U.S. patent application number 10/010479 was filed with the patent office on 2003-11-06 for foldable distribution container for conveying perishable foods.
This patent application is currently assigned to YUSHIN SYSTEM CO., LTD. Invention is credited to Ichimura, Akihiro, Itoh, Hiroji, Nakabayashi, Yasuo, Okamura, Kousaku, Ura, Hiroshi, Yamada, Hideo, Yudo, Yasuhito.
Application Number | 20030205612 10/010479 |
Document ID | / |
Family ID | 26605448 |
Filed Date | 2003-11-06 |
United States Patent
Application |
20030205612 |
Kind Code |
A9 |
Okamura, Kousaku ; et
al. |
November 6, 2003 |
Foldable distribution container for conveying perishable foods
Abstract
Conventionally, distribution containers, particularly,
corrugated cardboard containers and EPS containers, have been used
as containers for conveying perishable foods. These containers are
disposed as waste after the containers have been used repeatedly by
a few times. The amount of these containers disposed as waste is
huge, and it has been necessary to reduce the waste, from the
viewpoint of resource protection and environmental protection.
Particularly, in the EPS containers, bacteria are easily propagated
on the inner walls. Further, in the case of the corrugated
cardboard containers, they have not been satisfactory from the
viewpoint of heat insulation and cooling of the contents. The
present invention provides a foldable distribution container for
conveying perishable foods of which a foldable container main body
and a lid unit covered on the upper opening of the container main
body are manufactured as three-wall structures made of a
transparent synthetic resin material and having two air layers.
Inventors: |
Okamura, Kousaku;
(Saitama-Shi, JP) ; Nakabayashi, Yasuo; (Kobe-Shi,
JP) ; Ichimura, Akihiro; (Tokyo, JP) ; Itoh,
Hiroji; (Kobe-Shi, JP) ; Yudo, Yasuhito;
(Kobe-Shi, JP) ; Ura, Hiroshi; (Kobe-Shi, JP)
; Yamada, Hideo; (Himeji-Shi, JP) |
Correspondence
Address: |
Richard P. Berg, Esq.
c/o LADAS & PARRY
Suite 2100
5670 Wilshire Boulevard
Los Angeles
CA
90036-5679
US
|
Assignee: |
YUSHIN SYSTEM CO., LTD
DAISEKI CO., LTD
|
Prior
Publication: |
|
Document Identifier |
Publication Date |
|
US 0070267 A1 |
June 13, 2002 |
|
|
Family ID: |
26605448 |
Appl. No.: |
10/010479 |
Filed: |
December 5, 2001 |
Current U.S.
Class: |
229/117.04;
229/117.08 |
Current CPC
Class: |
B65D 81/3818 20130101;
B65D 11/186 20130101 |
Class at
Publication: |
229/117.04;
229/117.08 |
International
Class: |
B65D 005/36 |
Foreign Application Data
Date |
Code |
Application Number |
Dec 7, 2000 |
JP |
2000-373285 |
Jun 11, 2001 |
JP |
2001-175672 |
Claims
What is claimed is:
1. A foldable distribution container for conveying perishable
foods, comprising: a container main body formed with an
approximately rectangular bottom plate for mounting perishable
foods thereon, four side walls having hinge portions hinged to four
side edges of said bottom plate and foldable to said bottom plate,
and a holding member for holding the erection of said side wall by
reinforcing said hinge portions; and a lid unit for covering an
upper opening of said container main body, wherein the bottom plate
and the four side walls that constitute said container main body,
and said lid unit are formed as multi-layer wall structures having
a plurality of air layers inside these structures respectively.
2. A foldable distribution container for conveying perishable foods
according to claim 1, wherein said structures are three-wall
structures having two air layers respectively.
3. A foldable distribution container for conveying perishable foods
according to claim 1 or 2, wherein the bottom plate and the four
side walls that constitute said container main body, and said lid
unit are made of a synthetic resin material.
4. A foldable distribution container for conveying perishable foods
according to claim 3, wherein said synthetic resin material is
polypropylene.
5. A foldable distribution container for conveying perishable foods
according to any one of claims 1 to 4, wherein a foldable inner
case having a set of folding lids is mounted inside said container
main body.
6. A foldable distribution container for conveying perishable foods
according to claim 5, wherein said inner case is made of a material
prepared by having an aluminum-deposited polyester film adhered to
foamed polyethylene.
7. A foldable distribution container for conveying perishable foods
according to any one of claims 1 to 6, wherein the four side walls
foldable to said bottom plate are hinged to the adjacent side walls
respectively, with two opposite side walls formed with angular
hinge portions rising from both lower ends of said side walls, and
said holding members for reinforcing said hinge portions are
sliders.
