US20110168598A1

US20110168598A1 - Collapsible crate

Info

Publication number: US20110168598A1
Application number: US13/008,480
Authority: US
Inventors: Gary Rees; David John Emerson; Kerry Ann Glenn
Original assignee: Not Box Co Ltd
Current assignee: NOT BOX Co (HK) Ltd
Priority date: 2007-10-22
Filing date: 2011-01-18
Publication date: 2011-07-14

Abstract

A collapsible crate having a four sided base with at least one pair of parallel sides, upstanding opposing semi-rigid side walls and upstanding opposing semi-rigid end walls, the side walls being connected to the end walls via hinges, the base comprising a flexible web connected to the lower end of at least two of the opposing walls and a semi-rigid flap connected via a hinge to the lower end of one of the side walls such that the flap overlies and is supported by the flexible web when the crate is in a constructed state and is upstanding when the crate is in a collapsed state for flat packing, wherein the semi-rigid side and end walls and the flap each have a sandwich construction of a semi-rigid panel or panels between flexible webs, and wherein each end wall comprises at least two semi-rigid sections connected via a central upstanding hinge.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. application Ser. No. 12/738,605 filed Apr. 16, 2010, which application is incorporated herein by reference.

FIELD OF THE INVENTION

The present invention relates to a collapsible crate.

BACKGROUND TO THE INVENTION

At present, items, such as shoes, garments, underwear, toys etc, are transported from a factory in which they are manufactured to a retail outlet in crates made of corrugated cardboard. The flat packed cardboard crates are erected in the factory where they are filled with the items to be transported. The filled crates are typically stacked in a standard container for shipment by road, rail or air. Upon opening the container the filled crates are typically identified by electronic reading of a barcode of the like printed on the side of the crate whereupon the crate is automatically sensed by a magic eye, picked by grabbers and moved to a location for transport to its final destination. At the final destination, such as the retail outlet, the cardboard crate is opened and the items removed for sale. Once the crate has been emptied the crate is flat packed or broken up and disposed of either via a recycling scheme, or more typically as general waste. Cardboard crates are generally unsuitable for re-use due to the damage to the crate sustained during movements.
In recent years, retailers have taken their responsibilities with regard to the environment more seriously and it is no longer considered acceptable for millions of used cardboard crates to simply be thrown away in this manner. There is therefore an urgent need for a collapsible crate for the transport of items that has a significantly lower impact upon the environment.
Supermarket shoppers are also taking their environmental responsibility more seriously and there is a need for a crate which reduces the requirement of plastic bags.

