U.S. patent application number 10/441710 was filed with the patent office on 2004-11-25 for collapsible shipping container.
Invention is credited to Boomgaard, Patrick D., Kessler, John E..
Application Number | 20040232146 10/441710 |
Document ID | / |
Family ID | 33450057 |
Filed Date | 2004-11-25 |
United States Patent
Application |
20040232146 |
Kind Code |
A1 |
Kessler, John E. ; et
al. |
November 25, 2004 |
Collapsible shipping container
Abstract
A collapsible delivery container having hinged legs that fold
inwardly to permit the top of the container to collapse toward the
bottom of the container. The container is configured to permit it
to be collapsed one side at a time. The container includes a handle
on each side that extends between the intermediate hinges of the
corresponding legs. The handle is configured to be accessible when
the container is collapsed, yet out of the way when the container
is raised. The container further includes a nesting structure that,
among other things, retains the first collapsed side in proper
alignment while the second side is collapsed. The nesting structure
also provides a force path from the top of the container to base so
that the hinges are not required to bear the weight of stacked
containers. The container preferably includes a lift assist
mechanism that bears some of the weight of the container as it is
collapsed and raised.
Inventors: |
Kessler, John E.; (Holland,
MI) ; Boomgaard, Patrick D.; (Grand Haven,
MI) |
Correspondence
Address: |
JOHN E. KESSLER ET AL
900 Fifth Third Center
111 Lyon Street, N.W.
Grand Rapids
MI
49503-2487
US
|
Family ID: |
33450057 |
Appl. No.: |
10/441710 |
Filed: |
May 20, 2003 |
Current U.S.
Class: |
220/6 |
Current CPC
Class: |
B65D 7/26 20130101; B65D
19/12 20130101; B65D 2519/00691 20130101; B65D 2519/00532 20130101;
B65D 2519/00562 20130101; B65D 7/32 20130101; B65D 2519/00164
20130101; B65D 2519/00905 20130101; B65D 2519/0097 20130101; B65D
2519/00059 20130101; B65D 2519/00995 20130101; B65D 2519/00656
20130101; B65D 2519/00233 20130101; B65D 2519/0081 20130101; B65D
2519/00293 20130101; B65D 2519/0096 20130101; B65D 2519/00333
20130101 |
Class at
Publication: |
220/006 |
International
Class: |
B65D 006/12; B65D
006/16; B65D 006/28; B65D 008/14 |
Claims
The embodiments of the invention in which an exclusive property or
privilege is claimed are defined as follows:
1. A collapsible shipping container comprising: a base; a top; a
plurality of supports mounted between said base and said top, each
of said supports including a top hinge, a bottom hinge and an
intermediate hinge permitting each of said supports to fold
inwardly and thereby permitting said container to be selectively
movable between a raised position and a collapsed position; and a
handle movably mounted to at least one of said supports adjacent
said intermediate hinge, said handle being accessible from an
exterior of said container when said container is in said collapsed
position.
2. The collapsible shipping container of claim 1 wherein said
handle is mounted between at least two of said supports.
3. The collapsible shipping container of claim 1 wherein said
handle is generally U-shaped having a first end connected to a
first of said supports and a second end connected to a second of
said supports.
4. The collapsible shipping container of claim 1 wherein at least
one of said supports travels through a plane as the container moves
between said raised position and said collapsed position, said
handle including a portion extending into said plane, whereby said
portion is capable of engaging at least one of said supports as the
container moves between said raised position and said collapsed
position.
5. The collapsible shipping container of claim 3 wherein an opening
is defined between said first support and said second support, said
opening being substantially unimpeded by said handle.
6. The collapsible shipping container of claim 1 wherein said
handle includes a first extension portion connected to a first of
said supports, a second extension portion connected to a second of
said supports and a cross member interconnecting said first
extension portion and said second extension portion, wherein when
said handle is in said raised position said first extension portion
extends substantially along said first support, said second
extension portion extends substantially along said second support
and said cross member extends substantially along one of said top
and said base, whereby said handle does not substantially impede
access to an interior of said container through a space between
said first support and said second support.