8. A foldable distribution container for conveying perishable foods
according to any one of claims 1 to 7, wherein the upper surface of
said lid unit is formed with recess portions, and the lower surface
of the bottom plate of said container main body is provided with
projected bases that are engaged with said recess portions.
9. A foldable distribution container for conveying perishable foods
according to any one of claims 1 to 8, wherein the lower surface of
said bottom plate is formed in a shape to be engaged with the upper
opening of said container main body.
10. A foldable distribution container for conveying perishable
foods according to any one of claims 1 to 9, wherein the side wall
of said container main body is provided with an IC card
accommodation pocket capable of accommodating an IC card.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to a distribution container
for conveying perishable foods, and relates, more particularly, to
a foldable distribution container for conveying perishable foods
that can be easily folded, that is excellent in cold-temperature
retention (insulation and cooling effect), and that can be
re-utilized.
DESCRIPTION OF THE RELATED ART
[0002] In the distribution of perishable foods such as livestock
products like frozen meet and marine products like fresh fish,
packaging containers having various shapes, functions, performance,
and materials are used for perishable foods at present, from the
needs of cold-temperature retention and protection from shock.
[0003] Among them, corrugated cardboard containers have generally
been used as packaging containers for distributing livestock
products. This is for the purpose of protecting the frozen contents
from external shocks and for distributing the contents in lots. The
cool keeping of the contents is achieved through keeping of the
contents in cold storage and distribution of the contents by
refrigerator car. Usually, the corrugated cardboard containers once
used are not utilized again, as these containers are easily broken
and stained, or as the cost of manufacturing these containers is
low. The once-used containers are disposed as waste at the retailer
side or the consumer side.
[0004] Further, EPS(expandable polystyrene) containers are
generally used as containers for distributing marine products. The
purpose of this is similar to the above. The cool keeping is
achieved by similar means to the above. In addition, excellent heat
insulation performance of EPS is utilized. In many cases, after ice
or a cold insulator is inserted into the container, the contents of
fresh fish are accommodated. However, bacteria are easily
propagated in micro pores of a porous material composition that is
a unique characteristic of EPS. Therefore, usually, the EPS
container is utilized repeatedly by two or three times in many
cases. Thereafter, the used EPS container is disposed as waste at
the retail side or the consumer side, like the corrugated cardboard
container.
[0005] Containers having various shapes have already been provided
as distribution containers that can be re-utilized, such as,
distribution containers like return boxes, for example. Usually, in
order to improve the accommodation efficiency of these containers
in a truck at the time of recovering the containers, it is required
to reduce the volume of each container itself by folding the
container. Therefore, because of the characteristics of the shapes,
used materials, or the folding mechanism of the containers, these
containers cannot satisfy the cold insulation performance that is
required for the perishable foods, unless an optional insulation
part is added to each container. Consequently, the corrugated
cardboard containers and EPS containers have been employed as
distribution containers for the perishable foods up to the
present.
[0006] The corrugated cardboard containers and EPS containers use
various kinds of materials and have various kinds of structures and
durability, by reflecting the variety of the contents accommodated
in these containers. Further, usually most of them are distributed
in one way from producers to consumers, or used repeatedly by a few
times, and are then disposed as industrial waste or combustible
waste. The amount of the used packaging containers that are
disposed as waste is huge, judging from the amount of perishable
foods that are daily consumed. Therefore, it is necessary to reduce
the waste from the viewpoint of global resource protection and
environmental protection, and this requirement has been enhanced
recently. However, because of the variety in functions and
performance required for the packaging containers as described
above, standardization and common use of the containers have not
yet been realized. As a result, only the problems have been made
clear.
SUMMARY OF THE INVENTION
[0007] In the light of the above situation, the present applicant
has proposed "a foldable distribution container for conveying
perishable foods, comprising: a container main body formed with an
approximately rectangular bottom plate for mounting perishable
foods thereon, four side walls having hinge portions hinged to four
side edges of said bottom plate and foldable to said bottom plate,
and a holding member for holding the erection of said side wall by
reinforcing said hinge portions; and a lid unit for covering an
upper opening of said container main body" under Japanese Patent
Application No. 2000-373285 A. Further, the present applicant has
proposed particularly "a foldable distribution container for
conveying perishable foods, wherein said container main body and
said lid unit are formed as double-wall structures each having
one-layer air layer inside". According to these containers, it is
possible to assemble and fold the container main body quickly and
securely in extremely simple operation. Further, it is possible to
securely shut out the external air and insulate and keep cool the
inside of the container. Furthermore, waste is not produced. Thus,
there are excellent effects in the using aspect, the cooling
aspect, and the environmental aspect.