SUMMARY OF THE INVENTION

According to a first aspect of the present invention there is provided a collapsible crate having a four sided base with at least one pair of parallel sides, upstanding opposing semi-rigid side walls and upstanding opposing semi-rigid end walls, the side walls being connected to the end walls via hinges, the base comprising a flexible web connected to the lower end of at least two of the opposing walls and a semi-rigid flap connected via a hinge to the lower end of one of the side walls such that the flap overlies and is supported by the flexible web when the crate is in a constructed state and is upstanding when the crate is in a collapsed state for flat packing, wherein the semi-rigid side and end walls and flap each have a sandwich construction of a semi-rigid panel or panels between flexible webs, and wherein each end wall comprises at least two semi-rigid sections connected via a central upstanding hinge.
The present invention is advantageous in that the crate can be collapsed to a flat packed state and yet is easy to erect and has a sturdy construction suitable for stacking due to the integrity of the semi-rigid panel or panels of the sandwich construction. The hinges ensure that the collapsible crate maintains its integrity when collapsed from an erected state a plurality of times such that the collapsible crate in accordance with the present invention has a life cycle considerably greater than that of cardboard crates of typical construction that have been used to date. The flexible web of the base supports the semi-rigid flap of the crate when in an erected state as the flexible web is made taught between the at least two opposing walls to which the web is connected. However, the web is flexible and so can easily be gathered up within the crate when collapsed, ensuring that the crate is easier to erect from a flat packed state than prior art crates whilst at the same time providing at least the same, if not greater, stackability. The end walls fold inwardly about the upstanding hinges as the crate is collapsed.
Preferably, the base web is connected to the lower end of each of the side and end walls. This provides maximum support for the semi-rigid flap of the erected crate.
Preferably, the side and end walls are planar when the crate is in a constructed state. This allows the crate to be stacked easily and minimizes the storage space required when the crate is in a constructed state.
The base of the crate may be a rectangle. When the base of the crate is rectangular in shape it allows multiple crates to be easily stacked together reducing the requirements of the storage space and allows the crate to be collapsed to a flat packed state for ease of storing when the crate is collapsed.
The shape of the base may alternatively be a trapezium. A trapezium is defined herein as a quadrilateral with one pair of parallel sides that is not a parallelogram. When the base of the crate is a trapezium it allows for the crate to be inserted into a shopping trolley and the user can then insert items into the crate whilst grocery shopping for example.
Preferably, the end walls of the crate are parallel when the crate is in a constructed state. This allows the base of the crate to be either rectangular or a trapezium to allow the crate to either be used as a storage item or for insertion into a shopping trolley such as a supermarket trolley.
Preferably, the semi-rigid flap further comprises a handle on the opposite side to the hinge for raising and lowering the flap when constructing and collapsing the crate. The addition of the handle to the flap allows the user to more easily raise and lower the flap when constructing and collapsing the crate. Typically, the handle will comprise a strip of fabric stitched to the side of the flap opposite to the hinge.
Preferably, the collapsible crate further comprises a lid, connected to the upper end of one of the side walls via a hinge. The lid preferably has a sandwich construction of a semi-rigid panel or panels between flexible webs, similar to the construction of the flap and walls of the crate.
The collapsible crate preferably further comprises securing means for securing the lid to at least the upper end of the side wall opposite the lid hinge and preferably also to the upper end of each end wall. The securing means may comprise one or more zips. The securing means may comprise in the alternative one or more tabs extending from the lid and comprising hook and loop fastening strips one strip of which being arranged to extend from the lid and the other strip being disposed on the inner side of the respective side or end walls. In a yet further alternative construction, the securing means may comprise one or more tabs extending from the lid for engagement within a slot disposed on the inner side of the respective side or end walls.
For manual lifting of the collapsible crate the crate preferably further comprises one or more carry handles. Typically, the carry handles are a length of fabric stitched to the end walls. However, other forms of handle can also be used.
The flexible web of the crate is preferably a woven fabric and most preferably is bio-degradable such that the crate may be composted after its several use cycles. The flexible woven material preferably includes at least one of the group comprising: natural fibres, a corn based plastic, polylactic acid (PLA), and jute. However, it is also envisaged that the flexible web material may be a sheet of plastics material, paper, fabric, or virtually any sort of flexible web material in a woven or unwoven state. Suitable biodegradable materials are jute and corn based plastics such as polylactic acid (PLA).
The semi-rigid panel material may also take virtually any form and may include at least one of the group comprising: hardboard, cardboard, plywood, wood, plastics, metal, a com based plastic, polylactic acid (PLA) and jute. However, the semi-rigid panel material is most preferably bio-degradable such that when used in combination with bio-degradable flexible web material, the entire collapsible crate may be composted following the final one of its several use cycles.
