Patent Application
20130168391
This invention relates generally to collapsible containers, and more particularly to a collapsible container for receiving, storing, transporting, and discharging products.
Historically, cardboard, wood, or synthetic containers have been used for receiving, storing, transporting, and discharging products of all types. These containers are typically constructed in square, rectangular, or circular shapes with lift straps attached to each of the uppermost corners of the container. Content is placed over the side of a container until the container is full. The high sides of the containers make automation of container loading difficult because content must be lowered into the container.
Typically, cardboard, wood, or synthetic containers store large volumes of content. When loaded with content, the containers can be costly to transport because of their weight. Many containers are not collapsible because of the difficulty in designing a container that can both support the weight of the contents and also collapse for ease of storage and return shipping. Often designing a container that can collapse for storage makes the container too weak to efficiently transport content.
Some shippers include cardboard dividers to separate containers into smaller compartments but this approach has multiple drawbacks. First, the cardboard dividers are often not reusable because they are deformed during transport, which raises costs. Second, the cardboard dividers introduce box dust that can cause problems in manufacturing facilities as well as be a source of contamination in pharmaceutical and food-grade contents. Third, standard cardboard dividers have a greater x and y dimension than the containers when folded flat, causing problems in storage and return shipping.
Thus, there is a need for a strong collapsible container that can be loaded while the container is in a flattened position but that can also efficiently transport content.
The present invention relates generally to a collapsible container that provides improved storage, stacking ability, and strength. The containers are designed to store content such as manufacturing line products, pharmaceutical and personal hygiene products, food-related products, plastic parts and/or injection molded plastic parts, and the like. In general, the containers are manufactured of polyethylene or polypropylene fabric; have four walls, a base, and optionally a lid; and include stiffening panels in pockets formed in the four walls. In some embodiments, the containers include wings attached to end walls that allow the end walls to reversibly secure to the front and back wall and maintain the container in an upright position.
The containers are designed to collapse to a substantially flat position, which allows the containers to be easily loaded as well as easily stored and transported. In an embodiment, the containers are loaded with content while in a flattened configuration, erected into a box-shaped configuration, and efficiently transported in a stack. The containers can be unloaded in a flattened configuration or while still in a box-shaped configuration and then collapsed for ease in return shipping. The containers save money for shippers by providing efficient transport, ease of return, and re-usability.
In one embodiment, the container includes a base, a rigid front wall, a rigid back wall, and a pair of end walls defining four corners. The end walls include a first section, a second section, and a pair of wings, wherein the wings maintain the container in an upright position by reversibly attaching to the front wall and the back wall. In an embodiment, the wings include attachment devices, such as Velcro, adhesive, or other attachment devices for reversibly mating with attachment devices on the front wall and the back wall.
In a still further embodiment, the container includes a first lid portion attached to the back wall and a second lid portion attached to the front wall. The first lid portion and second lid portion are configured to fold over the base to a position substantially parallel with the base and to reversibly attach to one another, thereby enclosing the contents of the container when the container is erected. The lid portions can be detached from one another when the container is collapsed.
In further embodiments, the container includes an access door in the front wall and/or the back wall, wherein the access door can be sealed shut to store contents in the container or the access door can be opened to allow easy removal of contents in the containers. The access door is advantageous when the walls of the container are too high for convenient access from the side. In some embodiments, the container includes a girdle that reduces deflection in the front wall and the back wall. The girdle is attached to either wall and reversibly attaches to a point attached to the opposing wall. In still further embodiments, the container includes a partition that is able to separate the container into smaller compartments. The partition can be set up on the container when the container is in a flattened configuration. When the product is loaded onto the container, the partition will confine the content into smaller compartments that are formed when the walls of the container are raised.
The features, functions, and advantages that have been discussed may be achieved independently in various embodiments of the present invention or may be combined with yet other embodiments, further details of which can be seen with reference to the following description and drawings.
The present invention generally relates to collapsible containers, methods for transporting and storing content in collapsible containers, and uses of collapsible containers. It is to be understood that the collapsible container described herein can be compatible with and may be used for storing and transporting any type of content. The collapsible container is easily loaded with content and allows convenient transport of the content. In an embodiment, the collapsible container is configured to receive content from an assembly line and then the walls swing up to enclose the content. In this manner, the content is not crushed or distorted during transport. Additionally, the containers are designed to be stackable, reusable, and collapsible. Surprisingly, the containers may be stacked up to eight high while containing loads of up to one hundred and fifty pounds each. Plastic rigid panels support less weight per square inch than plywood rigid panels, but both types of panels are appropriate for the content stored within these containers. The containers are designed for collapsible storage of up to about 150 lbs. It should be understood that varying the strength of the rigid panels will also affect the weight the panels are able to support. The container easily meet the minimum federal requirements of a 5:1 safe stacking factor for single use and the 6:1 safe stacking factor for reusable containers.