[0008] It is an object of the present invention to provide a
foldable distribution container for conveying perishable foods
capable of exhibiting further advanced insulation and cooling
effect, by adding further improvement to a foldable distribution
container for conveying perishable foods.
[0009] The present invention relates to a foldable distribution
container for conveying perishable foods, and it is possible to
achieve the above object of the invention by a foldable
distribution container for conveying perishable foods. Namely, the
foldable distribution container comprises: a container main body
formed with an approximately rectangular bottom plate for mounting
perishable foods thereon, four side walls having hinge portions
hinged to four side edges of the bottom plate and foldable to the
bottom plate, and a holding member for holding the erection of the
side wall by reinforcing the hinge portions; and a lid unit for
covering an upper opening of the container main body, wherein the
bottom plate and the four side walls that constitute the container
main body, and the lid unit are formed as multi-layer wall
structures having a plurality of air layers inside these structures
respectively.
[0010] Further, it is possible to achieve the above object of the
present invention more effectively by a foldable distribution
container for conveying perishable foods, wherein the structures
are three-wall structures having two air layers respectively.
[0011] It is possible to achieve the above object of the present
invention more effectively by a foldable distribution container for
conveying perishable foods, wherein the bottom plate and the four
side walls that constitute the container main body, and the lid
unit are made of a synthetic resin material.
[0012] It is possible to achieve the above object of the present
invention more effectively by a foldable distribution container for
conveying perishable foods, wherein the synthetic resin material is
polypropylene.
[0013] Further, it is possible to achieve the above object of the
present invention more effectively by a foldable distribution
container for conveying perishable foods, wherein a foldable inner
case having a set of folding lids is mounted inside the container
main body.
[0014] Further, it is possible to achieve the above object of the
present invention more effectively by a foldable distribution
container for conveying perishable foods, wherein the inner case is
made of a material prepared by having an aluminum-deposited
polyester film adhered to foamed polyethylene.
[0015] It is possible to achieve the above object of the present
invention more effectively by a foldable distribution container for
conveying perishable foods, wherein the four side walls foldable to
the bottom plate are hinged to the adjacent side walls
respectively, with two opposite side walls formed with angular
hinge portions rising from both lower ends of the side walls, and
the holding members for reinforcing the hinge portions are
sliders.
[0016] Further, it is possible to achieve the above object of the
present invention more effectively by a foldable distribution
container for conveying perishable foods, wherein the upper surface
of the lid unit is formed with recess portions, and the lower
surface of the bottom plate of the container main body is provided
with projected bases that are engaged with the recess portions.
[0017] Further, it is possible to achieve the above object of the
present invention more effectively by a foldable distribution
container for conveying perishable foods, wherein the lower surface
of the bottom plate is formed in a shape to be engaged with the
upper opening of the container main body.
[0018] Still further, it is possible to achieve the above object of
the present invention more effectively by a foldable distribution
container for conveying perishable foods, wherein the side wall of
the container main body is provided with an IC card accommodation
pocket capable of accommodating an IC card.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] In the accompanying drawings:
[0020] FIG. 1 is a perspective view of the whole container relating
to one embodiment of the present invention;
[0021] FIG. 2 is a perspective view of the container main body
according to the present invention;
[0022] FIG. 3 is a top plan view of the container main body
according to the present invention;
[0023] FIG. 4 is a side view of the container main body according
to the present invention;
[0024] FIG. 5 is a bottom plan view of the container main body
according to the present invention;
[0025] FIG. 6 is a perspective view showing a structure of a hinge
portion of the container main body according to the present
invention;
[0026] FIGS. 7A and 7B are a side view showing a structure of a
slider portion provided on the container main body and a
cross-sectional view cut along the B-B line;
[0027] FIG. 8 is a cross-sectional view of the container main body
cut along the A-A line of FIG. 1;
[0028] FIG. 9 is a perspective view for explaining the sequence of
folding the container main body according to the present
invention;
[0029] FIG. 10 is a perspective view for explaining the sequence of
folding the container main body according to the present
invention;
[0030] FIG. 11 is a perspective view for explaining the sequence of
folding the container main body according to the present
invention;
[0031] FIG. 12 is a top plan view for explaining the sequence of
folding the container main body;
[0032] FIG. 13 is a time-temperature change characteristic
line-diagram showing the heat insulation and cooling effect of a
container relating to the present invention;
[0033] FIGS. 14A and 14B are a side view showing another structure
of a slider portion provided on the container main body relating to
the present invention and a cross-sectional view cut along the C-C
line;
[0034] FIG. 15 is a top plan view showing a status that a container
main body having the slider portions are folded flat;
[0035] FIG. 16 is a perspective view showing still another
structure of a slider portion provided on the container main body
relating to the present invention;
[0036] FIG. 17 is a perspective view of a container having an inner
case relating to another embodiment of the present invention;
and
[0037] FIG. 18 is a perspective view showing a method of folding
the inner case.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0038] Embodiments of a foldable distribution container for
conveying perishable foods relating to the present invention will
be explained in detail based on attached drawings.
