WO2005068305A1

WO2005068305A1 - Collapsible container

Info

Publication number: WO2005068305A1
Application number: PCT/GB2005/000060
Authority: WO
Inventors: Stephen Capon
Original assignee: Stephen Capon
Priority date: 2004-01-13
Filing date: 2005-01-12
Publication date: 2005-07-28
Also published as: GB0400667D0

Abstract

There is provided a collapsible container (10) including a plurality of substantially planar panels (20, 30a, 30b, 40, 50, 100, 150, 310). The container (10) is capable of being folded into a folded state wherein the planar panels (20, 30a, 30b, 40, 50, 100, 150, 310) are substantially mutually parallel. Moreover, the container (10) is capable of being unfolded into a deployed state in which the panels (20, 30a, 30b, 40, 50, 100, 150, 310) define a volume within the container (10) capable of receiving one or more items. The panels (20, 30a, 30b, 40, 50, 100, 150, 310) are of mutually unitary construction and mutually pivotally joined together by way of one or more hinges (70, 80, 330). Unitary construction of the container (10) renders the container (10) less expensive to manufacture and more robust in use.

Description

COLLAPSIBLE CONTAINER

Field of the invention

The present invention relates to collapsible containers; for example, the invention concerns collapsible containers which are operable to fold-closed into a substantially flat shape for storage, and to fold-open in a deployed state in which they are able to accommodate items. Moreover, the invention also relates to methods of fabricating the collapsible containers.

Background to the invention

Collapsible containers are well known and include foldable corrugated cardboard boxes suitable for storage, for house removals and for transporting goods where reuse of the containers is envisaged. Such boxes are often each fabricated from a unitary sheet of corrugated cardboard with flaps and panels which can be inter-engaged to provide rigidity when the container is to be deployed in use. The inventors have appreciated that such cardboard boxes are unsuitable for heavy-duty prolonged use and are degraded when made wet on account of the corrugated cardboard disintegrating.

Collapsible fabric containers are also widely known and include cloth sacks and plasticized fabric bags fabricated from flexible sheet fabric materials. However, such fabric containers do not retain their shape and therefore do not exhibit two definite states of being collapsed in a folded state and deployed in an expanded state. The inventors have appreciated that it is possible to fabricate collapsible containers manufactured from fabric sewn or otherwise bonded to relatively rigid panels, the panels providing relatively rigid side walls, lid and base to the container with the fabric serving as a flexible hinge between the panels; suitable fabrics include polyvinylchloride (PVC) plasticized cloth. Such containers are described in a published international PCT application no. PCT/GB2004/000132 (WO2004/063030), the containers being foldable into a substantially planar flat form when not deployed, and then folded out into a deployed state when deployed. On account of the containers having rigid side walls, they are capable of retaining their shape in their deployed state when items are placed therein. Moreover, use of flexible fabric enables the containers to be more robust and hard- wearing, and also potentially resistant to damage when made wet, thereby rendering them useable in outdoor environments.

However, the inventors have appreciated that such fabric collapsible containers including rigid panels are potentially costly and/or complex to manufacture on account of having to stitch or otherwise bond numerous parts together. In consequence, it is often only economical to manufacture such collapsible containers including fabric in lower wage cost countries in the Far East.

The inventors have appreciated that it is feasible to design a collapsible container in a more automated manner which is susceptible to rendering manufacture of such collapsible containers viable in higher wage cost countries, for example in Europe and the United States of America. A person skilled in the art would be expected to address such a technical problem by employing robotic equipment to assemble various container parts together.

Summary of the invention

An object of the invention is to provide a collapsible container which is simple and inexpensive to manufacture.

According to a first aspect of the present invention, there is provided a collapsible container including a plurality of substantially planar panels, the container being capable of being folded into a folded state wherein the planar panels are substantially mutually parallel, the container being capable of being unfolded into a deployed state in which the panels define a volume within the container capable of receiving one or more items, the panels being of mutually unitary construction and mutually pivotally joined together by way of one or more hinges.

The invention is of advantage in that the container is capable of being fabricated more inexpensively and is potentially more robust in use.

Optionally, the container is injection molded substantially as a unitary component. Such injection molding, despite the complexity of the container requiring a relatively complex and therefore costly molding tool, is capable of rendering the container less expensive to manufacture in comparison to alternative fabrication approaches such as sewing together fabric-covered panel components.

Optionally, the container is fabricated from sheet plastics material substantially as a unitary component. Use of sheet plastics material is capable of reducing cost of fabricating the container whilst circumventing a need to invest in a complex molding tool.

