FOLDING CONTAINER

Abstract

A collapsible bin assembly includes an upper support having upper walls, a lower support having lower walls and a collapsible wall structure. The collapsible wall structure has a deployed position and a folded position. The collapsible wall structure has solid walls and collapsible walls, with each solid wall being hingedly connected to two of the collapsible walls at a living hinge. Each of the collapsible walls has a middle hinge allowing the collapsible walls to fold upon themselves. Each of the collapsible walls has a support panel connected to an interior face of the collapsible wall on a first side of the middle hinge such that the support panel abuts the interior face of the collapsible wall on a second side of the middle hinge when the collapsible wall and the collapsible wall structure are in the deployed position.

Description

FIELD OF THE INVENTION

The present invention relates to storage assemblies, and in particular to a folding container.

BACKGROUND OF THE INVENTION

U.S. Pat. No. 4,700,862 illustrates therein a stackable bin which has met with significant commercial success, and which has proven highly desirable for permitting storage of product therein in such a fashion as to permit shipment between locations, and storage at a selected location. This type of collapsible bin 10, as illustrated in FIG. 1, employs an upright hollow wall structure 12 (FIG. 2), normally a four-sided wall structure, which is removably positioned between an upper pallet-like support 14 and a lower pallet-like support 16 to define an enclosed compartment for the goods being transported. The upper pallet-like support 14 and the lower pallet-like support 16 typically have a structure which defines an opening or recess of a rectangular profile around the outer edge portion 18 of the pallet-like supports 14, 16 so as to sidewardly confine the edge of the wall structure 12 to maintain same in its non-collapsed position. The wall structure 12 is provided with four corner folds 20 and is also provided with two intermediate folds 22 to facilitate collapsing of the sidewall structure 12.

After transportation and removal of the goods, the empty collapsible bin 10 is folded down into a compact unit that facilitates return shipment of the empty bin while occupying only minimal space. In order to fold down a traditional bin, such as that described above, the upper and lower pallet-like supports 14, 16 are first removed from the four-sided wall structure 12. The four-sided wall structure 12 is then folded down into a compact unit as shown in FIG. 2. This results in three relatively compact pieces, including the upper and lower pallet-like supports 14, 16 and the folded down wall structure 12.

SUMMARY OF THE INVENTION

The present invention, according to one aspect, is directed to a collapsible bin assembly comprising an upper support, a lower support and a collapsible wall structure. The upper support has a plurality of upper walls forming an upper interior periphery. The lower support has a plurality of lower walls forming a lower interior periphery, the lower interior periphery having the same shape as the upper interior periphery. The collapsible wall structure has a deployed position and a folded position. The collapsible wall structure in the deployed position has an exterior peripheral shape that is substantially identical of the lower interior periphery and the upper interior periphery such that the upper support is configured to have the upper walls thereof surround an upper portion of the collapsible wall structure when the collapsible wall structure is in the deployed position and such that the lower support is configured to have the lower walls thereof surround a lower portion of the collapsible wall structure when the collapsible wall structure is in the deployed position. The collapsible wall structure has at least one solid wall and at least two collapsible walls, with each at least one solid wall being hingedly connected to two of the at least two collapsible walls at a living hinge. Each of the collapsible walls has a middle hinge allowing the collapsible walls to fold upon themselves. Each of the collapsible walls has a support panel connected to an interior face of the collapsible wall on a first side of the middle hinge such that the support panel abuts the interior face of the collapsible wall on a second side of the middle hinge when the collapsible wall and the collapsible wall structure are in the deployed position.

BRIEF DESCRIPTION OF THE DRAWINGS

One or more embodiments of the present invention are illustrated by way of example and should not be construed as being limited to the specific embodiments depicted in the accompanying drawings, in which like reference numerals indicate similar elements.

FIG. 1 is a perspective view of a prior art collapsible bin in a deployed position.

FIG. 2 is a perspective view of a prior art wall structure of the prior art collapsible bin in a folded position.