Typically, each wall or one or more compartment in a wall will contain a single panel or two or more panels. The panels can be made of differing materials if required.
Typically, when the base is rectangular the collapsible crate of the present invention is particularly suitable for use in the transport of (un)packaged goods from factory to retail outlet. Around 80% of the traditional cardboard crates used to date for this purpose have a standard crate size of BDCM1, and so the collapsible crate in accordance with the present invention preferably adopts this standard crate size. However, it is also envisaged that crates having standard sizes corresponding to BDCM2, NL1, or NL2 are also applicable to the present invention. Since the collapsible crate in accordance with the present invention has far reaching uses beyond that suggested above, such as for household storage, groceries, recycling crates and so on, it is envisaged that the collapsible crate in accordance with the present invention may be virtually any size.
Preferably, the flexible web material is stitched to retain the semi-rigid panels therebetween and also to join adjacent flexible web portions together.
In a preferred aspect, the hinges are constituted by flexible web material extending between adjacent semi-rigid panels. In this manner, the hinges may be integrally formed with the walls, flap and lid, where provided, of the collapsible crate. This simplifies the construction such that the collapsible crate may be constructed of only a few parts.
Preferably, the crate is adapted for packaging loose items for shipment or for storing loose items.
Preferably, at least one of the said walls has dimensions which conform with the internal surfaces of a shopping trolley. This allows the crate to fit snugly inside a shopping trolley such that at least three walls of the crate lie adjacent to the corresponding walls of the trolley for example. Thus, at least one of the side and/or end walls have dimensions that conform with the internal surface of the trolley. For example, this could be solely one of the end walls which is about the same length as the maximum internal width of a supermarket trolley. The opposing end wall might therefore be arranged to be about the same width as that of the trolley at its location, since a supermarket trolley is the shape of a trapezium.
Preferably, each side wall and end wall have dimensions which conform with the internal surfaces of a shopping trolley. This allows all four walls of the crate to be positioned adjacent the walls of a shopping trolley and therefore the crate approximately has the dimensions of a shopping trolley and fits snugly within it. The crate may occupy substantially all of the internal surface area of the trolley base and typically substantially all of the volume defined by the internal dimensions of the trolley.
A second aspect of the present invention includes a stackable crate system comprising a first collapsible crate according to the first aspect of the present invention, a second collapsible crate according to the first aspect of the present invention wherein the second crate is adapted for insertion into and removal from the first crate. This allows separate compartments within the first crate to be created and allows smaller amounts of the contents to be removed from the first crate should the contents of the first or second crate be heavy.
Preferably, the second crate has at least one wall that conforms with the internal dimensions of the first crate such that at least three of the walls stand adjacent the respective walls of the first crate when the second crate is inserted into the first crate. For example, this allows the second crate to fit inside the first but not fill the entire volume of the first crate allowing for further crates or other objects to be inserted into the remaining space in the first crate. Two or more second crates can be inserted into the first crate at any one time.
Preferably the second crate further comprises one or more carry handles for insertion and removal from the first crate. Typically, these will be a length of fabric stitched to the upper end of at least one of the walls to allow a user to more easily lift the second crate from the first. However, other handle types can also be used.
Typically, the system further comprises a third collapsible crate adapted for insertion and removal from either of the first or second crates, the third crate comprises a four sided base with at least one pair of parallel sides, upstanding opposing semi-rigid side walls and upstanding opposing semi-rigid end walls, the side walls being connected to the end walls via hinges, the base comprising a flexible web connected to the lower end of at least two of the opposing walls, wherein the semi-rigid side and end walls each have a sandwich construction of semi-rigid panels between flexible webs, and wherein each end wall and side wall comprise two semi-rigid sections connected via a central upstanding hinge.
The third crate does not contain a semi-rigid flap that overlies and is supported by the flexible web and therefore the third crate only remains in a constructed state when the crate is filled or supported by the walls of either of the first or second crates. The side walls and the end walls of the third crate each comprise two semi-rigid panels allowing the third crate to be collapsed by either drawing the side walls together or drawing the end walls together.
Typically, the third collapsible crate further comprises a plurality of flexible webs stitched to the side and end walls to define compartments within the third crate. These flexible webs can comprise longitudinal, transverse or are stitched to form a number of vertices defining compartments.