Optionally, one or more of the hinges of the container are formed in substantially thinner regions included between the panels. By including on-average relatively thinner regions between the panels and yet unitary with the panels, it is possible to render the container easy to fold into its folded state and yet provide sufficient rigidity of its panels when unfolded into its deployed state. Optionally, the hinges of the container are formed by a plurality of substantially mutually parallel grooves in the thinner regions included between the panels. Use of a plurality of groves is capable of avoiding highly stressed folding points and therefore enhances reliability of the container when deployed repeatedly.

Optionally, the grooves of the container are of substantially "V" or rectangular cross- sectional profile. Such "V" groves are convenient to employ because they are susceptible to being formed by several fabrication techniques.

Optionally, the groves of the container are formed directly by initial molding or by one or more subsequent grove-forming operations. More optionally, the groove-forming operations include at least one of: mechanical cutting, laser cutting, scoring, machining, thermal indenting.

Optionally, in the container, there are including one or more deployable rigidity- enhancing features for enhancing rigidity of the container when in its deployed state. More optionally, the one or more rigidity-enhancing features are included as one or more unitary parts of the container.

Optionally, the container is fabricated substantially from polypropylene plastics material. Polypropylene is especially beneficial on account of its ability to withstand repeated bending cycles without exhibiting substantial work-hardening characteristics.

According to a second aspect of the invention, there is provided a method of fabricating a collapsible container including a plurality of substantially planar panels, the container being capable of being folded into a folded state wherein the planar panels are substantially mutually parallel, the container being capable of being unfolded into a deployed state in which the panels define a volume within the container capable of receiving one or more items, the panels being of mutually unitary construction and mutually pivotally joined together by way of one or more hinges, said method including a step of molding the container as a unitary component.

Optionally, the method includes an additional step of forming the one or more hinges into the container by way of at least one of: initial molding, mechanical cutting, laser cutting, scoring, thermal indentation.

Optionally, the method includes a step of forming the one or more hinges as a plurality of mutually substantially parallel grooves.

Optionally, in the method, the container is fabricated from a polypropylene plastics material. It will be appreciated that features of the invention are susceptible to being combined in any combination without departing from the scope of the invention.

Description of the diagrams

Embodiments of the invention will now be described, by way of example only, with reference to the following diagrams wherein :

Figure 1 is a diagram of a collapsible container according to the invention in a deployed state;

Figure 2 is a diagram of an interior region of the container in Figure 1 with its lid in a raised open position;

Figure 3 is a diagram of the container of Figure 1 with its lid in an open position and its pivotally-mounted base strengthening panel raised to be substantially parallel to an upright rear panel in preparation for folding the container into its folded state;

Figure 4 is a view of the container of Figure 3 with the base panel raised parallel to the rear panel with side clips in a down position to provide rigidity to side panels of the container;

Figure 5 is a view of the container in Figure 1 in a partially folded state where each side panel folds inwardly about a mid-point hinge, where the side clips have been raised to disengage from a top edge of a first section of the side panels to facilitate closure of the container;

Figure 6 is a view of the container of Figure 1 with its front and rear panels folded together with the side panels folded in between the front and rear panels, and the lid in an open state;

Figure 7 is a view of the container of Figure 1 in a folded state, for example for storage when not deployed, the lid being retained by clips to the front panel; and

Figure 8 is a view of a folding edge of the container, the edge including two substantially parallel and relatively closely spaced V-profile grooves defining thinner regions to sheet material from which the container of Figure 1 is fabricated. Description of embodiments of the invention

In Figure 1, a collapsible container according to the invention is indicated generally by 10. The container 10 includes a front panel 20, a RHS side panel 30 including a first side section 30a and a second side section 30b, a rear panel 40 and a lid 50. The side sections 30a, 30b are capable of mutually hinging about a hinge feature 70. Moreover, the side sections 30a, 30b are also pivotally joined at edge hinge features 80 to the panels 20, 40 respectively as illustrated. Moreover, the lid 50 is mounted along its rear peripheral edge to an upper edge of the rear panel 40 in a pivotal manner. It will be appreciated that a hidden LHS side panel 100 is also included, wherein this LHS panel 100 is generally similar to the RHS side panel 30. The front panel 20 includes two fastening features 60a, 60b for use when the container 10 is folded into its folded non- deployed state as will be described in more detail later.