The design of the container minimizes bulging sides caused by heavy loads. Additionally, the containers weigh less than metal, wood, or plastic containers but can store products and be transported with at least the same level of efficiency. Further, the synthetic material used to manufacture the walls eliminates concerns related to cardboard or plywood such as dust that can contaminate pharmaceutical, food and personal hygiene products or damage sensitive equipment.
Any type of product may be transported in the containers. For example, solids or liquids can be transported in the collapsible containers. Solids can include, but are not limited to, powders, pre-formed components, and semi-solids. Liquids can include, but are not limited to, heavy oils, cooking fluids, and other viscous, semi-viscous, or non-viscous fluids. Specific examples of types of content than can be transported and stored in the containers include, but are not limited to, injection molded plastic parts, pharmaceuticals, personal hygiene components, and food products. Advantageously, the container may be laid flat at the end of an assembly line and products can be pushed onto the base of the container. Once the container is fully loaded, the walls of the container can be folded up and secured so that the products will be enclosed in the collapsible container and conveniently transported.
Thus, the present application provides a simple apparatus and method for reusable collapsible containers.
The containers are constructed of materials such as woven polypropylene, polyethylene, PVC vinyl, urethane vinyl, or any other fabric or film of appropriate strength. For example, woven polypropylene fabric having a weight of between 3 to 10 ounces per square yard or 6-35 mil film, preferably between 4 to 8 ounces per square yard, and most preferably of about 6.5 ounces per square yard can be used to construct the containers.
In one embodiment, a wall panel is a single sheet of fabric or film. This type of wall panel has no rigidity. The single sheet of fabric may bulge when the container is filled. In an embodiment, the single sheet of fabric is under pressure by being stretched from the corners when the container is erected. Advantageously, wall panels that are manufactured from a single sheet of fabric are flexible and can be folded inward easily when the container is collapsed.
In another embodiment, the container is constructed by sewing two layers of woven polypropylene or woven polyethylene fabric together to create a wall panel having a pocket between the layers. In another embodiment, the wall panels are welded together to eliminate needle holes and create the pocket. Advantageously, welding provides a sealed environment in the container suitable to meet sterile and/or food storage standards.
The material can be welded together by any type of welding including hot gas welding, freehand welding, speed tip welding, extrusion welding, contact welding, hot plate welding, high frequency welding, ultrasonic welding, friction welding, laser welding, and solvent welding.
The pockets in the wall panels are designed to receive panels that provide rigidity and support to the container. Each wall can have a single pocket or multiple pockets. If the wall is designed with multiple pockets, each pocket can be defined by a sewn or welded seam. In one embodiment, the pockets have the panels placed therein and are then sealed shut (e.g., sewn or welded shut) to prevent the panel from falling out. In another embodiment, the pockets are open at one end or are reversibly sealable, such as by Velcro, a zipper, or other attachment means. Pockets that open allow the panels to be easily removed for transport or replacement.
The rigid panels can be made of plastic, engineered wood product, corrugated paperboard, or other suitable materials. The plastic can be corrugated or flat. Corrugated plastic can be between 4 mil and 25 mil thick, preferably between 10 mil and 16 mil thick, most preferably about 13 mil thick. Optionally, plywood can be from ⅛ inch thick to 2 inches thick, preferably from ¼ inch thick to 1 inch thick, most preferably about ½ inch thick. Additionally, different weight panels can be used for different parts of the container. For example, the panels in the front wall and back wall can be ½ inch plywood while the panels in the end walls 105 can be 13 mil corrugated plastic such as Interpro™.
In an exemplary embodiment of the container depicted in
In the embodiment depicted in
The second section 107 is configured to fold towards the center of the base 101 at a seam, weld, or fold line when the first section 106 is substantially perpendicular to the base 101. In an embodiment, the second section 107 folds toward the center of the base 101 until the second section 107 is substantially parallel to the base 101. In some embodiments, a tab 112 is placed over the seam, weld line, or fold line, and the tab supports the second section 107 in a position substantially parallel to the base 101. In other embodiments, however, a tab 112 is not present and the second section 107 is free to fold into the container formed by the base 101 and the four walls. In some embodiments, the second section 107 includes a rigid panel. In other embodiments, however, the second section 107 is flexible material without a rigid panel.