BRIEF DESCRIPTION OF THE DRAWINGS

Preferred embodiments of the present invention will now be described in detail with reference to the accompanying drawings, in which:

FIG. 1 shows the rectangular crate of a first embodiment in an erected state with the lid closed;

FIG. 2 shows the rectangular crate in a collapsed, flat packed state;

FIG. 3 shows the rectangular crate in a partially erected state with the flap folded upwardly;

FIG. 4 shows the rectangular crate in a partially-erected state with the flap being folded downwardly;

FIG. 5 shows the rectangular crate in an erected state with the lid open;

FIG. 6 shows a cross section of a side wall;

FIG. 7 shows a partially transparent view of the crate of a second embodiment with a trapezium shaped base in a constructed state.

FIG. 8 a shows the system of the second embodiment of the present invention;

FIG. 8 b shows the second collapsible crate of the second embodiment of the present invention; and

FIG. 8 c shows the third collapsible crate of the third embodiment of the present invention.

DESCRIPTION OF EXAMPLES

With reference to FIGS. 1 to 6 and particularly FIG. 3, a stackable crate according to a first embodiment will now be described. Thereafter, a second embodiment constructed according to similar principles will be described. The crate 1 comprises a rectangular flexible web base 2, upstanding opposing semi-rigid side walls 3,4 and upstanding opposing semi-rigid end walls 5,6. The side walls 3,4 have a sandwich construction of a semi-rigid panel 7 between flexible webs 8, 9. The end walls have a sandwich construction of two semi-rigid panels 10 between flexible webs 11, 12. The construction of these walls will be further described with reference to FIG. 6.
The base flexible web 2 is stitched to the flexible webs of each of the side and end walls 3,4,5,6 so creating a seam at each juncture. The flexible webs of the side walls 3,4 are stitched to the flexible webs of the adjacent end walls 5,6, again forming a seam at each juncture. Upstanding hinges 12 are therefore formed at the location of each seam between adjacent side and end walls. In addition, upstanding hinges 13 are formed at the location where the flexible webs 11,12 of each end wall 5,6 are stitched along a vertical centre line of each end wall 5,6. Each of the side and end walls 3, 4, 5, 6 are also stitched around their periphery to enclose the semi-rigid panel or panels 7,10 between respective flexible webs 8,9 and 11,12.
The base of the collapsible crate further comprises a semi-rigid flap 14 (shown in the cutaway views of FIGS. 3 and 4) which also has a sandwich construction of a semi-rigid panel between flexible webs. The flexible webs are stitched around the periphery of the flap 14 and the flap 14 is stitched to the lower end of the side wall 4 to form a further seam and a further hinge 15 such that the flap 14 may be moved between an upstanding position (as shown in FIG. 3) in the direction of arrow A (as shown in FIG. 4) to a position where the flap 14 is supported by the base flexible web 2. To that end, the flap 14 has substantially the same rectangular dimensions as the base flexible web 2.
The collapsible crate 1 further comprises a lid 16 (FIG. 1) also having a sandwich construction of a semi-rigid panel between flexible webs. The flexible webs are stitched together around the periphery of the panel and the flexible webs are further stitched to the upper end of the side wall 4 to form a seam and a hinge 17. Extending from the lid 16 are flaps 18 (FIG. 2) also having a sandwich construction of a semi-rigid panel between flexible webs. The flexible webs are stitched around the periphery of the panel and each of the flaps 18 are stitched to the lid 16 along hinge lines 19.
Each of the flaps 18 has a securing means comprising one side (part) of a hook and loop fastening strip 20 a, the other side (part) of the hook and loop fastening strip 20 b being disposed on the inner side of the upper end of respective side and end walls 3, 4, 5, 6.
When in the flat packed state the lid 16 of the collapsible crate 1 lies flush against the side wall 4. The lid 16 is moveable from an open position of the erected crate 1 (as shown in FIG. 4) in the direction of arrow B (shown in FIG. 5) until the lid 16 assumes the closed position (as shown in FIG. 1).
The lid 16 further comprises a strip 21 of flexible web material having one side of a hook and loop fastening strip 22 a disposed thereon, the other side of the hook and loop fastening strip 22 b being disposed upon the upper end of the outer side of the side wall 3. Engagement of the hook and loop fastening strips 20 a,20 b and 22 a,22 b retains the lid 16 in the closed position.
The crate 1 further comprises carry handles 23 comprising a length of fabric stitched to each end wall 5,6.
The crate 1 is openable from the collapsed state shown in FIG. 2 by drawing the side walls 3,4 away from one another in the direction of arrow C (FIG. 3) which causes the base flexible web 2 to unfold from between the side walls 3,4 and move downwardly in the direction of arrow D until the base flexible web 2 lies substantially perpendicular to the upstanding side and end walls 3, 4, 5, 6. During this motion, the end walls 5,6 unfold about hinge 13 to form substantially planar end walls 5,6. The flap 14 remains flush against the inner side of side wall 4 until the base flexible web 2 has unfolded to lie perpendicular to the upstanding side and end walls at which time it may be moved in the direction of arrow A (FIG. 4) until the flap 14 lies flush and is supported by the base flexible web 2.