7. The collapsible shipping container of claim 6 wherein at least
one of said supports includes a lift assist means for biasing at
least one of said supports toward a raised position.
8. The collapsible shipping container of claim 6 further including
a lift assist mechanism bearing at least a portion of the weight of
the container as the container is moved between said raised
position and said collapsed position.
9. The collapsible container of claim 8 wherein at least one of
said top and said bottom includes a nesting protrusion, the other
of said top and said bottom including a nesting recess, whereby
said nesting protrusion and said nesting recess nest when together
said container is in said collapsed position.
10. The collapsible shipping container of claim 7 wherein said list
assist means includes at least one of an extension spring, a
torsion spring and a gas assist cylinder.
11. The collapsible shipping container of claim 1 further
comprising a locking sleeve movably fitted over at least one of
said supports.
12. A collapsible shipping container comprising: a base; a top; a
plurality of supports mounted between said base and said top, each
of said supports including a top hinge, a bottom hinge and an
intermediate hinge permitting each of said supports to fold
inwardly and thereby permitting said container to be selectively
movable between a raised position and a collapsed position; a
nesting means for nesting said top and said bottom when said
container is moved into said collapsed position.
13. The collapsible container of claim 12 wherein said nesting
means include an upper nesting section connected to said top and a
lower nesting section mounted to said base.
14. The collapsible container of claim 12 wherein said nesting
means includes an upper nesting section connected to said top in
vertical alignment with one of said supports and a lower nesting
section mounted to said base in vertical alignment with one of said
supports.
15. The collapsible container of claim 12 wherein said container
includes a plurality of corners, said plurality of supports
including a separate support disposed substantially in each of said
corners, said nesting means including a plurality of upper nesting
sections and a plurality of lower nesting sections, one of said
upper nesting sections and one of said lower nesting sections being
vertically aligned with a corresponding one of said supports.
16. The collapsible container of claim 15 further comprising a
handle mounted to at least one of said supports adjacent said
intermediate hinge, said handle being accessible from an exterior
of said container when said container is in said collapsed
position.
17. The collapsible container of claim 15 wherein said handle is
generally U-shaped having a first end connected to a first of said
supports and a second end connected to a second of said
supports.
18. The collapsible container of claim 16 further including a lift
assist mechanism.
19. A collapsible container, comprising: a base; a top; a plurality
of supports mounted between said base and said top, each of said
supports being hinged to permit each of said supports to fold
inwardly, thereby permitting said container to be selectively
movable between a raised position and a collapsed position; and a
lift assist means for bearing a portion of the weight of the
container when the container is moved between said raised position
and said collapsed position.
20. The collapsible container of claim 19 wherein said lift assist
means includes a lift assist device mounted to at least one of said
supports.
21. The collapsible container of claim 19 where said lift assist
means includes a lift assist device mounted to each of said
supports.
22. The collapsible container of claim 20 wherein at least one of
said supports includes a first section hingedly secured to a second
section, said lift assist device includes an extension spring
mounted between said first section and said second section.
23. The collapsible container of claim 20 wherein at least one of
said supports includes a first section hingedly secured to a second
section, said lift assist device includes a torsion spring mounted
between said first section and said second section.
24. The collapsible container of claim 20 wherein said lift assist
device includes a gas assist cylinder mounted between at least one
of said supports and at least one of said top and said base.
25. The collapsible container of claim 22 wherein said at least one
support defines an internal void, said extension spring being
disposed within said internal void.
26. The collapsible container of claim 20 wherein each of said
supports includes an intermediate hinge; and further comprising a
handle mounted to at least one of said supports adjacent said
intermediate hinge, said handle being accessible from an exterior
of said container when said container is in said collapsed
position.