[0039] FIG. 1 is a perspective view showing the appearance of a
foldable distribution container for conveying perishable foods
(hereinafter to be referred to as a "container C") relating to a
first embodiment of the present invention. In the drawing, 1
denotes a container main body for accommodating perishable foods,
and 50 denotes a lid unit covered on an upper opening of the
container main body 1.
[0040] FIG. 2 is a perspective view showing an internal structure
of the container main body 1, with the lid unit 50 removed. This
container main body 1 consists of a bottom plate 10 and four side
walls 20, 21, 22 and 23. In other words, the bottom plate 10 is in
approximately a rectangular shape. The four side walls 20, 21, 22,
and 23 are erected from four side edges. These four side walls 20,
21, 22 and 23 and the bottom plate 10 form the container main body
1 capable of accommodating perishable foods. In FIG. 2, 30 denotes
slider portions to be described later, and 43 denotes a grip.
[0041] As shown in a top plan view in FIG. 3, four side edges 11 of
the bottom plate 10 are connected with four hinges H10. The four
side walls 20, 21, 22 and 23 are erected, and can be folded on the
upper surface of the bottom plate 10 with the respective hinges H10
as creases. The four side walls 20, 21, 22 and 23 are formed as
three-wall structures consisting of external walls 20a, 21a, 22a
and 23a, inner walls 20b, 21b, 22b and 23b, and intermediate walls
20c, 21c, 22c and 23c, respectively, as shown in partially
sectional views in FIG. 3. Two air layers S1 and S2 are formed
between the walls. External air is shut out by these air layers S1
and S2, and the inside of the container main body 1 is insulated
and held at low temperature. Ribs 35 for reinforcing the three
walls are provided at some portions of the air layers S1 and S2,
and the bottom plate 10 and the lid unit 50 also have similar
structures to those of the side walls 20. These will be explained
in detail later with reference to FIG. 8. As a result of
experiments relating to insulation and cooling effect to be
described later, it has been confirmed that it is preferable to set
4 to 12 mm, most preferably a value around 8 mm, as the layer
thickness of the air layers S1 and S2 respectively, that is, the
distance between the inner wall and the intermediate wall and the
distance between the intermediate wall and the external wall
respectively.
[0042] The four side walls 20, 21, 22 and 23 and the bottom plate
10 that constitute the container main body 1 are formed with a
transparent or translucent synthetic resin, preferably
polypropylene. With this arrangement, it is possible to look
through the inside of the container main body 1 from the outside.
Further, the inner wall surface of the container main body 1 is a
smooth surface having no micro pores at all. Therefore, it is
possible to prevent propagation of bacteria inside the container
main body.
[0043] The container main bodies 1 are structured such that they
can be stacked together in a vertical direction. In other words, as
shown in a side view in FIG. 4, the end portion of the bottom plate
10 supports approximately a half of the inside of the lower end
portions of the side plates 22 and 23 of the container main body 1.
On the other hand, recess portions 22c and 23c are provided inside
the upper end portions of the side walls 22 and 23. A short-sided
portion of the bottom plate 10 provided on the bottom portion of a
separate container main body 1 that is stacked above is engaged
with these recess portions 22c and 23c. At the same time, a
long-sided portion of the bottom plate 10 is engaged with the inner
wall surface of the side walls 20 and 21. Thus, a plurality of the
container main bodies 1 can be stacked together in a vertical
direction in a status that the inside of each container main body 1
is sealed. When the container main bodies 1 are stacked together in
this way, the lid unit 50 is covered on only the upper opening of
the container main body 1 that is positioned at the top of the
stacking. In this case, the bottom plate 10 of the container main
body 1 placed at the lowest position supports the whole vertical
load.
[0044] Further, the lower surface of the bottom plate 10 of the
container main body 1 is provided with triangular bases 12, 13, 14
and 15 in projection as shown in the side view in FIG. 4 and in a
bottom plan view in FIG. 5. These bases 12, 13, 14 and 15 have a
function of preventing a collapse or a positional deviation of the
containers C when they are conveyed in a stacked status, as
described later. In addition, the bases 12, 13, 14 and 15 have a
function of preventing a collapse of the container main bodies 1
when they are stacked together in a folded status, as shown in a
top plan view in FIG. 12(or FIG. 15).
