia: Time 17:12 Date 2004-02-18

Claims (26)

1. A folding bulk container including: a base unit including a base and peripheral edge wall extending upwardly from the base, which edge wall has an outer edge wall surface, an inner edge wall surface and an upper edge wall surface, and at least one side wall pivotably mounted on the base unit for rotation about a fixed axis adjacent the peripheral edge wall and located outside of a space defined by a first plane in which the outer edge wall surface substantially lies and a second plane in which the inner edge wall surface substantially lies *10i whereby the side wall is adapted for movement between an erect position :~%and a folded position, wherein the upper edge wall surface extends upwardly from the outer edge wall surface through to the inner edge wall surface and the side wall includes a complementary surface corresponding to the upper edge wall surface. is

2. A bulk container according to claim 1, wherein the base unit includes a floor and the pivotal mounting of the side wall includes a hinge pin.

3. A bulk container according to claim 2, wherein the hinge pin. is positioned relative to the bottom of the side wall whereby, when the side wall is moved through -an arc fr~om a substantially horizontal to a substantially vertical position, the bottom of the side wall locks against the floor of the base unit thereby retarding the side wall from pivoting substantially beyond 90 degrees.

4. A bulk container according to any one of claims 1 to 3, wherein the peripheral edge wall retards the side wall from pivoting substantially beyond the vertical.

A bulk container according to any one of claims 1 to 4, wherein the upper edge wall'surface is inclined approximately 12 degrees to the horizontal. 17 COMS ID No: SMBI-00624811 Received by IP Australia: Time 17:12 Date 2004-02-18 18/02/2004 17:05 18/2/0041705ChrysIIlou Law 99534744 22/52 \\server Mdocs~patents\comp\9542auamended.doc

6. A bulk container according to claim 4 or 5, wherein the bottom of the side wall is recessed and the hinge pin is not located in e ach edge wall but is sufficiently spaced from the inner surface of the peripheral edge wall inside the base unit to define the centre of an arc through which the complementary surface of the side wall travels, whereby the complementary surface of the side wall is located on top of the upper surface of the peripheral edge wall when the side wall is pivoted into the vertical position.

7. A bulk container according to any one of claims I to 6, wherein the container includes an opposed pair of side walls pivotably mounted on @000010 the base unit for movement between upright erect positions and horizontal folded positions, each of said side walls having an inner side wall surface, an :.0:outer side wall surface and an upper side wall surface extending from the outer side wall surface to said inner side wall surface, in said erect position said upper side wall surface has a first side wall portion which extends downwardly and inwardly ftrm the outer side wall surface .0.00.and a second side wall portion which extends inwardly and upwardly to said :inner side wall surface, and :0:0:the base unit includes longitudinally extending supports depending downwardly and along or adjacent two opposed side edges of the base unit, each of said supports has a lower support surface including a complementary support portion which extends upwardly and inwardly complementary to said second side wall portion, whereby a plurality of erect containers may be stacked one on top of another such that the complementary support portion of a first container rests on the upper side wall surface of an adjacent lower container. 18 COMS ID No: SMBI-00624811 Received by IP Australia: Time 17:12 Date 2004-02-18 18/02/2004 17:05 10/2/0041105Chryclllou Law 99534144 23/52 \\server~edocspatents\comp\9542auamended~doc

8. A bulk container according to claim 7, wherein the second side wall portion extends upwardly at approximately 12 degrees to the horizontal, when the side wall is in the erect position.

9. A bulk container according to any. one of claims I to 8, wherein the base unit includes a base having an underside base surface and at least one support mounted to the underside base surface, the at least one support and the base have complementary engagement means including at least one male extension adapted to cooperate with one female sees.:receptacle, said male extension having a cross-sectional width in a transverse direction and a cross-sectional length in a longitudinal direction, said female receptacle having a cross-sectional width in the transverse direction and a cross-sectional length in the longitudinal direction, and the cross-sectional width of the male extension and the female receptacle are substantially the same and the cross-sectional length of the female receptacle is greater than the cross-sectional length of the male extension.

10. A bulk container -according to claim 9, wherein the at least one support is friction-welded or press-fitted to the base.

11. A bulk container according to claim 9 or 10, wherein the male extension is circular in cross-section and the female receptacle is slot-shaped in cross-section With straight elongated sides and rounded ends, the rounded ends having a radius adapted to conform substantially and fit within the radius of the male extension.