The wings 108 are designed so that they are reversibly movable into a position substantially adjacent to the front wall 102 and the back wall 104. As used herein, the term “substantially adjacent” means positioned next to and contacting or coming close to contacting. In some embodiments, the wings 108 comprise an attachment device 109, such as Velcro™, that attaches to matching attachment devices 109 (shown in
In an embodiment, the base 101 includes a rigid panel, such as enclosed within a pocket in the base 101. In another embodiment, the base 101 is not rigid and the bottom of the container is physically supported by resting on a rigid surface, such as a pallet. In another embodiment, a cassette (not shown) can be positioned in the container to provide rigid support for the flexible base 101. In this embodiment, the container can be used with or without a pallet because the bottom of the container is already supported and will not flex or bulge when the container is filled. For example, a container with a cassette supporting the bottom portion can be pushed or pulled off of a pallet and onto a truck, rail car, or ocean container. The cassette also allows the container to retain its shape when the container is tipped over and the contents are poured out.
The cassette is constructed from two layers of material creating a pocket and a rigid panel is inserted into the pocket, as described herein. In one embodiment, the rigid panel is sewn into the pocket and in another embodiment the pocket is reversibly sealed by Velcro™ or the like. In an embodiment, the cassette is placed in the container as the container is erected and removed from the container when the container is going to be collapsed. In some embodiments, the cassette includes a lanyard (not shown) for ease of movement. For example, the cassette may include a 0.5 inch to 2 inch wide strip of webbing sewn to the free end of the cassette. This webbing can be made into a handle so that it is easier to move the cassette to various positions within the container.
In operation, the container of
In some embodiments, the first lid portion 116 includes a tab (not shown), similar to the tab between the first section 106 and the second section 107 of the end walls 105. The tab prevents the first lid portion 116 from extending more than substantially parallel to the base 101. The second lid portion 118 may have a similar tab.
It should be understood that the integral lid depicted in
In an embodiment shown in
In another embodiment shown in
In another embodiment depicted in
In another embodiment, the girdle 406 includes a single piece of material having attachment means sewn or welded to a wall and corresponding attachment means attached to the opposing wall. The single piece of material is from one wall panels to an opposing wall panel and connected to the attachment means to prevent the wall panels from deflecting because of weight. The attachment means may be Velcro, hook and loop fasteners, zippers, pressure lock buckles, pinch clips, or the like.
The partition 700 may be sized to fit within the collapsible containers disclosed herein. In particular, the partition 700 may be sized so that the lateral walls 702 contact the front wall 102 and back wall 104 of the container and the center wall 704 contacts the end walls 105. In some embodiments (not shown), the lateral walls 702 and center wall 704 include attachment devices, such as Velcro or adhesive, that are configured to attach to matching attachment devices on the interior surfaces of the front wall, back wall, and end walls of the container. In this manner, the partition 700 may be reversibly secured in the container but easily removable. In an embodiment, the partition 700 has a height to substantially match the height of the container. In another embodiment, the partition 700 has a height that is less than the height of the container. For example, the partition 700 may be used with a cassette to define smaller compartments in a container.
In an embodiment depicted in
It should be understood that the partitions 700, 800 may be made with a wide variety of number of lateral walls 702, 802. While
In some embodiments, the containers include document pockets 122 or placards on the container, as depicted in
In still further embodiments, the container includes bin handles (not shown) for use in moving the container. The bin handles can be attached by sewing or welding to the vertical seams or to the outside layer of the walls. In some embodiments, two to four loops made from webbing are sewn into the vertical seams so that the container can be picked up for stacking or to allow discharge of contents. In other embodiments, handles for picking up the empty container when erected or collapsed can be located anywhere on the container. The handles can be sewn or welded onto the material comprising the container.
In another embodiment, any of the containers described herein can include a liner (not shown) for storage of dry flowable parts. For example, a polyethylene film liner can be included in the container. The liner is easy to clean and allows the contents to be quickly removed from the container.
In another aspect of the invention, a method for storing content in collapsible containers is provided. In an embodiment, the method includes providing containers as described herein, loading content onto the flattened containers, erecting the containers around the content, unloading the content from the containers after storage and/or transport, and then collapsing the containers for easy transport. The containers can be stored and transported in a stacked position and because of the square or rectangular shape of the containers, storage spaces can be used efficiently with the containers. Collapsing the containers occurs as described herein and allows the containers to be reduced to a fraction of their size. The method provides several advantages over the previously known methods including that the containers are lightweight and reusable, that the containers are strong enough to be stacked up to eight high with heavy loads yet can be folded down when not needed, and that the method allows manufacturers to save money and time by having an efficient use of space when shipping the containers loaded and when shipping the empty containers.
Although the invention has been variously disclosed herein with reference to illustrative embodiments and features, it will be appreciated that the embodiments and features described hereinabove are not intended to limit the invention, and that other variations, modifications and other embodiments will suggest themselves to those of ordinary skill in the art, based on the disclosure herein. The invention therefore is to be broadly construed, as encompassing all such variations, modifications and alternative embodiments within the spirit and scope of the claims hereafter set forth.