[0045] The four side walls 20, 21, 22, and 23 that can be folded on
the bottom plate 10 are connected together with hinges H12, H2, H3
and H4 at adjacent end portions respectively, as shown in the top
plan view in FIG. 3 and in a partially enlarged perspective view in
FIG. 6. FIG. 6 shows this status for the side wall 20 and the side
wall 23. As shown in the drawing, one end of the side wall 20 is
hinged to the adjacent one end of the side wall 23 with the hinge
H1. Similarly, the other end of the side wall 20 is hinged to one
end of the side wall 22 with the hinge H2. The other end of the
side wall 23 is hinged to one end of the side wall 21 with the
hinge H3. The other end of the side wall 22 is hinged to the other
end of the side wall 21 with the hinge H4. These hinge portions are
formed thin having strength sufficient enough to easily fold the
side walls 20, 21, 22 and 23. As explained above, the four side
walls 20, 21, 22 and 23 can be folded based on the hinge connection
of mutually adjacent side walls.
[0046] Of the four side walls 20, 21, 22 and 23, two opposite
long-sided side walls are formed with angular hinge portions H5 and
H7, and H6 and H8 that rise from both lower ends of the side walls
respectively, as shown in the side view in FIG. 4 and a top plan
view in a folded status in FIG. 12. Along these hinges H5, H6, H7
and H8, the corner portions of the container main body 1 are folded
on the upper surface of the bottom plate 10, as shown in FIG.
12.
[0047] The slider portions 30 are disposed along the hinges H5, H6,
H7 and H8 respectively, as shown in side views in FIG. 4 and FIG.
7A, and in the top plan view in FIG. 12. FIG. 7A is the side view
of a structure of the slider portion 30 disposed on the hinge H8 of
the side wall 21 as a part of the slider portions. FIG. 7B is a
view of the surface cut along the B-B line of FIG. 7A. As shown in
the drawings, an upper sheath portion 31 is disposed at a right
upper slanted position orthogonal with the hinge H8, and a lower
sheath portion 32 is disposed at a lower slanted position. A slider
33 is slidably inserted in the upper sheath portion 31 and the
lower sheath portion 32 respectively. A recess portion 21h is
formed on the surface portion of the side wall 21 where the slider
33 is inserted and slides. The lower end of this slider 33 can move
between a position L indicated by a solid line of the lower sheath
portion 32 and a position U indicated by a dotted line of the upper
sheath portion 31. When an operator moves the lower end of the
slider 33 to the position L with a knob 33a, the slider 33 works as
a bar to the hinge H8. Consequently, the erected status of the side
wall 21 is held firm. On the other hand, when the lower end is
moved to the position U, the holding of the hinge H8 by the slider
33 is canceled, and the corner portion of the side wall 21 becomes
foldable along the hinge H8. FIG. 7 and FIG. 12 show the foldable
status.
[0048] Further, on the external surface of the side wall 21, there
is provided an IC card accommodation pocket 40 capable of
accommodating an IC card 41 on which various kinds of information
is written such as the name of a product like perishable foods
accommodated in the container main body 1 and a product convey
destination, as shown in the side view in FIG. 4. With this
arrangement, a relationship between the accommodated product and
the convey destination becomes clear, and it becomes possible to
prevent troubles like an error in the contents and a transportation
error, etc. Further, at the outside of the side wall 22 and the
side wall 23 respectively, there is provided a grip 43 for carrying
the container C, as shown in the perspective view in FIG. 2 and in
the side view in FIG. 4.
[0049] The lid unit 50 is covered on the upper opening of the
container main body 1 having the above structure. This lid unit 50
is prepared using the same material and in the same structure as
those of the container main body 1, as shown in the perspective
view in FIG. 1 and in a sectional view cut along the A-A line of
FIG. 1 in FIG. 8. In other words, the lid unit 50 is formed as a
three-wall structure consisting of an external wall 50a, an inner
wall 50b, and an intermediate wall 50c, each made of a transparent
or translucent synthetic resin material of polypropylene. Two air
layers S1 and S2 are formed between the walls. The reinforcing ribs
35 are provided at some portions of the air layers S1 and S2.
External air is shut out by this lid unit 50, and the inside of the
container main body 1 is insulated and held at low temperature.
Further, as the lid unit 50 is made of the same material as that of
the container main body 1, the lid unit 50 is crashed together with
the container main body 1, and is utilized again as a raw material,
after the service life of the distribution container.
[0050] As shown in the cross-sectional view in FIG. 8, the lower
surface of the external peripheral edge portion of the lid unit 50
is cut in a hook shape, and is formed with a stage portion 53. This
stage portion 53 is engaged with each upper end of the side walls
20, 21, 22 and 23 respectively, and has a function of completely
cutting the external air. Further, a recess portion 54 is formed
inside the upper surface peripheral portion of the lid unit 50.