12. A bulk container according to claim 11, wherein the length of the elongated sides is sufficient to enable free movement of the male extension in the longitudinal direction during friction welding and to assist the support in withstanding lateral and longitudinal impacts. 19 COMS ID No: SMBI-00624811 Received by IP Australia: Time 17:12 Date 2004-02-18 18/02/2004 17:06 Chryslllou Law 99534744 24/52 \\server\e\docs\patents\comp\9542auamended.doc

13. A bulk container according to any one of claims 9 to 12, wherein the base includes a middle support and two corer supports wherein the middle support is substantially wider than the corer supports.

14. A bulk container according to any one of claims 1 to 13, wherein: the container includes an opposed pair of side walls pivotably mounted on the base unit which are adapted to travel between erect and folded positions; the base includes an upper base surface against which all or part of the inner side wall surface of at least one of the side walls rests when in the folded position, said upper base surface and the inner side wall surface being configured to allow the first folded side wall to pivot more than 90 degrees from the vertical position to the folded position, whereby the first folded side wall is folded in a lower position than if the upper base surface were not so configured.

A bulk container according to claim 14, wherein the upper base surface is V- 15 shaped.

16. A bulk container according to claim 14 or 15, wherein the upper base surface is bilaterally symmetrical. a*

17. A bulk container according to any one of claims 14 to 16, wherein the first folded side wall pivots sufficiently to allow the other side wall to lie substantially horizontal, when both walls are in the folded position.

18. A bulk container according to any one of claims I to 6, and any one of claims 9 to 13 when dependent on claims 1 to 6, wherein the side wall is pivotably mounted on the base unit inwardly of the inner edge wall surface about a revolving axis substantially parallel to the peripheral edge wall; COMS ID No: SMBI-00624811 Received by IP Australia: Time 17:12 Date 2004-02-18 18/02/2004 17:06 18/2/0041708Chrys I Ilou Law 99534144 25/52 \Nserver\edacs~patents\camp\9542auamanded.doc the side wall is movable between the erect position in which it is substantially vertical and the folded position in which it is substantially horizontal; the side wall has a first portion having an outer surface which, when the side wall is in the erect position, extends generally vertically adjacent to the inner edge wall surface to at least the highest point of the peripheral edge wall and, when the side wall is in the folded position, extends generally horizontally below a horizontal plane passing through said highest point of the peripheral edge wall. ic

19. A bulk container acrigto any one of claims i to 6 and 18, and any one of claims 9 to 13 when dependent on claims 1 to 6, wherein the side wall in the erect position has a second portion with an outer surface which is substantially coplanar with the outer edge wall surface.

A bulk container according to claim 19, wherein the side wall has an 1s intermediate side wall surface extending between the outer surface of the first 040~ portion and the outer surface of the second portion, which intermediate side wall S surface is complementary to the upper edge wall surface. 2S.Abl.otie codigt n n fcam t ,ayoeo lis9t 1. Ahe bulkncontnracditay one ofclms i to 6,an any one of claims 98 to20we dependent on claims I to 6 and 9 to 13, wherein the container includes two adjacent pairs of opposed side walls, each side waif terminating at its sides in end walls, the adjacent pairs of opposed side walls adapted to engage each other in the erect position by a series of engaging male tabs and corresponding female receptacles, and said male tabs extend from each of the end walls of a first opposed pair of side walls and engage corresponding said female receptacles in the end walls

21 COMS ID No: SMBI-00624811 Received by IP Australia: rime 17:12 Date 2004-02-18 18/02/2004 17:07 ChrysIllou Law 99534744 26/52 \\server\e\docs\patents\comp\9542auamended.doc of the other opposed pair of side walls, said tabs and receptacles extending away from the axes of rotation of each of the side walls.

22. A bulk container according to claim 21, wherein the tabs and the receptacles have a generally triangular shape, the included angle of the apex of each tab being less than the included angle of the apex of the adjacent tab nearer the axis about which the or each side wall pivots.

23. A bulk container according to claim 21 or 22, wherein the included angle of the apex of each tab ranges from about 800 adjacent the axis to about 200 furthest from the axis. 10

24. A bulk container according to any one of claims 1 to 23, wherein the base unit includes an injection moulded plastics base having an upper base surface and said peripheral edge wall is blown to form an enclosed void which extends substantially along the length of the peripheral edge wall between the inner and outer edge wall surfaces. is

25. A bulk container according to any one of claims 1 to 24, wherein said outer edge wall surface is substantially planar. a. a

26. A bulk container substantially hereinbefore described with reference to the accompanying drawings. 22 COMS ID No: SMBI-00624811 Received by IP Australia: Time 17:12 Date 2004-02-18