The interior volume of the erected crate 1 may be filled with items as desired before finally the lid 16 is moved in the direction of arrow B (FIG. 5) to its closed position. Just prior to complete closure of the lid 16 care is to be taken to ensure that the flaps 18 are disposed on the inner side of the side wall 3 and end walls 5,6 such that the hook and loop fastening strips 20 a,20 b can be engaged to secure the lid 16 in its closed position. Finally, the tab 21 is folded over such that the hook and loop fastening strip 22 a,22 b engages to secure yet further the lid 16 in the closed position. The filled crate 1 may then be carried using the handles 23 and also may be moved mechanically by suitable grabbers and conveying means in a processing plant, distribution centre, or the like.
Once the filled crate 1 has reached its final destination and the items therein are to be unpacked, the lid is opened by releasing the hook and loop fastening strips 22 a,22 b and 20 a,20 b and the lid 16 moved to the open position in the direction opposite to arrow B. The items may then be removed from the interior volume of the crate 1. For flat packing of the crate 1 the flap 14 is moved in a direction opposite to arrow A until the flap 14 lies flush with the inner side of the side wall 4. The side walls 3,4 may then be drawn together opposite the direction of arrow B causing the base flexible web 2 to move opposite the direction of arrow D. As this occurs, the end walls 5,6 fold along hinge line 3 until the crate 1 returns to the flat packed configuration shown in FIG. 2. The flat packed crate 1 may then be stored easily as it occupies minimal space or may be returned to be filled with further items for transportation.
The flexible webs are made of woven bio-degradable corn based plastic material such as polylactic acid (PLA) or jute such that the flexible web material is bio-degradable. The semi-rigid panels within the side and end walls 3, 4, 5, 6, the flap 14 and the lid 16 are made of cardboard and so are also bio-degradable. The crate 1 of the preferred embodiment has the standard crate size BDCM1.
However, it will be appreciated by those skilled in the art that other suitable flexible web materials, both bio-degradable and non bio-degradable, may be suitable and other semi-rigid panels, both bio-degradable and non bio-degradable, may be used. Similarly, other crate dimensions may be used within the scope of the present invention such as BDCM2, NL1, or NL2, or virtually any other desired crate dimension.
As an alternative to the flaps 18 of the lid 16 having the hook and loop fastening strips 20 a,20 b for cooperation with the upper end of the inner side of the end walls 5,6 and the side wall 3, other securing means may be employed. For example the hook and loop fastening strips 20 a,20 b and the flaps 18 may be dispensed with and replaced by one or more zips running around the upper end of the end walls 5,6 and the side wall 3 such that the lid 16 may be joined to the upper ends of the side walls 5,6 and the end wall 3 by zip fastening. In a yet further alternative embodiment, the flaps 18 may be retained but the hook and loop fastening strips 20 a,20 b dispensed with and slots may be formed on the inner side at the upper end of the end walls 5,6 and the side wall 3 into which the flaps 18 engage to restrict lateral displacement of the lid 16 with respect to the side and end walls 3, 4, 5, 6.
Whilst the collapsible crate in accordance with the first embodiment is likely to cost 2-3 times that of a conventional cardboard crate since it may be used in excess of 15 times, over a projected life of around 3 years, in comparison with the single use prior art cardboard crate cost savings overall of around 500% are envisaged. The many times reused crate has a significantly lower impact upon the environment in comparison to the single use prior art crates due to the reduction in waste. In addition this durable crate in accordance with the present invention when constructed of bio-degradable materials may have a further reduced impact upon the environment when it has finished its useful life.
The collapsible crate of this invention is preferably used in a crate pooling scheme in a range of retail and supply chains in a similar manner to the way pallets and containers are pooled by companies such as CHEP®.
FIG. 6 illustrates the construction of a side wall and is shown in cross section. The construction of this side wall is equivalent to the construction of each of the end walls and semi-rigid flap. Semi-rigid panel 7 is rectangular in shape, has a rectangular cross section and is covered on each side with a flexible web 8, 9. These flexible webs 8, 9 are stitched together at each end of the semi-rigid panel to enclose the semi-rigid panel with flexible web. However, they are not attached to the panel itself. The flexible web is stitched around the entire periphery of the semi-rigid panel. A single sheet of flexible web can be used for each side of the semi-rigid panel to enclose two semi-rigid panels side by side, the join between the panels forming the hinge which allows the semi-rigid panels to articulate.