27. The collapsible container of claim 26 wherein said handle is
generally U-shaped having a first end connected to a first of said
supports and a second end connected to a second of said
supports.
28. The collapsible container of claim 27 wherein said top includes
an upper nesting portion and said base includes a lower nesting
portion, said upper nesting portion interfitting with said lower
nesting portion when said container is in said collapsed
position.
29. A collapsible delivery container having a first side and a
second side, the container adapted to be raised and collapsed one
side at a time, comprising: a base; a top; a first pair of hinged
supports extending between said base and said top on a first side
of said container; a second pair of hinged supports extending
between said base and said top on a second side of said container,
said second pair of supports being actuatable independently of said
first pair of supports; a first handle mounted to each support in
said first pair of hinged supports, whereby said first handle
facilitates simultaneous folding and unfolding of both supports of
said first pair of supports; and a second handle mounted to each
support in said second pair of hinged supports, whereby said second
handle facilitates simultaneous folding and unfolding of both
supports of said second pair of supports.
30. The container of claim 29 wherein said first handle is U-shaped
having a first end connected to one of said supports of said first
pair of supports and a second end connected to the other of said
supports of said first pair of supports.
31. The container of claim 30 wherein each of said support of said
first pair of supports includes an intermediate hinge, said first
end of said handle being mounted proximate to said intermediate
hinge of one of said supports of said first pair of supports, said
second end of said handle being mounted proximate to said
intermediate hinge of the other of said supports of said first pair
of supports.
32. The container of claim 31 wherein said handle is accessible
from an exterior of said container when said container is in said
collapsed position.
33. The container of claim 29 wherein said top includes a first
upper nesting portion on said first side of said container and a
second upper nesting portion on said second side of said container,
said base includes a first lower nesting portion on said first side
of said container and a second lower nesting portion on said second
side of said container, said first upper nesting portion
interfitting with said first lower nesting portion when said first
side of said container is in said collapsed position, said second
upper nesting portion interfitting with said second lower nesting
portion when said second side of said container is in said
collapsed position.
34. The container of claim 29 further comprising a lift assist
means for bearing a portion of the weight of the container when the
container is moved between said raised position and said collapsed
position.
35. The container of claim 29 further comprising a first lift
assist device mounted to said first side of said container and a
second lift assist device mounted to said second side of said
container.
36. The container of claim 35 where said first lift assist device
includes at least one of an extension spring, a torsion spring and
a gas assist cylinder.
Description
BACKGROUND OF THE INVENTION
[0001] The present invention relates to reusable shipping
containers, such as dunnage containers, and more particularly to
collapsible reusable shipping containers.
[0002] Shipping containers, such as dunnage containers are widely
used to deliver parts and products from one location to another.
One of the most common uses for shipping containers is to ship
parts in bulk from the manufacturer to the purchaser. In these
applications, the shipping container is filled by the manufacturer
and shipped to the purchaser. The purchaser unloads the parts. In
many applications, shipping containers are reusable so that they
can be used repeatedly. This is particularly common in applications
where durable, high strength containers are required to ship the
products, for example, in shipping relatively large components in
the automotive industry. When reusable containers are employed, the
purchaser must unload the parts and then returns the container to
the manufacturer. The purchaser is typically required to store the
empty containers for some period of time before returning them to
the manufacturer. With conventional shipping containers, the
purchaser is required to dedicate a relatively large amount of
space to the storage of empty containers before return to the
manufacturer. Similarly, the manufacturer is required to dedicate a
large amount of storage to empty containers waiting to be filled.
Further, a relatively large amount of space in a truck or other
delivery vehicle is required to return the containers to the
manufacturer.
[0003] In an effort to reduce the space occupied by empty shipping
containers, for example, during storage and return shipping, a
variety of collapsible shipping containers have been developed.