FIG. 3 is a perspective view of a collapsible bin of the present invention in a deployed position.

FIG. 4 is a perspective view of the collapsible bin of the present invention in the deployed position with an upper pallet-like support removed.

FIG. 5 is a perspective view of a wall structure of the collapsible bin of the present invention in a partially folded position.

FIG. 6 is a side view of the wall structure of the collapsible bin of the present invention in a fully folded position.

FIG. 7 is a top view of the collapsible bin of the present invention in the deployed position with the upper pallet-like support removed and with goods therein.

The specific devices and processes illustrated in the attached drawings and described in the following specification are simply exemplary embodiments of the inventive concepts. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting.

DETAILED DESCRIPTION

For purposes of description herein, it is to be understood that the invention may assume various alternative orientations, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings and described in the following specification are simply exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise.

The reference number 100 (FIG. 3) generally designates a collapsible bin according to the present invention. The collapsible bin 100 includes an upper pallet-like support 102, a lower pallet-like support 104, and a wall structure 106. The upper pallet-like support 102 and the lower pallet-like support 104 capture the wall structure 106 therebetween. In use, the upper pallet-like support 102 is not fitted onto the wall structure 106 such that the collapsible bin 100 is open such that objects 200 can be inserted into and stored within an interior 108 of the collapsible bin 100 (see FIG. 7).

In the illustrated example, the upper pallet-like support 102 and the lower pallet-like support 104 support the wall structure 106 to form the collapsible bin 100. Each of the upper pallet-like support 102 and the lower pallet-like support 104 includes a base portion 110 and a side wall 112 extending perpendicularly from the base portion 110. The side walls 112 of both the upper pallet-like support 102 and the lower pallet-like support 104 have the same interior shape. For example, in the collapsible bin 100 as shown, interior surfaces of the side walls 112 of the upper pallet-like support 102 and the lower pallet-like support 104 form a rectangle, with the rectangle formed by the side walls 112 of the upper pallet-like support 102 and the lower pallet-like support 104 being the exact same shape and size. Therefore, for a rectangle, each short wall 114 of the side walls 112 of the upper pallet-like support 102 and the lower pallet-like support 104 have the same length and each long wall 116 of the side walls 112 of the upper pallet-like support 102 and the lower pallet-like support 104 have the same length. However, the side walls 112 of the upper pallet-like support 102 can have a different height than the side walls 112 of the lower pallet-like support 104.

The illustrated wall structure 106 is collapsible and fits between the side walls 112 of the upper pallet-like support 102 and the side walls 112 of the lower pallet-like support 104 to form the collapsible bin 100. The wall structure 106 includes a pair of opposite solid walls 118 and a pair of opposite collapsible walls 120. Each of the opposite collapsible walls 120 are connected to the opposite solid walls 118 at a living hinge 122. Each of the collapsible walls 120 includes a middle hinge 124. The middle hinge 124 allows the collapsible walls 120 to be folded upon themselves from a fully deployed position as shown in FIGS. 3, 4 and 7, to a partially folded position as shown in FIG. 5, to a fully folded position as shown in FIG. 6.

As shown in FIG. 7, the objects 200 within the interior 108 of the collapsible bin 100 force the pair of opposite solid walls 118 and the pair of opposite collapsible walls 120 outward about the living hinges 124 and the middle hinges 124 to abut against the side walls 112 of the upper pallet-like support 102 and the lower pallet-like support 104. After use, the wall structure 106 can be removed from the upper pallet-like support 102 and the side walls 112 of the lower pallet-like support 104 to allow the collapsible bin 100 to be collapsed. With the wall structure 106 in the collapsed position, the collapsible bin 100 will take up less space for storage and/or for shipping the collapsible bin 100.