FIG. 7 describes a crate according to the second embodiment of the present invention and is constructed using a similar method to the first embodiment. This embodiment is for insertion into a shopping trolley for packing loose items and to reduce the requirement for plastic bags. The crate 30 comprises a trapezium shaped (when flat) flexible web base 31, upstanding opposing semi-rigid side walls 32,33 and upstanding opposing semi-rigid end walls 34,35. Thus, walls 32 and 33 are of equal size whereas wall 34 is wider than wall 35. The side walls 32,33 have a sandwich construction of a semi-rigid panel between flexible webs. The end walls have a sandwich construction of two semi-rigid panels between flexible webs and are parallel with each other. The side and end walls are also planar. The construction of the side and end walls is identical to the description of FIG. 6 and the first embodiment.
The base flexible web 31 is stitched to the flexible webs of each of the side and end walls 32, 33, 34, 35 so creating a seam at each juncture. The flexible webs of the side walls 32,33 are stitched to the flexible webs of the adjacent end walls 34,35, again forming a seam at each juncture. Upstanding hinges 42 are therefore formed at the location of each seam between adjacent side and end walls. In addition, upstanding hinges 43 are formed at the location where the flexible webs of each end wall 34,35 are stitched along a vertical centre line of each end wall 34,35. Each of the side and end walls 32, 33, 34, 35 are also stitched around their periphery to enclose the semi-rigid panel or panels between respective flexible webs as described in the first embodiment.
The trapezium shaped base of the collapsible crate further comprises a semi-rigid flap 44 which also has a sandwich construction of a semi-rigid panel between flexible webs. The flexible webs are stitched around the periphery of the flap 44 and the flap 44 is stitched to the lower end of the side wall 32 to form a further seam and a further hinge 45 such that the flap 44 may be moved between an upstanding position to a position where the flap 44 is supported by the base flexible web 31. To that end, the flap 44 has substantially the same dimensions as the base flexible web 31. The flap further comprises a handle 47 comprising a length of fabric stitched to the side of the flap opposite to hinge 45 for raising and lowering the flap.
The crate 30 further comprises carry handles 46 comprising a length of fabric stitched to each end wall 34,35.
The crate 30 is openable from the collapsed state by drawing the side walls 32,33 away from one another which causes the base flexible web 31 to unfold from between the side walls 32,33 and move downwardly until the base flexible web 31 is flat and lies substantially perpendicular to the upstanding side and end walls 32, 33, 34, 35. During this motion, the end walls 34,35 unfold about hinge 43 to form substantially planar end walls 34,35. The flap 44 remains flush against the inner side of side wall 32 until the base flexible web 31 has unfolded to lie perpendicular to the upstanding side and end walls at which time it may be lowered towards the base flexible web 31 until the flap 44 lies flush and is supported by the base flexible web 31.
The interior volume of the erected crate 30 may be placed within a shopping trolley, the shape of the crate generally conforming with the internal geometry of such a trolley. The crate may be then filled with items as desired. The filled crate 30 may then be lifted into a vehicle or otherwise carried, using the handles 46.
For flat packing of the crate 30 the flap 44 is moved upwards away from base flexible web 31 until the flap 44 lies flush with the inner side of the side wall 32. The side walls 32,33 may then be drawn together causing the base flexible web 31 to collapse. As this occurs, the end walls 34,35 fold along hinge line 43 until the crate 30 returns to the flat packed configuration. The flat packed crate 30 may then be stored easily such as in a vehicle as it occupies minimal space.
Once the crate 30 is in a constructed state this can then be used for filling with loose items to enable the user to more easily carry the items without an increased requirement for plastic bags. However, it is also possible to use the crate 30 as a vessel for carrying further collapsible crates as will now be discussed with reference to FIGS. 8 a, 8 b, 8 c.
FIG. 8 a illustrates the collapsible crate 30 in its constructed state, a second collapsible crate 50 and third collapsible crate 51. The second collapsible crate 50 is illustrated in FIG. 8 b and is constructed according to the same principles as collapsible crate 30. Crate 50 has a trapezium shaped base flexible web 52, side walls 53,54 and end walls 55,56 and these features are identically constructed and connected together as previously described with respect to crate 30. End wall 55 and side walls 53,54 have dimensions that allow the crate 50 to conform with the internal surfaces of the crate 30 (end wall 34 and side walls 32,33). The crate 50 can be collapsed for flat packing of the crate 50 in the same method as previously described with respect to crate 30. The semi-rigid flap 57 of crate 50 (constructed as previously described with respect to semi-rigid flap 44) is connected to the lower end of side wall 53 to form a hinge 58 to allow the flap to be moved between an upstanding position lying adjacent to side wall 53 and a lower position where the flap 57 is supported by the base flexible web 52. The flap 57 further comprises a handle 59 for raising and lowering the flap 57 as previously described with respect to handle 47 and crate 30). The crate 50 further comprises carry handles 60 for lifting crate 50 from and inserting crate 50 into crate 30.