Conventional collapsible containers include a base and a top that
are interconnected by supports or legs. These supports fold,
telescope or can be otherwise manipulated to lower the top onto the
base when the container is empty, thereby dramatically reducing the
height of the container. Although collapsible containers provide a
marked improvement, conventional collapsible containers suffer
several drawbacks. Perhaps the most significant drawback is that
conventional containers can be difficult to collapse and raise,
particularly large, heavy-duty containers. In many applications,
the container is designed to receive large, heavy components, such
as engine transmission components and other component parts for
large consumer goods. To accommodate these types of components, the
container must have a large footprint and be manufactured from
strong, durable materials, such as thick-wall, steel tubing. With
conventional collapsible containers, the user is required to bear
the weight of the container, actuate the supports and guide the
collapsing top into proper alignment with base. For example, with
conventional hinged supports, the weight of the container must be
supported while simultaneously moving around the container to
separately initiate the folding of each support. Once the supports
begin to fold, the top must be supported to provide a controlled
lowering of the top. A similar, but reverse, process is required to
raise the container. Experience has revealed that this process of
manually collapsing and raising the container can require a
cooperative effort of two or more people. As a result of the
shortcomings of conventional collapsible containers, there is a
need for a collapsible shipping container that is more easily
raised and collapsed.
SUMMARY OF THE INVENTION
[0004] The aforementioned problems are overcome by the present
invention wherein a collapsible shipping container is provided with
corner supports that are uniquely hinged to permit the container to
be collapsed one side at a time. Each corner support preferably
includes an offset hinge that permits the support to fold inwardly
and downwardly onto itself.
[0005] In one embodiment, each corner support includes upper and
lower nesting segments that are interfitted when the container is
collapsed. The interfitted nesting segments also provide a force
path that permits stacking of containers without placing undue load
on the hinges.
[0006] In another embodiment, the collapsible container includes a
pair of handles that facilitate collapse and assemble of the
container. Each handle is preferably pivotally mounted between a
pair of corner support at or near the hinge location. For example,
one handle may be mounted to the left and right supports located at
the front of the container while the other is mounted to left and
right supports at the rear of the container. This arrangement
facilitates separate collapse and assembly of the front and rear of
the container. The handles are preferably somewhat U-shaped and
configured to permit them to be accessible from the exterior when
the container is collapsed and to place them substantially outside
of the opening between the supports when the container is
assembled.
[0007] In a further embodiment, at least one of the supports is
providing with a movable locking collar that will selectively lock
the support in the extended position to prevent inadvertent
collapse of the support. The locking collar is preferably fitted
over and slidably movable along the support in a vertical
direction. The locking collar preferably includes a locking pin
that permits the collar to be secured in place over the hinge where
it prevents any substantial folding movement of the hinge.
[0008] In yet another embodiment, at least one support is provided
with a lift assist mechanism. The lift assist mechanism preferably
includes a spring or other resilient device that biases the support
in the raised (or unfolded) position. The lift assist works against
the weight of the container making it easier to collapse and raise
the container.
[0009] The present invention provides a simple and inexpensive
collapsible container that can be collapsed and assembled one side
at a time. This permits operation of the container by a single
individual. The handles facilitates controlled and efficient
operation by providing a mechanism for controlling movement of the
supports at the hinges. The handle is readily accessible when the
container is collapsed and does not hinder access to the interior
of the container when the container is raised. The nesting segments
facilitate collapse of the container one side at a time by
providing a mechanism for maintaining proper alignment of the top
and the base as each side is separately collapsed. The nesting
segments of the supports also provide a strong vertical force path
that conveys the weight of the upper portion of the container and
any above stacked containers to the ground or other surface upon
which the collapsed container is disposed.
