GB2539653A - Box and modular load layer connector - Google Patents

Abstract

A box (shown in fig 3) 10 including: a base, a lid and two end panels 30, arranged at opposite ends of the box from each other, and each arranged to span two corners of the lid and two corners of the base. Each end panel comprises two edge posts 32, each forming an edge of the box between the lid and the base, and a flange 34 extends from each of said edge posts, from one end panel towards the other end panel. Each flange may include a groove 35 for receiving side panels 40. A modular load layer connector (shown in fig 10) 200 includes two panels 60, 70, which are connected by four edge posts 80 arranged at the corners of the panels. The outer surface of these panels are provided with connectors 50 for cooperating with connectors on boxes of a modular load, thereby allowing repeated attachment and detachment of the modular load to/from the connector.

Description

BOX AND MODULAR LOAD LAYER CONNECTOR

The present invention relates to a box, particularly a box for forming modular loads for logistics purposes. It also relates to a modular load layer connector, which can be used in conjunction with boxes of the invention.

Efficient freight transport is crucial to the European and world-wide economies. In some sectors total logistics costs now exceed manufacturing. It has been estimated that a 10% to 30% efficiency improvement in the EU logistics sector would provide between 100-300 billion cost relief for EU industry, and reduce the EU 27 CO2e footprint by 1.3%. Research into the relationship of logistics costs to growth in GDP has indicated that a 15% reduction in the logistics cost of a country could increase growth in its economy by 0.45%.

The Fast Moving Consumer Goods (FMCG) industry is normally one of the largest in most economies and in Europe has average logistics costs of 30% of value versus a global average of 14.3% with a rising trend. Transport costs are often the highest component of logistics costs, and increasing truck utilisation is key to reducing costs. Yet the utilisation of freight transport vehicles has remained broadly static at around 50-59% by weight, with up to 29% empty running in Heavy Goods Vehicles (HGV) for the past 15 years.

Given the lack of improvement in the last 15 years it might be assumed that industry indifference or incompetence are to blame, which is not actually the case.

These utilisation statistics actually conceal huge industry efforts to contain the negative impacts on truck loading and increase in costs caused by ever more frequent deliveries, fragmentation of transport flows due to the growth of convenience stores and internet commerce, coupled with a proliferation in product ranges. Effectively the industry has been running very fast to stay in the same place.

Initiatives such as the Physical Internet (PI) aim to address the utilisation issue by providing a more modular approach to load handling. However, so far, a practical way of implementing such aims has not been forthcoming. The practical constraints surrounding the creation of such a system have proved intransigent: such a system should allow the coupling of loads of different sizes to create standard size loads that can be handled by existing infrastructure (which implies a certain level of robustness), but also allow easy decoupl ng so that individual loads (or subsets of a larger load) can be accessed or removed.

A considerable amount of design work had been undertaken within the PI initiative, and the Modulushca consortium have developed prototype boxes which are able to lock together on the top and bottom surfaces using a sophisticated locking mechanism.

However, it is not possible to join these prototype boxes side to side, or back to front, which limits the number of modular combinations available, overall load stability and handling as an unsupported unit load. It is also not possible to collapse or nest the boxes when empty, and while PI should enable less empty running over time.

It is also critical to cost reduction that the box handling is as efficient overall as current handling per handled unit. The locking lever on the top of the Modulushca prototype box is "closed in" when another box is attached to it. To release a box under two or more other boxes requires the whole stack to be released to access its locking lever.

Finally, the prototypes are made of rigid plastic, and are relatively fragile and heavy. From initial transport and handling feedback it appeared there was a high likelihood of physical damage from using clamp trucks, or any other mechanised materials handling equipment (MEE) such as fork lift trucks. Without any other specific manual or mechanised handling means being available, the unit load would require a pallet, which reduces the potential for cost and environmental savings significantly.

The present invention aims to at least partly address these problems.

According to the invention there is provided a box comprising: a base; a lid; two end panels, arranged at opposite ends of the box from each other, and each arranged to span two corners of the lid and two corners of the base; wherein each end panel comprises two edge posts, each forming an edge of the box between the lid and the base, and a flange extends from each of said edge posts, from one end panel towards the other end panel. The flange construction of the edge posts provides a wrap-around end panel that lends strength to the box against torsional forces.