In Figure 2, the container 10 is shown with its lid 50 in an open position to expose an interior region of the container 10 including a base strengthening panel 150 in a flat deployed state. The section 30b has mounted in an upper region thereof a fixing clip 210 which is optionally pivotally mounted to the section 30b by a fixture 200, for example a rivet; alternatively, the fixing clip 210 can be integrally connected as a part of the section 30b, for example integrally molded therewith and coupled thereto by way of a flexible elongate strip. The clip 210 is generally of a "U"-shape profile with a exterior-facing slot 220 as shown. The clip 210 is designed to be a firm press fit over a top edge of the sections 30a, 30b for providing positive retention thereto. Similar considerations apply to the clip 210 associated with the LHS side panellOO.

In Figure 3, the base panel 150 is shown moved pivotally upwards about a hinge 300 at a lower edge of the rear panel 40. As shown, the container 10 includes a bottom panel 310 in two sections mutually pivotally mounted along a central hinge 330. Optional flexible bottom regions 320 connect from the bottom panel 310 to the side panels 30, 100. The flexible regions 320 are conveniently fabricated integrally with the bottom panel 310 and the side panels 30 and can be implemented as a form of molded mesh or elongate strips which bend easily.

In Figure 5, it will be seen that the slot 220 of the clip 210 enables the sections 30a, 30b to fold inwardly with the hinge 70 aligning with the slot 220. The clip 210 is capable of pivoting upwardly in a direction as shown by an arrow 400. Thus, when folding the container 20, the side panels 30, 100 fold inwardly and the bottom panels fold upwardly about their hinges 70, 330. The container 10 is preferably fabricated as a unitary item, for example from polypropylene or similar plastics material. When such plastics materials are thinned down, they are potentially capable of flexing a large number of times, for example potentially several hundred or even several thousands of times. Thus, hinges of the box 10, for example one or more of the hinges 70, 300, 330, are preferably formed by thinning polypropylene or similar plastics material sheet in a manner as illustrated in Figure 8. Alternatively, one of the hinges of the box 10 can be molded to have a thinned groove profile as will be further elucidated later.

In Figure 8, there is shown a polypropylene sheet 500, for example forming the front panel 20 and its associated side section 30a, between which a hinge indicated by 450 is formed. The hinge 450 comprises one or more grooves, for example two grooves 510, 520 as illustrated. Preferably, the grooves 510, 520 have a "V"-shape profile although other types of profile are also feasible, for example a square profile. The grooves 510, 520 define corresponding thinned regions 530, 540 respectively capable of providing the flexible hinge 450. Use of a plurality of grooves is advantageous in that stress arising at the hinge 450 can thereby be spatially distributed, thereby reducing stress concentrations and thereby extended operating lifetime of the container 10 when subject to frequent deployment and folding away operations.

The grooves can be at least one of: machined, cut, injection molded and thermally formed into the sheet 500; for example, laser cutting of the grooves is feasible. Optionally, the grooves are formed in a side of the sheet 500 in a direction the sheet 500 is intend to fold in use. For example, grooves 510, 520 of the hinges 70, 330 are arranged to face towards an interior region of the container 10. Alternatively, the grooves 510, 520 can face outwardly from the interior region of the container 10. The use of "V"-shapes grooves 510, 520 is to allow the hinge 450 to be capable of pivoting in both directions. Rectangular-type grooves are also possible, namely groves with substantially parallel sidewalls and a substantially flat base to the grooves.

In certain colours, polypropylene plastics materials used to fabricated the container 10 can be rendered resistant to ultra-violet degradation caused by exposure to sunlight. Use of such plastic materials compositions enables the container 10 to be used in outdoors application, for example for rubbish bins, for compost bins, for children's garden toys, for salt/sand containers a roadsides for grinding roads in winter, for water holders to mention just a few potential applications.

The container 10 is preferably injection molded as a unitary item, thereby reducing manufacturing cost in comparison to assembling numerous individual parts together which is potentially costly. Alternatively, it can be fabricated from polypropylene or similar plastics material sheet which is cut to form a former into which the aforementioned grooves, for example the grooves 510, 520 are machined, scored and/or cut. Alternatively, applying heat and pressure to create thermally-indented grooves is an alternative technique for generating the aforementioned grooves. Such cutting, machining and scoring is susceptible to being implemented using automated robotic machinery. Use of sheet in this manner is more suitable when a range of container sizes is to be implemented using stock polypropylene sheet. Conversely, when considerable quantities of a particular size of the container are to be manufactured, injection molding of substantially all parts of the container 10 is a potentially beneficial method of manufacture.