[0010] These and other objects, advantages, and features of the
invention will be readily understood and appreciated by reference
to the detailed description of the preferred embodiment and the
drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a perspective view of a collapsible delivery
container in accordance with a preferred embodiment of the present
invention;
[0012] FIG. 2 is a is a perspective view of a collapsible delivery
container with the dunnage structure removed;
[0013] FIG. 3 is a is a perspective view of a collapsible delivery
container with the dunnage structure removed and one side partially
collapsed;
[0014] FIG. 4 is a is a perspective view of a collapsible delivery
container with the dunnage structure removed and one side fully
collapsed;
[0015] FIG. 5 is a is a perspective view of a collapsible delivery
container with the dunnage structure removed and the container
fully collapsed;
[0016] FIG. 6 is an enlarged view of a portion of a support showing
the central hinge and a portion of the handle;
[0017] FIG. 7 is a side elevational view of a portion of a support
showing an alternative lift assist; and
[0018] FIG. 8 is a side elevational view of a portion of a
collapsed support showing the alternative assist.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0019] A collapsible delivery container according to a preferred
embodiment of the present invention is shown in FIG. 1 and
generally designated 10. The container 10 generally includes a base
12 and a top 14 that are interconnected by folding supports 16a-b,
preferably located in the four corners of the container 10. The
folding supports 16a-b permit the container to be collapsed when
empty, thereby saving space during storage and return shipment. The
container 10 includes handles 52 and 54 that facilitate collapse of
the container 10 one side at a time. The present invention is
described in connection with a generally rectangular delivery
container configured to ship relatively large and heavy components.
The present invention is, however, well suited for use in other
application and may be fitted with a variety of alternative dunnage
structures or with no dunnage structure at all.
[0020] As noted above, the container 10 includes a base 12, which
generally forms the bottom of the container 10, and a top 14, which
generally closes the upper end of the container 10. In the
illustrated embodiment, the base 12 includes a peripheral frame
generally following the footprint of the container. The base 12 is
preferably dimensioned to correspond in size and shape with a
conventional pallet. Referring to FIG. 2, the base 12 includes four
cross members 20a-d arranged in a generally rectangular
configuration. In the illustrated embodiment, the cross members
20a-d are interconnected with and extend between the supports 16a-d
(described below). The cross members 20a-d are preferably connected
to the lower nesting sections 28a-d of the supports 16a-d a
sufficient distance from the bottom end of the supports 16a-d to
permit the forks of a fork lift to pass beneath the cross members
20a-d. A plate 22a-d extends beneath each cross member 20a-d,
preferably in alignment with the bottom of the supports 16a-d and
in parallel relationship. Accordingly, the plates 22a-d cooperate
with the bottom ends of the supports 16a-d to form the bottom of
the container 10. The illustrated base construction is merely
exemplary, and one skilled in the art will readily appreciate that
the base 12 may include a wide variety of alternative
constructions.
[0021] The top 14 is mounted upon the supports 16a-d to generally
form the top of the container 10. In the illustrated embodiment,
the top 14 includes a peripheral frame generally matching the size
and shape of the base 12. Referring to FIG. 2, the top 14 includes
four cross members 21a-d arranged in a generally rectangular
configuration. The cross members 21a-d are mounted between the four
upper nesting sections 26a-d of the supports 16a-d, for example, by
welding. As with the base 12, the illustrated top construction is
merely exemplary, and one skilled in the art will readily
appreciate that the top 14 may include a wide variety of
alternative constructions.
[0022] The base 12 and top 14 may, as in the illustrated
embodiment, include mounting structure to permit the installation
of a dunnage structure. For example, the base 12 and top 14 may
each include a plurality of parallel rods 24 adapted to receive and
hold a flexible dunnage structure 200. The rods 24 are illustrated
in FIG. 2. The dunnage structure 200 may be a conventional flexible
bag-type structure that includes a plurality of pockets 202 adapted
to received and separately support the products to be shipped. The
size, shape and configuration of the pockets 202 may vary from
application to application. Flexible dunnage structure is preferred
in many embodiments because it can be collapsed and raised
automatically with the container 10. Although rigid dunnage
structure may be used, it may be necessary to remove rigid
structure before the container can be collapsed and then reinsert
the rigid structure when the container is raised. The collapsible
delivery container may be provided with any of a wide variety of
alternative dunnage structures, including without limitation
hanging pouches, racks and bags. In some applications, the
container may include no dunnage structure, and hence no dunnage
mounting structure is necessary. In some applications it may be
desirable to provide the container with a full or partial floor
(not shown) or ceiling (not shown) that is supported by the
corresponding cross members. If desired, the floor and ceiling may
be solid, such as sheet or plate metal, or may be perforated, such
as expanded metal.