The box can further comprise two side panels, each extending between the end panels. Each flange can comprise a groove for receiving one of the side panels, and the base and/or the lid can comprise grooves for receiving the side panels. Alternatively, each side panel can extend between a flange of each end panel, wherein the side panels and the flanges comprise connectors configured to cooperate with each other to allow repeated attachment and detachment of the side panels to/from the flanges.

The end panels, lid and base can comprise connectors configured to cooperate to allow repeated attachment and detachment of the end panels to/from the lid and base. As such, the box can be decomposed into constituent parts when empty, thereby saving space.

The box can further comprise connectors disposed in the outer surfaces of the edge posts for cooperating with connectors on other boxes to allow repeated attachment and detachment of the box to/from said other boxes. These connectors allow the box to be combined with other such boxes to form a modular load.

The box can further comprise a locking mechanism for locking and releasing all the connectors on at least one face of the box simultaneously.

The box can further comprise connectors disposed in the outer surfaces of the base and lid for cooperating with connectors on other boxes to allow repeated attachment and detachment of the box to/from said other boxes. These connectors allow the box to be combined with other such boxes to form a modular load, particularly with other boxes stacked below or above the first box.

The box can further comprise a locking mechanism for locking and releasing all the connectors on the lid and/or base simultaneously.

Any connectors on the outer surface of the box can lie flush, or below, the surface of the box in an unconnected or unlocked state, so as to allow neighbouring boxes to be moved over/past each other without the boxes catching on the connectors.

The box is preferably substantially cuboid, to allow for ease of attachment with other boxes so as to form a modular load.

A plurality of the boxes can be of differing sizes, pre-defined to allow the attachment of the boxes into a modular load.

According to another aspect of the invention, there is provided a modular load layer connector, the layer connector comprising: two panels, connected by four edge posts arranged at the corners of the panels; wherein outer surfaces of the panels are provided with connectors for cooperating with connectors on boxes of a modular load, to allow repeated attachment and detachment of the modular load to/from the layer connector.

The modular load layer connector can further comprise connectors disposed in the outer surfaces of the edge posts for cooperating with connectors on other modular load layer connectors to allow repeated attachment and detachment of the layer connector to/from said other layer connectors.

The present invention is described below, with reference to the the accompanying exemplary Figures in which: Fig. 1 is projected view of a first box; Fig. 2 is projected view of a first box, including dotted lines to reveal features not normally visible, particularly the internal connectors; Fig. 3 is a schematic plan view of the first box, without its lid; Fig. 4 is projected view of a second box; Fig. 5 is projected view of a second box, including dotted lines to reveal features not normally visible; Fig. 6 is projected view of a third box; Fig. 7 is projected view of a third box, including dotted lines to reveal features not normally visible; Fig. 8 is projected view of a fourth box: Fig. 9 is projected view of a fourth box including dotted lines to reveal features not normally visible; Fig. 10 is projected view of a modular load layer connector; Fig. 11 is projected view of a modular load layer connector, including dotted lines to reveal features not normally visible; Fig. 12 is a projected view of the second box, with a side panel removed; Fig. 13a is a projected view of a Clamex P14Tm connector; and Fig 13b is a cross-sectional view of a groove for receiving a Clamex PILITm connector.

The present invention aims to provide a suitable box and associated materials for use in handling modular loads as envisaged by the PI initiative. In approaching this problem, the inventors have utilised modem wood joinery techniques previously typically used in exhibition stand and flat pack furniture construction. An example of such a joint is called a Clamex PI4TM made by Lamello AG (Switzerland). Fig. 13a shows an illustration of the Clamex PI4TM 130. Fig. 3b illustrates the cross-sectional shape of the groove 133 into which each of the connector parts 131, 132 are located. As shown in the figures, this is a two part connector, each part inserting into a (different) piece of wood (or other material), and then the two parts can be brought together and locked to connect the two pieces of wood. The shape of the grooves 133, with internal overhangs, catch on peripheral projections of the connector parts 131, 132 to keep the parts 131, 132 in place when subjected to loads when connected, but allows for the parts 131, 132 to be slid in and out of the grooves 133 when unconnected.