In the illustrated example, the wall structure 106 includes at least one support panel 130 connected to the interior of the collapsible walls 120. The support panel 130 is connected to an interior face of the collapsible walls 120 on one side of the middle hinge 124. The support panel 130 prevents the middle hinge 124 from hyperextending or extending beyond 180°. When the middle hinge 124 is fully opened, the support panel 130 will be connected to the interior of the collapsible walls 120 on a first side of the middle hinge 124 and will abut against the interior of the collapsible walls 120 on a second side of the middle hinge 124. It is contemplated that the support panel 130 can be connected to the interior of the collapsible walls 120 on the first side of the middle hinge 124 in any manner (e.g., adhesive, welding, etc.). In the illustrated example, the support panel 130 is connected to substantially the entire interior side of the collapsible walls 120 on the first side of the middle hinge 124. However, it is contemplated that the support panel 130 can be smaller than the entire interior side of the collapsible walls 120 on the first side of the middle hinge 124. Likewise, the portion of the support panel 130 that abuts the interior side of the collapsible walls 120 on the second side of the middle hinge 124 can be any size, including substantially the same size or smaller than the entire interior side of the collapsible walls 120 on the second side of the middle hinge 124. Moreover, while the support panel 130 is illustrated as having the same height as the collapsible walls 120, it is contemplated that the support panel 130 could have any height.

It is contemplated that the upper pallet-like support 102, the lower pallet-like support 104, and the wall structure 106 of the collapsible bin 100 can be formed of any material. For example, each of the upper pallet-like support 102, the lower pallet-like support 104, and the wall structure 106 can be formed of metal, plastic or paper material. Moreover, if formed as plastic or paper material, it is contemplated that the plastic or paper material could be corrugated. It is further contemplated that the upper pallet-like support 102, the lower pallet-like support 104, and the wall structure 106 could each be formed of different material. Additionally, it is contemplated that the support panel 130 could be made of different material than the collapsible walls 120, could have flutes in a different direction than the flutes of the collapsible walls 120 (e.g., horizontal for the support panel 130 and vertical for the collapsible walls 120), or could have additional strengthening features (e.g., horizontal ridges in the support panel or the exterior sheets of a corrugated panel).

In the illustrated example, the collapsible bin 100 is shown as having a rectangular periphery. However, it is contemplated that the collapsible bin 100 could have any exterior shape. If the collapsible bin 100 has a shape other than rectangular, the collapsible bin 100 should be configured such that all but two walls of the wall structure have middle hinges 124. Moreover, while every collapsible wall 120 is shown as including the support panel 130, it is contemplated that some of the collapsible walls 120 could be without a support panel 130.

Although particular preferred embodiments of the invention have been disclosed in detail for illustrative purposes, it will be recognized that variations or modifications of the disclosed apparatus, including the rearrangement of parts, lie within the scope of the present invention.

Claims

1. A collapsible bin assembly comprising: an upper support, the upper support having a plurality of upper walls forming an upper interior periphery;a lower support, the lower support having a plurality of lower walls forming a lower interior periphery, the lower interior periphery having the same shape as the upper interior periphery; anda collapsible wall structure, the collapsible wall structure having a deployed position and a folded position, the collapsible wall structure in the deployed position having an exterior peripheral shape that is substantially identical of the lower interior periphery and the upper interior periphery such that the upper support is configured to have the upper walls thereof surround an upper portion of the collapsible wall structure when the collapsible wall structure is in the deployed position and such that the lower support is configured to have the lower walls thereof surround a lower portion of the collapsible wall structure when the collapsible wall structure is in the deployed position;the collapsible wall structure having at least one solid wall and at least two collapsible walls, each at least one solid wall being hingedly connected to two of the at least two collapsible walls at a living hinge;each of the collapsible walls having a middle hinge allowing the collapsible walls to fold upon themselves;each of the collapsible walls having a support panel connected to an interior face of the collapsible wall on a first side of the middle hinge such that the support panel abuts the interior face of the collapsible wall on a second side of the middle hinge when the collapsible wall and the collapsible wall structure are in the deployed position.