[0023] The base 12 and top 14 are interconnected by folding
supports 16a-d that permit the container 10 to collapse when
desired. The container 10 of the illustrated embodiment includes
four supports 16a-d, one located in each corner of the container
10. The supports 16a-d extend in a generally vertical orientation
and are interconnected with the base 12 and the top 14. As noted
above, the supported 16a-d are articulated to permit collapse of
the container 10. To provide this function, each support 16a-d
includes a plurality of hinged sections. More specifically, each
support 16a-d generally includes a lower nesting section 28a-d
interconnected with the base 14, a lower folding section 38a-d
hingedly secured to the lower nesting section 28a-d at a lower
hinge 72a-d, an upper folding section 36a-d hingedly secured to the
lower folding section 28a-d at a central hinge 74a-d and an upper
nesting section 26a-d that is interconnected with the top 14 and
hingedly secured to the upper folding section 36a-d at an upper
hinge 76a-d. The various support sections 26a-d, 28a-d, 36a-d and
38a-d of the illustrated embodiment are manufactured from tubular
steel. The materials from which the container is manufactured may,
however, vary from application to application depending on various
factors, including the desired strength, price point, weight and
intended use of the container. In the illustrated embodiment, the
lower, central and upper hinges are configured to provide offset
hinge locations so that the folding sections 36a-d and 38a-d fold
flat onto one another when the container 10 is collapsed. The lower
hinge 72a-d includes a pair of hinge plates 86a-b that are affixed
to the corresponding lower folding section 38a-d, a hinge sleeve 88
that is affixed to the lower nesting section 28a-d and a hinge pin
90 that pivotally interconnected the hinge plates 86a-d and the
hinge sleeve 88a-d (See FIG. 3). The hinge pin 90 may be a
conventional bolt that passes through the hinge plates 86a-d and
the hinge sleeve 88a-d, and that is secured by a lock nut. The
central hinge 74a-d includes a first hinge plate 92a affixed to the
lower folding section 38a-d and a second hinge plate 94b affixed to
the upper folding section 36a-d (See FIGS. 3 and 6). The hinge
plates 92a-b are pivotally interconnected by the handles 52 and 54
as described in more detail below. The upper hinge 76a-d includes a
pair of hinge plates 96a-b that are affixed to the upper folding
section 36a-d, a hinge sleeve 98 that is affixed to the upper
nesting section 26a-d and a hinge pin 100 that pivotally
interconnected the hinge plates 96a-d and the hinge sleeve 98a-d.
Like hinge pin 90, hinge pin 100 may be a conventional bolt that
passes through the hinge plates 96a-b and the hinge sleeve 98, and
that is secured by a lock nut. It should be noted that the
structure of the lower, central and upper hinges may vary from
application to application. For example, in certain applications,
the hinges of the preferred embodiment may be replaced by
conventional piano hinges or other similar hinging mechanisms.