The connector has the ability to be used in materials down to 14mm in depth (others will fit into lOmm) and has a tensile strength in particle board (e.g. chipboard) of 80 Kg and harder wood (e.g. beech) of 130 Kg. One of the two sections has lugs 134 that align in sockets (not visible in Fig. 13a) of the other section. A locking lever (also not visible in Fig. 13a, but located in part 131) can then be turned out from one section, when the two sections are suitably aligned, to fit into the other section in a receiving cavity 135 so as to lock the two parts together. The cavity 135 extends behind overhanging flanges, thereby allowing the locking lever to be swung into place and then bear against the flanges when a load is place on the locked connector 130. As the fitting is internal to the material, and protruding external lugs can be removed, parts and panels with the fixing installed can be stacked flat without any damage or loss of space efficiency. Resistance to twisting is high, and there is a relatively high tolerance for lateral movement between the male and female connectors prior to locking if the fixings are left loose in the groove.

Such fixings can be rapidly installed using a custom biscuit cutter tool called a Zeta P2TM which cuts a specially shaped elliptical groove and slot in a single, rapid action. The cutter and fixings work in most materials except metal and stone (e.g. Conan, injection moulded plastic etc.).

Such fixings provide a connection that can be repeatedly locked and unlocked, allowing repeated attachment and detachment of the component parts. Further, they provide a strong and durable joint. Any functionally equivalent fixings may be used. Using such fixings, a system of modular boxes has been developed that are suitable for implementing the Pl. However, the invention is not limited using to using such fixings.

A further issue identified with previous design concepts is that panel-based box designs have converged around joining all the panels at the edges. While this approach maximises the internal space, assuming the panel is relatively thin, it also transfers the majority of the load stresses to the panel interfaces. However, to function in a modular load system, each box must be able to withstand compressive, tensile and torsional forces as these will all be encountered (e.g. boxes will be compressed when other boxes are stacked above them; boxes will be placed in tension if a load formed of connected boxes is lifted from the top; individual boxes will experience twisting/shear forces if a load is poorly balanced or lifted off-centre).

The present system of modular boxes also addresses this problem by providing a construction that is strong, but allows for boxes to be decomposed into component parts (e.g. to allow return of empty boxes in a space-saving manner).

Figs 1&2, 4&5, 6&7 and 8&9 show a series of boxes 100 in different sizes, forming part of a modular set of inter-connectable boxes. In these examples, the box of Figs 1&2 is around 800 x 600 x 600 mm; the box of Figs 4&5 is around 600 x 400 x 400 mm the box of Figs 6&7 is around 400 x 300 x 300 mm; the box of Figs 8&9 is around 300 x 200 x 200 mm (all dimensions referring to outer dimensions). The boxes are constructed from wood, which offers a good balance of strength, weight and cost. However, other materials may be used, and it is envisioned that plastic may be used in mass-manufacture due to ease of manufacturing.

With particular reference to Figs 1&2, the box 100 is formed by a base 10, a lid 20, two end panels 30, and two side panels 14.

The two end panels 30, are arranged at opposite ends of the box from each other. That is, they form opposite faces of the substantially cuboid shape of box 100. Similarly, side panels 40 form opposite faces of the box 100. The end panels 30 and side panels 40 extend from the base 10 to the lid 20.

As can be seen from Fig. 1, end panels 30 span two corners of the lid 20 and two corners of the base 30. In the depicted example, the end panels 30 are constructed using a typical wooden frame construction using horizontal rails 31 and vertical stiles 32 (which act as edge posts for the box 100, forming the edge of the box 100 between the base 10 and the lid 20), which are both strong and light, and an inner panel 33 (which can be, in this wooden construction, plywood housed in a groove in the rails 31 and stiles 32). However these details of the construction are not necessarily required. Whilst they represent a preferable way to construct the box 100 from wood, they may not be appropriate when the box 100 is constructed from other materials. For example, when using plastic, the entire end panel 30, including the edge posts 32) may be moulded as a single piece. Nonetheless, whilst the invention does not require the use of such a construction, it provides the following benefits. The overall panel 30 is both strong and light. Further, the use of the rails 31 and stiles 32 provides a suitable thickness of material for inserting the connectors 50, 51.