This recess portion 54 is designed to be engaged with the external
side end portions of the stretched bases 12, 13, 14 and 15
respectively provided on the bottom surface of the container main
body 1. Based on this engagement, it is possible to prevent a
collapse or a positional deviation of the distribution containers
when they are conveyed in a stacked status.
[0051] Next, a method of using the container C having the
above-described structure will be explained. Products like
perishable foods are accommodated inside the container main body 1,
and the container C is conveyed in a status that the container main
body 1 is completely sealed with the lid unit 50, as shown in the
perspective view in FIG. 1 and in the cross-sectional view in FIG.
8. Then, the container main body 1 after it has been used is folded
in a flat shape according to the order shown in FIG. 9 to FIG.
12.
[0052] First, as explained with reference to FIG. 7, the lower end
portion of each slider 33 provided on the side walls 20 and 21 is
slid from the lower position L to the upper position U. Based on
this, the holding of the hinges H5 and H7, and H6 and H8 formed on
the side walls 20 and 21 by the sliders 33 is canceled, as shown in
FIG. 9. Therefore, the side walls 20 and 21 are gradually folded to
the inside, with the respective hinges H5 and H7, and H6 and H8 as
creases. Along the work of the side walls 20 and 21, the
short-sided side walls 22 and 23 that are linked to these side
walls and the hinges H1, H2, H3 and H4 are also gradually folded to
the inside, as shown in FIG. 10 and FIG. 11 in sequence. Finally,
all the side walls are folded flat on the upper surface of the
bottom plate 10, as shown in FIG. 12. As explained above, the
container main body 1 is folded flat in simple operation by only
slightly sliding the sliders 33.
[0053] On the other hand, in the case of assembling an erected
container main body 1 as shown in FIG. 2 from the folded status as
shown in FIG. 12, this can be achieved by carrying out the
operation in the opposite order to that of the folding operation.
In other words, the side walls 22 and 23 of the container main body
1 in the folded status as shown in FIG. 12 are stretched to the
left and right respectively by holding the upper end of the side
wall. Then, the side walls 20, 21, 22 and 23 are erected
immediately. In this status, the lower end portion of each slider
33 is slid from the upper position U to the lower position L,
thereby to firmly hold the erected status of the side walls 20, 21,
22 and 23. As explained above, the container main body 1 according
to the embodiment of the present invention can be assembled or
folded flat in extremely simple operation.
EXAMPLE
[0054] In order to confirm the heat insulation and the cooling
effect(low-temperature retention) of the container C explained
above, the following experiments have been carried out by making
trials of various kinds of containers with changed materials that
constitute the container C and changed sizes of structures.
[0055] First, three kinds of materials are selected for
manufacturing the container main body 1 and the lid unit 50
respectively. Namely, a container C1 is manufactured using a
synthetic resin(polypropylene), a container C2 is manufactured
using corrugated cardboard, and a container C3 is manufactured
using EPS. Next, structures that constitute the container main body
1 and the lid unit 50 are selected as follows. The container C1 has
the following three types. A container C1a has two air layers(S1,
S2), each having a layer thickness of 8 mm, and the walls that form
these air layers have a thickness of 2 mm respectively. Similarly,
a container C1b has two air layers(S1, S2), each having a layer
thickness of 5 mm, and the walls that form these air layers have a
thickness of 2 mm respectively. Then, a container C1c relating to
the above-described prior application has one air layer having a
layer thickness of 14 mm, and the walls that form this air layer
have a thickness of 2 mm respectively. Further, the container C2
and the container C3 have no dirt(no air layers) respectively, and
walls of these containers have a wall thickness of 15 mm and 5 mm
respectively. The capacity of 2000 cc is set to each of the above
five kinds of containers(that is, C1a, C1b, C1c, C2 and C3).
[0056] Next, 2000 cc of an antifreezing fluid at -15.degree. C. is
sealed into these five kinds of containers that have been
manufactured in the above-described manner. Temperatures of the
inside of each container along the lapse of time(0 to 8 hours)are
measured with a self-recording thermometer in the room at a normal
temperature(22.degree. C.). As a result, data showing temperature
changes(a vertical axis) along the lapse of time(a horizontal axis)
as shown in FIG. 13 has been obtained.