The third collapsible crate 51 is illustrated in FIG. 8 c and comprises a trapezium shaped flexible web base 61. Crate 51 does not comprise a semi-rigid flap as described with respect to crates 30 and 50 and so therefore does not remain in a constructed state unless supported by the walls of crate 30 when the crate 51 has been inserted into crate 30 or when filled. It also comprises upstanding opposing semi-rigid side walls 62,63 and upstanding opposing semi-rigid end walls 64,65. Each of the side and end walls 62, 63, 64, 65 are constructed from two semi-rigid panels between flexible webs. The panels comprising side walls 62,63 are illustrated by reference numeral 66 and the panels comprising end walls 64,65 are illustrated using reference numeral 67. The base flexible web 61 is stitched to the flexible web for each of the side and end walls 62, 63, 64, 65 so creating a seam at each juncture. A further flexible web is stitched to end walls 64,65 and side wall 62 below base flexible web 61. This provides additional support for the contents of crate 51. The flexible webs of the side walls 62,63 are stitched to the flexible webs of the adjacent end walls 64,65 again forming a seam at each juncture. Upstanding hinges 68 are therefore formed at the location of each seam between adjacent side and end walls. In addition, upstanding hinges 69,70 are formed at the location where the flexible webs of each side and end wall are stitched along a vertical centre line of each side and end wall separating the panels 66,67. Each of the side and end walls are also stitched around their periphery to enclose the semi-rigid panels 66,67 between respective flexible webs. Crate 51 further comprises carry handles 71 stitched to the upper end of the end walls for aiding insertion and removal of crate 51 from crate 30.
Crate 51 further comprises a number of flexible webs stitched to the flexible webs of the side and end walls to define an array of compartments 73 within the third crate 51 which occupy approximately half of its base area. A first longitudinal web 72 is stitched to the end walls of the crate 51. It is stitched at the midpoints of end walls 64 and 65 along the hinges 70. Longitudinal web 72 is not stitched to flexible web base 61. An array of compartments 73 are defined by three separate pieces of flexible web 74, 75, 76. Flexible web 75 is shaped in an “L” shape and is stitched to the end wall 64 at the midpoint between longitudinal web 72 and side wall 62. It is also stitched one third of the way along the side wall 62 from end wall 64 to form a corner compartment. Flexible web 76 forms an inverted “L” shape in the same manner by being stitched to end wall 65 halfway between longitudinal web 72 and side wall 62 and two thirds of the way along side wall 62 from end wall 64. This again defines a compartment. Finally, flexible web 74 is formed in a “n” shape such that the vertices of the “n” shape are joined at the vertices of flexible webs 75 and 76. The “free” ends of the n shaped flexible web 74 are joined one third of the way and two thirds of the way along the flexible web 72 from end wall 64. Flexible webs 72, 74, 75, 76 are not stitched to flexible web base 61. This arrangement of flexible webs therefore defines six compartments for storage of bottles and the like in a three by two array. These compartments 73 for example could be used for carrying bottles to prevent them falling over or contacting one another whilst stored in the crate 51.
The crate 51 can be opened by drawing the side walls 62,63 away from each other which causes the base flexible web 61 to unfold from between the side walls and moved downwardly until the base flexible web 61 lies substantially perpendicular to the upstanding side and end walls 62, 63, 64, 65. The side and end walls unfold about their respective hinges 69,70 to form a substantially planar side and end wall. As the side and end walls of crate 51 each contain two semi-rigid panels and a hinge crate 51 can be opened and constructed by also drawing the end walls 64,65 away from each other as described with respect to the side walls. The crate 51 is collapsed by drawing either the side or end walls towards each other and allowing the base flexible web 72 to collapse. The side walls 62,63 and end wall 65 have internal dimensions so that they are able to conform with the interior surface of crate 50 (side walls 32,33 and end wall 35).
Crates 30, 50 and 51 can all be collapsed and flat packed for minimal storage space requirements and then opened and constructed for use within a shopping trolley and the two smaller crates 50,51 once filled with loose items can be more easily removed for carrying the stored loose items.