In particular, connectors 51 can be inserted into the horizontal rails 31 to allow connection of the end panel to the base 10 and the lid 20. These connectors cannot be seen in Fig. 1, but are shown in Fig. 2 which reveals the internal construction by use of dotted lines. In particular, in Fig. 2, a single internal connector 51 is referenced for ease of identification. Such internal connectors 51 are used for constructing the box 100 itself, as opposed to connecting individual boxes 100 to each other (as discussed later). The connectors 51 may be of the Clamex' type discussed above, for example. The connectors 51 cooperate with each other to allow repeated attachment and detachment of the end panels 30 to/from the lid 20 and base 10.

As is apparent from Fig. 2, the end panels 30 are connected to the base 10 and lid 20 via internal connectors 5L However, no such connectors are present, in the example of Fig. 2, for the side panels. Whilst such an option is possible, it is envisioned that the side panels 40 will more commonly be held in place by a system of grooves.

In particular, the edge posts 32 of the end panels 30, are shaped to extend around the corner edges of the box 100. That is, these edge posts 32 wrap around the corner of the box 100, so as to form a flange which extends from an end panel 30 along the direction of a perpendicular side of the box 100 towards the other end panel 30. As such, these flanges 34 extend from an edge of the box 100, between the lid 20 and base 10, into the same faces of the box as occupied by the side panels 40. A grooves 35 for receiving a side panel 40 is provided in each flanges 34. Fig. 3 shows a simplified cross-sectional diagram through the box 100, in plan view. This helps illustrate the construction of the end panels 30 and reveals the flanges 34 formed by each edge post of the end panel 30.

As previously mentioned, the provision of the edge posts 32 provides a "wraparound" shape to the end panels 30, which provides strength to the box 100. That is, when the box is fully assembled, the wrap-around construction provides strength to resist torsional and shearing forces that the box 100 might encounter due to uneven loading etc. It should be noted that the although the edge post 32 shown in Fig. 1 is constructed of two panels arranged at right angles, such a construction could also be formed from a single piece of material, shaped appropriately (as shown in Fig. 3). Further, the edge post may be formed integrally with the entire end panel 30. Indeed, such a construction could be beneficial, reducing the number of j oints in the box and thereby increasing the strength. However, even in the construction depicted, it should be noted that there is no joint between pieces which is coincident with the corner edge of the box 100. That is, the corner edge of the box 100 is not formed by two pieces tapering to meet each other, but by an outer edge of a single piece of material. This provides strength to the box 100 under shearing/torsional loads, as there is not point of weakness at the corner edges where stresses are maximised.

As mentioned above, flange 34 can be provided with a groove 35, into which a side panel 40 can fit. Similar grooves are preferably provided in the internal faces of the base 10 and lid 20, such that, in the finally constructed box 100, the edges of the side panel 40 will all rest within a series of grooves. As a result, the side panels 40 extend between the opposite end panels 30 and between the base 10 and lid 20. This construction is both simple and cheap (i.e. because there is no need to provide additional connectors), whilst providing the necessary strength and resistance to lateral distortion for the overall box 100.

However, if it is desirable for the side panels 40 to be removable (e.g. in a commercial situation, it may be required that a box 100 can be taken into a store, and the side opened to allow removal of the products contained therein), the side panels 40 could instead be connected by internal connectors 51, in the same way as the end panels 30, for example. This is illustrated in Fig. 12, where a single side panel 40 has been removed to allow access to the inside of the box 100. In these types of scenarios, it may be preferable for the internal connectors 51 holding the side panel in place to be lug-less (as discussed below in connection with the external connectors 50) in the unlocked configuration, to aid ease of removal.

It can be seen in Fig. 1 that the side panel 40 in this large box also employs a rail 41 and stile 42 construction, to provide additional strength to the side panel 40. In addition a central muntin (vertical dividing rail) 43 is also provided. In smaller boxes such as in Fig. 4, the side panel 40 can simply be a single loose panel.

As shown in the Figures, the base 10 and lid 20 of the box 100 are also provided with edge frames 11, 21, which provides space to receive the necessary internal connectors 51 for attaching to the end panels (and optionally side panels). Such space could be provided by providing an entirely solid base or lid, but this will not normally be preferred due to the additional weight and loss in available internal space for the box 100.