[0057] As can be understood from FIG. 13, the temperature within
each container gradually rises along the lapse of time. Containers
with excellent heat insulation and cooling effect, that is, the
containers in which the rise in temperature is small along the
lapse of time, are in the order of the containers C3, C1a, C1b, C1c
and C2. Following the container C3(the EPS container), the
container C1a(the polypropylene container, with an air layer
thickness 8 mm) is excellent, and the container C2(the corrugated
cardboard container) shows the worst value. However, while the EPS
container C3 is excellent from the viewpoint of the heat insulation
and cooling effect, this container has drawbacks in that bacteria
are easily propagated in micro pores of the inner wall, and that
the used container is disposed as waste, as described above. On the
other hand, the synthetic resin container provided with air layers,
particularly, the container C1a, has heat insulation and cooling
effect, and has no propagation of bacteria, as the inner wall
surface is smooth. Further, this container has a high practical
value, as this container can be re-utilized. It is also possible to
provide three or more air layers in the structures. However, this
leads to an increase in manufacturing cost along the complexity of
the structures. Furthermore, from the viewpoint of heat insulation
and cooling effect, it is preferable to form the above-described
two-layer structures.
[0058] In investigating the synthetic resin(polypropylene)
container C1 from the viewpoint of heat insulation and cooling
effect, it is more preferable to provide two air layers than to
provide one air layer on each structure. Further, the layer
thickness of 8 mm is preferable to 5 mm. Further, according the
experiments carried out by the present inventors, it has been found
that the practical range of the layer thickness is 4 to 12 mm, and
most preferably, 8 mm. This is because the heat insulation and
cooling effect becomes lower when the layer thickness is equal to
or less than 3 mm. Also, the heat insulation and cooling effect
similarly becomes lower when the layer thickness is equal to or
larger than 13 mm, because of the generation of convection inside
the air layers.
[0059] While the content of the present invention has been
explained above with reference to one example, the present
invention is not limited to this example, and it is also possible
to make various modifications to the construction as follows.
[0060] First, as the holding member for holding the erection of the
side walls, it is possible to use slider portions 30A as shown in
FIGS. 14A and 14B in stead of the slider portions 30. As shown in a
front view in FIG. 14A and in a cross-sectional view cut along the
C-C line of FIG. 14A in FIG. 14B, slider portion 30A is provided in
a vertical direction across a hinge H8 formed on a side wall 21. It
is so structured that a slider 33 is slid along a vertical distance
between an upper sheath portion 31A and a lower sheath portion 32A
as shown by arrow marks, thereby to erect the side wall 21 and
cancel the erection. With the slider portion 30A provided in this
way, the floating of the upper end portion of the slider 30A is
restricted by the lower surface of the container main body 1
positioned above, that is, by the bottom surface of the bottom
plate 10, at the time of conveying the container main bodies 1 in a
stacked status. Therefore, it is possible to hold the erection of
the side wall 21 securely and firm, during the conveyance. When the
container main body 1 provided with this slider portion 30A is
folded flat as shown in FIG. 15, the upper portion of the knob of
the slider portion 30A is stretched above from the top of the side
wall 20 and the side wall 21 respectively. Consequently, the side
wall 20 and the side wall 21 are pressed against the upper surface
of the bottom plate 10. As a result, it is possible to fold the
whole unit more flat.
[0061] As a further modification of the holding member, it is also
possible to use sliders 30B as shown in FIG. 16. These sliders 30B
are provided with a U-shaped channel member facing downward
respectively, and are slidable on the upper end portions of the
side wall 20 that is formed with angular hinges H5 and H7 and the
side wall 21 that is formed with angular hinges H6 and H8
respectively, out of the four side walls 20, 21, 22, and 23 of the
container main body 1. For erecting the side walls 20 and 21, the
sliders 30B are disposed on the top of the hinges H5, H6, H7 and H8
respectively, as shown in FIG. 16. For folding the sliders 30B, the
sliders 30B are removed. According to these sliders 30B, it is
possible to manufacture the container at low cost because of a
simple mechanism. However, some device is necessary in the aspect
of sealing between the lid unit 50 and the container main body
1.
[0062] Further, as a method of folding the container main body 1,
it is possible to employ various known methods, such as a method
used for a plastic container disclosed in Japanese Patent
Application Laid-open No. 9-175541 A, for example. According to
this method, at the time of vacuum molding a plastic sheet, ribs
that can be folded toward the inside, when the container after the
molding is pressed to the up and down directions, are integrally
formed on side walls. Therefore, this plastic container is suitable
for conveyance and storage in a status that the side walls are
folded flat.