[0024] To permit stacking of containers, the top end of each
support 16a-d is configured to nest with the bottom end of another
support 16a-d. The nesting may be achieved by providing the top end
of each upper nesting section 26a-d with a protrusion 30 and the
bottom end of each lower nesting section 28a-d with a recess (not
visible) adapted to receive the protrusion 30. In a preferred
embodiment, the nesting sections 26a-d and 28a-d are also
configured to nest when the container is collapsed. As perhaps best
shown in FIG. 3, the bottom end of each upper nesting section 26a-d
includes a protrusion 31 and the upper end of each lower nesting
section 28a-d defines a recess 33 adapted to receive the protrusion
31. When the container 10 is collapsed the protrusion 31 and recess
33 nest to help maintain proper alignment between the top 14 and
bottom 12 (See FIGS. 4 and 5). The protrusions and recesses can be
replaced by other nesting structure as desired.
[0025] Each support 16a-d may also be fitted with a locking sleeve
120 that is selectively movable over one of the hinges to prevent
the hinge from opening, and consequently, the support from folding.
For purposes of disclosure, a locking sleeve 120 is shown in FIG. 3
over support 16c. Although only illustrated over support 16c, a
separate locking sleeve 120 is preferably mounted over each support
16a-d. In the illustrated embodiment, the locking sleeve 120 is a
generally tubular segment that is fitted over and slidably movable
along the support 16c. The locking sleeve 120 is loosely fitted
over the lower folding section 38c so that it may slide down over
the lower hinge 72 to prevent collapse of the support 16c. The
locking sleeve 120 preferably moves into the locked position
automatically by gravity as the lower folding section 38c reaches
the raised position. The container 10 preferably includes a
retaining pin 121 for securing the locking sleeve 120 in a raised
position when it is desired to collapse the container 10. The
locking sleeve 120 is shown in the raised position in phantom lines
in FIG. 3. The retaining pin 121 is preferably fitted through holes
in the locking sleeve 120 and corresponding holes in the lower
folding section 38a-d. The locking sleeve may alternatively be
secured using other conventional mechanisms, such as a
spring-loaded pin or by a friction fit. The illustrated locking
sleeve 120 is merely exemplary, and the size, shape and
configuration of the locking sleeve 120 may vary from application
to application.
[0026] As an additional or alternative locking mechanism, one or
more of the supports 16a-d may include a locking pin 122 that locks
one or more of the hinges in the raised position. For purposes of
disclosure, a locking pin 122 is shown mounted to a central hinge
74b in FIG. 7. Although only illustrated in central hinge 74b, a
separate locking pin 122 is preferably installed in each central
hinge 74a-d. In the illustrated embodiment, the locking pin 122 is
fitted into the central hinge 74 to lock the central hinge 74 in
the raised position. More specifically, the hinge plates 92a-b and
upper folding sections 36a-d define locking pin holes (not shown)
that are aligned when the support is raised. To lock the central
hinge 74, the support 16c is moved into the fully raised position,
thereby bring the locking pin holes into alignment. The locking pin
122 is then fitted through the holes 132 to lock the sleeve in
place. The locking sleeve 120 and locking pin 122 are exemplary
locking mechanisms, and may be replaced by other locking
mechanisms.
[0027] In the illustrated embodiment, the four supports 16a-d
extend between the upper and lower extremes of the container 10. As
shown, the upper and lower nesting sections 26a-d, 28a-d extend
through the corners of the top 14 and base 12. In this way, the
supports 16a-d directly engage the ground or other surface on which
the container is placed, while at the same time directly supporting
any above stacked containers. Alternatively, the upper and lower
nesting sections 26a-d, 28a-d of each support can be eliminated,
and the upper and lower folding sections can be hingedly secured
directly to the top and bottom. In this alternative embodiment (not
shown), the top and base are configured to provide a structural
framework having mounting locations at or near the corners for the
upper and lower folding sections of the supports.