The edge posts 32 of the box 100 are also provided with additional external connectors 50. These allow connection to other boxes 100 when they are arranged side by side, provided such boxes have the complimentary connectors. In an ISO modular system, the sizes of the boxes and the positions of the connectors are pre-defined so that boxes of different sizes can be appropriately stacked and connected to each other in this way.

As previously mentioned, the P15 Clamex connectors as presently commercially sold include locating lugs in one part of the connector (and these are shown in the Figures). However, in practice such lugs 53 (see Fig. 8) are preferably removed from the external connectors 50, such that they lie flush with the outer surface of the box 100, in the unlocked state. This allows boxes 100 to be stacked next to each other without the lugs interfering. This also allows boxes to slide over each other without the lugs 53 catching at the edges of boxes. For completeness, it is further noted that the connectors 50 containing the locking component are shown in the Figures in a locked position, such that the locking bar 52 is visible. However, in the unlocked configuration the locking bar 52 is contained within the connector 50, and so once again this will not interfere with the arrangement of boxes next to each other or the sliding of boxes over each other.

When two boxes 100 are appropriately aligned, so that pairs of connector pieces (one piece from each box) are facing each other, the pairs of connector pieces may be locked together. Then, after transportation, the boxes 100 may be unlocked from each other and handled separately. As such, the connectors 50 on neighbouring boxes cooperate to allow repeated attachment and detachment from each other, whether that be between a lid 20 and base 10 of boxes vertically stacked or two side or end panels 30, 40 of horizontally neighbouring boxes 100.

This is achieved by actuating the connectors 50 with an appropriate tool. In the Figures, the access holes for these tools are not shown, for simplicity, but one access hold is provided for each connector piece housing the locking part 52.

However, in other embodiments, all the connectors 50 forming part of the lid, or arranged down a particular edge or side of the box, may be actuated together (i.e. by one action), such that the required group of connectors (i.e. all the connectors one external face, such as the lid, base, side or end, or all the connectors on a particular face or edge of the box) are locked or released at once. Such an arrangement will make joining a modular load of boxes 100 easier. However, in some scenarios, it may be more desirable for each connector to be individually operable. For example, if different size boxes are to be joined together, in which case it may be preferable to lock only one or two connectors on the side of a bigger box to a neighbouring smaller box, leaving further connectors unlocked if the smaller box does not reach them, for example.

The construction of the boxes 100 discussed above allows for the boxes to be disassembled when they are empty, to pack down and therefore take up less room / incur less transport cost. Preferably, the pieces are sized (as in the examples described below), such that the side and end panels can pack into the lid and the base, to again allow modularity of packing in the empty state.

Details of the construction of each of boxes 100 shown in Figs 1&2, 4&5, 6&7 and 8&9 follow below.

Box 100 of Figs 8&9 (known as InceptM4 Design) Outer dimensions: 300 x 200 x 200 mm The materials used in construction were: * Panels and lids were 5.5mm plywood * Frames (rails / stiles) 15mm Spruce (pine) The protruding external connector lugs were removed in the actual boxes.

The side panels are loose, and slide into stopped grooves in the lids and end panels, with an interference fit.

The end panels have two external connectors, and the lids have eight external connectors with a maximum tensile load capacity of around 100 Kg each. The highest loadings are anticipated in the vertical plane Box 100 of Figs 6&7 (known as Incept M3 Design) Outer dimensions: 400 x 300 x 300 mm The materials used in construction were: * Panels and lids were 5.5mm plywood * Frames (rails / stiles) 15mm Spruce (pine) The protruding external connector lugs were removed in the actual boxes.

The side panels are loose, and slide into stopped grooves in the lids and end panels, with an interference fit.

The end panels have four external connectors arranged hi-directionally to allow connections in two directions, and the lids have eight with a maximum tensile load capacity of around 100 Kg each. The highest loadings are anticipated in the vertical plane.

Box 100 of Figs 4&5 (known as Incept M2 Design) Outer dimensions: 600 x 400 x 400 mm The materials used in construction were: * Panels and lids were 5.5mm plywood * Frames (rails / stiles) 15mm Spruce (pine) The protruding external connector lugs were removed in the actual boxes.