Claims

1. A collapsible crate having a four sided base with at least one pair of parallel sides, upstanding opposing semi-rigid side walls and upstanding opposing semi-rigid end walls, the side walls being connected to the end walls via hinges, the base comprising a flexible web connected to the lower end of at least two of the opposing walls and a semi-rigid flap connected via a hinge to the lower end of one of the side walls such that the flap overlies and is supported by the flexible web when the crate is in a constructed state and is upstanding when the crate is in a collapsed state for flat packing, wherein the semi-rigid side and end walls and the flap each have a sandwich construction of a semi-rigid panel or panels between flexible webs, and wherein each end wall comprises at least two semi-rigid sections connected via a central upstanding hinge.

2. A collapsible crate according to claim 1, wherein the base web is connected to the lower end of each of the side and end walls.

3. A collapsible crate according to claim 1, wherein the side and end walls are planar when the crate is in a constructed state.

4. A collapsible crate according to claim 1, wherein the base is a rectangle.

5. A collapsible crate according to claim 1, wherein the base is a trapezium.

6. A collapsible crate according to claim 1, wherein the end walls are parallel when the crate is in a constructed state.

7. A collapsible crate according to claim 1, wherein the semi-rigid flap further comprises a handle on the opposite side to the hinge for raising and lowering the flap when constructing and collapsing the crate.

8. A collapsible crate according to claim 1, further comprising a lid, connected to the upper end of one of the side walls via a hinge.

9. A collapsible crate according to claim 8, wherein the lid is semi-rigid and has a sandwich construction of a semi-rigid panel or panels between flexible webs.

10. A collapsible crate according to claim 8, further comprising securing means for securing the lid to at least the upper end of the side wall opposite the lid hinge and preferably also for securing the lid to the upper end of each end wall.

11. A collapsible crate according to claim 10, wherein the securing means comprises one or more zips.

12. A collapsible crate according to claim 10, wherein the securing means comprises hook and loop fastening strips, one strip of which being arranged to extend from the lid and the other strip being disposed on the inner side of the respective side or end walls.

13. A collapsible crate according to claim 10, wherein the securing means comprises one or more tabs extending from the lid for engagement within a slot disposed on the inner side of the respective side or end walls.

14. A collapsible crate according to claim 1, further comprising one or more carry handles.

15. A collapsible crate according to claim 1, wherein the flexible web material includes at least one of the group comprising: plastics, paper, natural fibres, a corn based plastic, polylactic acid (PLA), and jute.

16. A collapsible crate according to claim 1, wherein the flexible web material is biodegradable.

17. A collapsible crate according to claim 1, wherein the flexible web material is a woven fabric.

18. A collapsible crate according to claim 1, wherein the semi-rigid panel material includes at least one material selected from of the group consisting of hardboard, cardboard, plywood, wood, plastics, metal, a corn based plastic, polylactic acid (PLA), and jute.

19. A collapsible crate according to claim 1, wherein the semi-rigid panel material is biodegradable.

20. A collapsible crate according to claim 1, wherein when the base is rectangular the crate has dimensions according to a standard crate size selected from the group consisting of BDCM1, BDCM2, NL1, or NL2.

21. A collapsible crate according to claim 1, wherein the flexible web material is stitched.

22. A collapsible crate according to claim 1, wherein the hinges are made of flexible web material.

23. A collapsible crate according to claim 1 adapted for packaging loose items for shipment or for storing loose items.

24. A collapsible crate according to claim 1, wherein at least one of the said walls has dimensions which conform with the internal surfaces of a shopping trolley.

25. A collapsible crate according to claim 1, wherein each side wall and each end wall have dimensions which conform with the internal surfaces of a shopping trolley.

26. A stackable crate system comprising:

a first collapsible crate according to claim 1;

a second collapsible crate according to claim 1; wherein the second crate is adapted for insertion into and removal from the first crate.

27. A system according to claim 26, wherein the second crate has at least one wall that conforms with the internal dimensions of the first crate such that at least three of the walls stand adjacent the respective walls of the first crate when the second crate is inserted into the first crate.

28. A collapsible crate according to claim 26, wherein the second crate further comprises one or more carry handles for insertion and removal from the first crate.

29. A system according to claim 26 further comprising a third collapsible crate adapted for insertion and removal from either of the first or second crates, the third crate comprising:

a four sided base with at least one pair of parallel sides, upstanding opposing semi-rigid side walls and upstanding opposing semi-rigid end walls, the side walls being connected to the end walls via hinges, the base comprising a flexible web connected to the lower end of at least two of the opposing walls, wherein the semi-rigid side and end walls each have a sandwich construction of semi-rigid panels between flexible webs, and wherein each end wall and side wall comprise two semi-rigid sections connected via a central upstanding hinge.

30. A system according to claim 29 wherein the third collapsible crate further comprises a plurality of stitched flexible webs to the side and end walls to define compartments within the third crate.