The container 10 has potentially many uses. For example, it can be of a vertically elongate form when deployed and provided with one or more sets of wheels at its base to function as a disposable refuse bin. . Alternatively, the container 10 can be adapted to store a plurality of products therein during shipment from a manufacturer to a retailer, such that the container 10 can be returned from the retailer to the manufacturer for reuse by the manufacturer when despatching subsequent products to the retailer in the future. Such use is especially pertinent to agricultural industries in transporting perishable products such as fruits, vegetables and flowers; a characteristic that the container 10 is collapsible makes it easier and cheaper to transport the container 10 back from the retailer to the manufacturer.

It will be appreciated that embodiments of the invention described in the foregoing are susceptible to being modified without departing from the scope of the invention as defined by the accompanying claims.

Expressions such as "comprise", "include", "incorporate", "contain", "is" and "have" are to be construed in a non-exclusive manner when interpreting the description and its associated claims, namely construed to allow for other items or components which are not explicitly defined also to be present. Reference to the singular is also to be construed in be a reference to the plural and vice versa.

Symbols included within parentheses in the claims are intended to assist interpretation of the claims but is not intended to limit claim scope in any way.

Claims

1. A collapsible container (10) including a plurality of substantially planar panels (20, 30a, 30b, 40, 50,100, 150, 310), the container (10) being capable of being folded into a folded state wherein the planar panels (20, 30a, 30b, 40, 50, 100, 150, 310) are substantially mutually parallel, the container (10) being capable of being unfolded into a deployed state in which the panels (20, 30a, 30b, 40, 50, 100, 150, 310) define a volume within the container (10) capable of receiving one or more items, the panels (20, 30a, 30b, 40, 50, 100, 150, 310) being of mutually unitary construction and mutually pivotally joined together by way of one or more hinges (70, 80, 330).

2. A container (10) as claimed in Claim 1, wherein the container (10) is injection molded substantially as a unitary component.

3. A container (10) as claimed in Claim 1, wherein the container (10) is fabricated from sheet plastics material substantially as a unitary component.

4. A container (10) as claimed in Claim 1, wherein one or more of the hinges (70, 80, 330) are formed in substantially thinner regions included between the panels (20, 30a, 30b, 40, 50, 100, 150, 310).

5. A container (10) as claimed in Claim 4, wherein the hinges (70, 80, 330) are formed by a plurality of substantially mutually parallel grooves (510, 520) in the thinner regions included between the panels (20, 30a, 30b, 40, 50, 100, 150, 310).

6. A container (10) as claimed in Claim 5, wherein the grooves (510, 520) are of substantially "V" or rectangular cross-sectional profile.

7. A container (10) as claimed in Claim 5, wherein the groves (510, 520) are formed directly by initial molding or by one or more subsequent grove-forming operations.

8. A container (10) as claimed in Claim 7, wherein groove-forming operations include at least one of: mechanical cutting, laser cutting, scoring, machining, thermal indenting.

9. A container (10) as claimed in Claim 1, including one or more deployable rigidity-enhancing features (210) for enhancing rigidity of the container (10) when in its deployed state.

10. A container (10) as claimed in Claim 1, wherein the one or more rigidity- enhancing features (210) are included as one or more unitary parts of the container (10).

11. A container (10) as claimed in Claim 1, wherein the container (10) is fabricated substantially from polypropylene plastics material.

12. A method of fabricating a collapsible container (10) including a plurality of substantially planar panels (20, 30a, 30b, 40, 50,100, 150, 310), the container (10) being capable of being folded into a folded state wherein the planar panels (20, 30a, 30b, 40, 50, 100, 150, 310) are substantially mutually parallel, the container (10) being capable of being unfolded into a deployed state in which the panels (20, 30a, 30b, 40, 50, 100, 150, 310) define a volume within the container (10) capable of receiving one or more items, the panels (20, 30a, 30b, 40, 50, 100, 150, 310) being of mutually unitary construction and mutually pivotally joined together by way of one or more hinges (70, 80, 330), said method including a step of molding the container (10) as a unitary component.

13. A method as claimed in Claim 12, including an additional step of forming the one or more hinges (70, 80, 330) into the container (100) by way of at least one of: initial molding, mechanical cutting, laser cutting, scoring, thermal indentation.

14. A method as claim in Claim 12, including a step of forming the one or more hinges (70, 80, 330) as a plurality of mutually substantially parallel grooves.

15. A method as claimed in Claim 12, wherein the container (10) is fabricated from a polypropylene plastics material.