[0063] The above explains the container C structured in a single
unit consisting of the container main body 1 and the lid unit 50,
for accommodating perishable foods therein. It is possible to
further increase the heat insulation and cooling effect of the
container according to the present invention, by providing a
container C' that is mounted with an inner case(an inner box) 100
that is foldable inside the container main body 1, as shown in a
perspective view in FIG. 17. This inner case 100 is a foldable box
unit having a set of folding lids that are prepared by using a
material consisting of an EPS sheet of a few mm thickness adhered
with a thin aluminum-evaporated polyester film, with the
aluminum-deposited surface facing inside. As shown in the drawing,
this container C' has a set of foldable lid units 150a and 150b on
the top. FIG. 18 shows a folded status in a perspective view. The
container C' has four side walls 120, 121, 122, and 123 around, and
has bottom plates 110a and 110b at the bottom. This inner case 100
is designed as follows. When the inner case 100 is developed, this
becomes large enough to be brought into contact with the inner
surface of the container main body 1 including the lid unit 50 and
the bottom plate 10 of the container C, and when the inner case 100
is folded as shown by arrow marks in FIG. 18, this becomes in a
flat plate shape. For the material of the inner case 100, it is
also possible to use various kinds of plastic films or flexible
sheets having heat insulation property, in addition to the
above-described deposited film. However, it is preferable to use
the above-described material from the viewpoint of heat insulation
and cooling effect. Further, it is needless to mention that it is
possible to employ various kinds of known methods for folding the
inner case 100.
[0064] For using the container C' having the inner case 100
accommodated therein, perishable foods are accommodated inside the
inner case 100, and the lid units 150a and 150b are closed.
Further, the lid unit 50 is covered on the upper opening of the
container main body 1, thereby to insulate the inside in double. In
the case of the container C' that uses this inner case 100, it is
needless to mention that it is not necessary to manufacture the
container main body 1 and the lid unit 50 with a transparent or
translucent material.
[0065] As explained above, according to the present container C',
the inside of the container main body 1 is heat-insulated in
double. Therefore, it is possible to further improve the heat
insulation and cooling effect. Further, according to the
experiments carried out by the present inventors, it has been made
clear that changes in temperature of the container C' along the
lapse of time show approximately intermediate values between the
values of the container C3(the EPS container) and the container C1a
(the polypropylene container having two air layers, with the layer
thickness of 8 mm) shown in FIG. 13.
[0066] As explained above, according to the foldable distribution
container for conveying perishable foods relating to the present
invention, it is possible to obtain the following effects.
[0067] (1) The container main body is formed with an approximately
rectangular bottom plate for mounting perishable foods thereon,
four side walls having hinge portions hinged to four side edges of
the bottom plate and foldable to the bottom plate, and a holding
member for holding the erection of the side wall by reinforcing the
hinge portions. Therefore, it is possible to assemble and fold the
container main body quickly and securely in extremely simple
operation.
[0068] (2) Particularly, the four side walls foldable to the bottom
plate are hinged to the adjacent side walls respectively, with two
opposite side walls formed with angular hinge portions rising from
both lower ends of the side walls, and sliders for reinforcing the
hinge portions are provided. According to this container, it is
possible to further improve the above effect.
[0069] (3) Further, the bottom plate and the four side walls that
form the container main body, and the lid unit are formed as
three-wall structures having two air layers inside respectively.
Therefore, it is possible to securely shut out the external air and
insulate and keep cool the inside of the container.
[0070] (4) It is possible to further improve the above effect,
particularly by providing a container having a foldable inner case,
with a set of folding lids mounted inside the lid unit and the
container main body, more preferably, a container having the inner
case made of a material prepared by having an aluminum-deposited
polyester film adhered to foamed polyethylene
[0071] (5) Further, as the bottom plate and the four side walls
that form the container main body, and the lid unit are made of the
same material consisting of a transparent synthetic resin, it is
possible to confirm the products accommodated in the container main
body from the outside. Further, as the inner wall of the container
main body is a smooth surface having no micro pores at all, it is
possible to prevent propagation of bacteria. After using the
container main body, it is possible to use this container main body
again by simply cleaning it. Further, as the container main body
and the lid unit are made of the same material, it is possible to
use them for recycling of the raw material, by crashing the
container after the lapse of the service period.
[0072] (6) Further, as a recess portion is formed on the upper
surface of the lid unit, and also stretched bases for engagement
with this recess portion are provided on the lower surface of the
bottom plate of the container main body, a collapse or a positional
deviation does not occur even when a plurality of distribution
containers are conveyed in a stacked status. When the container
main bodies are stacked in a flat folded status, the bases are
engaged with the recess portion formed on the container main body
positioned above. Therefore, it is possible to prevent a positional
deviation.
[0073] (7) Further, as the lower surface of the bottom plate is
formed in a shape to be engaged with the upper opening of the
container main body, it is possible to seal the inside without the
lid unit, by stacking the distribution containers.
[0074] (8) Further, as an IC card accommodation pocket capable of
accommodating an IC card is provided on the side wall of the
container main body, a relationship between the accommodated
product and the convey destination becomes clear. It also becomes
possible to prevent troubles like an error in the contents and a
transportation error, etc.
* * * * *