The side panels are loose, and slide into stopped grooves in the lids and end panels, with an interference fit.

The end panels have six external connectors arranged bi-directionally to allow connections in two directions, and the lids have 12 connectors with a maximum tensile load capacity of around 100 Kg each. The highest loadings are anticipated in the vertical plane.

Box 100 of Figs 1&2 (known as Incept1W Design) Outer dimensions: 800 x 600 x 600 mm The materials used in construction were: * Panels and lids were 12mm plywood * Frames (rails / stiles) 15mm Spruce (pine) As part of the empty stacking modularity, the (outer) lid depth of each box size (M1, M2, M3, M4) is preferably the same: 50mm. However, in an alternative design of the M1 box, the lid had an external depth of 60mm.

The protruding external connector lugs were removed in the actual boxes.

The end panels have six external connectors arranged bi-directionally to allow connections in two directions. The lids have 12 connectors with a maximum tensile load capacity of around 100 Kg each. The highest loadings are anticipated in the vertical plane.

Whilst it is intended that the modular box loads formed by connecting boxes 100 into suitable configurations could be handled by equipment designed to do so efficiently, it is preferable for such loads to also be processable by existing equipment and infrastructure. To address this issue, Figs. 8 and 9 present a modular load carrier 200, also called a modular load layer connector.

The modular load layer connector 200 is formed of two panels 60, 70, separated by edge posts 80. The edge posts 80 are situated at the corners of the panels 60, 70, so as to provide horizontal space (in the orientation depicted) between the edge posts, and vertical space between the panels 60, 70. Tools such as a forklift may be inserted into this space to manipulate the modular load layer connector 200. Further, the outer surfaces of the panels 60, 70 and edge posts 80 are provided with external connectors 50 which can cooperate with connectors 50 on other boxes or modular load layer connectors, to allow repeated attachment and detachment.

Connectors 50 are provided on both top and bottom surfaces of the modular load layer connector 200. This allows multiple loads to be stacked on top of each other for ease of transport and subsequently separated to allow each individual load to be handled individually.

A load comprising boxes 100 of varying sizes can be attached to a single modular load layer connector or series of modular load layer connectors as required, to provide facility for manipulating the load using existing logistics infrastructure. Further, the provision of multiple modular load layer connectors 200 for attachment to a single load allows for the overall load to be subsequently split, by decoupling both boxes 100 and modular load connectors 200 at the required position, allowing for easy downstream decomposition of loads. That is, the modularity' of the loads is not undesirably constrained by the necessity to use a modular load connector. Rather, the load layer connector is also modular, and therefore enjoys and enables the same benefits of modularity as the boxes 100.

As for the boxes 100, the load layer connector 200 can be made from wood, as is common for existing pallets etc. However, the material for the invention is not particularly limited, and any functionally equivalent material can be used. In both the boxes 100 and the layer connector 200, it is envisioned that appropriate connectors 50 and 51 could be provided at the point of moulding if plastic materials were used in the construction, for example.

It is further noted, in connection with the layer connector 200, that the connector 200 is not intended particularly to support the load comprising the boxes 100. As such, the connectors 50 are only provided at the comer edges of the connector 200 (i.e. rather than providing a connector for every box 100 in the lowermost layer of a load being attached to the connector 200). Whilst the layer connector 200 should be strong enough to withstand both the weight of the load placed upon it, and the pulling forces generated by the load suspended below it, the load itself is self-supporting in the sense that the modular nature needs no further reinforcement. Traditional pallets are used as platforms placed below a load, which is supported by the pallet for lifting and storage. The load and platform are functionally separate to each other, and as they rely on gravity (i.e. to keep the load on the pallet) cannot be used to lift loads below them.

The layer connector's primary function is to connect loads together to form an integrated load that can be handled by existing infrastructure, rather than simply support them, as the modular loads are self-supporting. So, the main purpose of the layer connector deck 70 is to ensure the load bearing blocks 80 are in the correct position to connect with the boxes comprising the load above and below it.

Connecting to upper and lower loads integrates them with the layer connector, and once thus connected, the layer connector performance benefits from the added strength of the combined boxes. The blocks 80 primarily connect the upper and lower loads as an integrated load, where in effect the upper and lower loads behave as a deck when lifted by materials handling equipment such as fork lift trucks. As such, the layer connector 200 is not required to reinforce the modular connections, but merely to provide an easy means of handling with existing infrastructure.

As mentioned before, the modularity of the layer connectors allows for "store-friendly" loads which would normally be handled separately to be moved as one individual load and subsequently broken up. At that point, loads could be provided to specially designed dollies for in-store use, having similar connectors to the boxes and the layer connectors, such that e.g. a dolly could be easily connected to a layer connector to create a mobile load.

Details of the construction of the layer connector 200 of Figs. 10 & llfollow below.

Incept Layer connector Design Outer dimensions: 600 x 400 x 400 mm The materials used in construction were: * Deck panels are lOmm plywood * Blocks / edge posts are 100mm x 150mm Spruce (pine) * External dims are 600x400x100mm which are 30% lower than the standard Euro-pallet The blocks 80 can be fitted into a sandwich of material formed by gluing and screwing the deck boards 60, 70 to the blocks 80. The screws can be inserted in a random pattern based on the pattern used in pallet nailing to minimise damage to the fibre structure of the wood in the blocks 80, to maximise strength.

The blocks 80 can be almost identical to those in the existing euro-pallet with dimensions of 100x150x80 mm sandwiched betweenlOmm top and bottom boards 60, 70 (versus 22mm deck and stringer boards on Euro-pallets) to make a 100mm high platform. The overall footprint dimensions are equivalent to a 1/ 4 Euro-pallet, but the height is lower at 100m Vs 144mm. This will give an advantage in load height when loaded and empty in stacks.

Each connector fixing is rated to 130Kg tensile load so each layer connector could hold up to 1,040 KG.

Claims (4)

1. CLAIMS1. A box, comprising: a base; a lid; two end panels, arranged at opposite ends of the box from each other, and each arranged to span two corners of the lid and two corners of the base; wherein each end panel comprises two edge posts, each forming an edge of the box between the lid and the base, and a flange extends from each of said edge posts, from one end panel towards the other end panel.
2. 2. A box according to claim 1, further comprising two side panels, each extending between the end panels.
3. 3 A box according to claim 2, wherein each flange comprises a groove for receiving one of the side panels.
4. 4. A box according to claim 1 or claim 2, wherein the base and/or the lid comprise grooves for receiving the side panels.

   A box according to claim 1, wherein each side panel extends between a flange of each end panel, and wherein the side panels and the flanges comprise connectors configured to cooperate with each other to allow repeated attachment and detachment of the side panels to/from the flanges.

   6 A box according to any one of the preceding claims, wherein the end panels, lid and base comprise connectors configured to cooperate to allow repeated attachment and detachment of the end panels to/from the lid and base 7 A box according to any one of the preceding claims, further comprising connectors disposed in the outer surfaces of the edge posts for cooperating with connectors on other boxes to allow repeated attachment and detachment of the box to/from said other boxes.8. A box according to claim 7, further comprising a locking mechanism for locking and releasing all the connectors on at least one face of the box simultaneously.9 A box according to any one of the preceding claims, further comprising connectors disposed in the outer surfaces of the base and lid for cooperating with connectors on other boxes to allow repeated attachment and detachment of the box to/from said other boxes.10. A box according to claim 9, further comprising a locking mechanism for locking and releasing all the connectors on the lid and/or base simultaneously.11. A box according to any one of claims 7 to 10, wherein any connectors on the outer surface of the box lie flush, or below, the surface of the box in an unconnected state.12. A box according to any one of the preceding claims, wherein the box is substantially cuboid 13. A plurality of boxes according to any one of claims 7 to 12, wherein the boxes are of differing sizes, pre-defined to allow the attachment of the boxes into a modular load.14 A modular load layer connector, the layer connector comprising: two panels, connected by four edge posts arranged at the corners of the panels; wherein outer surfaces of the panels are provided with connectors for cooperating with connectors on boxes of a modular load, to allow repeated attachment and detachment of the modular load to/from the layer connector.15. The modular load layer connector of claim 14, further comprising connectors disposed in the outer surfaces of the edge posts for cooperating with connectors on other modular load layer connectors to allow repeated attachment and detachment of the layer connector to/from said other layer connectors.