[0028] The container 10 preferably includes a pair of handles that
facilitate collapse of the container 10 one side at a time. In the
illustrated embodiment, each handle is connected to two adjacent
legs so that both legs can be controlled by a single handle. This
permits an individual to simultaneously control the folding of two
legs and consequently the collapse of one side of the container. In
this embodiment, the container 10 is configured so that the front
and rear of the container 10 collapse separately. Accordingly,
handle 52 is connected to the left and right supports, namely
supports 16a-b, at the front of the container and handle 54 is
connected to the left and right supports at the rear of the
container 10, namely supports 16c-d. Alternatively, the container
10 may be configured to permit the left and right sides of the
container to collapse separately, for example, by connecting one
handle to the front and rear supports on the right side of the
container and the other handle to the front and rear supports on
the left side of the container. Referring now to FIGS. 2 and 5, the
handles 52, 54 are configured so that they are accessible when the
container is collapsed or raised, yet do not significantly extend
into the opening between the supports so that they do not interfere
with access to dunnage structure or components packaged in the
container. In the illustrated embodiment, the handles 52, 54 are
generally U-shaped and each includes a cross member 56 extending
between a pair of extension portions 58 and 60. The extension
portions 58 and 60 are configured to mount to the supports at or
near the central hinge location. More specifically, each extension
portion 58, 60 terminates in a mounting axle 62 (perhaps best shown
in broken line in FIG. 6) that is fitted through the hinge plates
64 on the corresponding support. To reduce components, the mounting
axle 62 also functions as an axle for the corresponding central
hinge 74a-d. A tubular spacing sleeve 66 is fitted over the
mounting axle 62. The outside diameter of the sleeve 66 is
preferably greater than the diameter of the corresponding holes in
the hinge plates 64. The length of the sleeve 66 corresponds to the
spacing between the hinge plates 64 so that it maintains the
spacing between the hinge plates 64 and hence the alignment between
the upper and lower folding sections. The end of each axle 62 is
preferably threaded to receive a lock nut 70 that secures the axle
62 in place. The axle 62 can be secured using other techniques, for
example, by flaring, peening, enlarging or otherwise changing the
shaping the end of the axle 62 so that it is not readily removed
from the hinge plates 64. Alternatively, the handle 52, 54 may be
separate from the central hinge, for example, by mounting to the
supports adjacent to the central hinge. In this alternative
embodiment (not shown), the central hinge may include a hinge pin
or other conventional hinge mechanism in place of the axle 62.
[0029] The extension portions 58 and 60 of each handle 52, 54
preferably include an intermediate bend 72 that provides additional
control over collapse and raising of the upper folding sections.
The intermediate bend 72 extends through the vertical plane defined
by the movement of the folding sections. As a result, when the
handles 52 are 54 are manipulated properly by the user, the
intermediate bends 72 can be brought into contact with the
corresponding upper folding sections 36a-d (See Arrow A, FIG. 3).
When collapsing the container 10, the bends 72 can thus be used as
a brake to slow or stop collapse of the container 10. When raising
the container 10, the bends 72 can also be used to lift the upper
folding sections. This can be particularly helpful in providing an
initial boost when raising the container. The shape and location of
the bend 72 may vary from application to application. The bend may
also be replaced by other structure extending into the vertical
plane of the supports, for example, by a leg or other protrusion
(not shown) extending into the vertical plane from each extension
portion 58, 60.
[0030] With large containers, the supports 16a-d are preferably
provided with a lift assist that biases the supports toward the
raised (or unfolded) position or otherwise bears at least a portion
of the weight of the collapsing portions of the container 10. The
lift assist can be provided by a variety of mechanisms. In the
illustrated embodiment, the list assist includes an extension
spring 110, such as a coil spring, fitted within each support
16a-d. For purposes of disclosure, an extension spring 110 lift
assist is illustrated in broken lines in support 16a of FIGS. 2 and
3. Although only illustrated in support 16a, a separate extension
spring 110 or other lift assist is preferably installed on or
within each support 16a-d. As shown, the extension spring 110 is
affixed at one end to the lower folding section 38a and at the
other end to the upper folding section 36a. The extension spring
110 is preferably affixed to the upper folding section 36a-d by a
cable 112 or other similar component so that the extension spring
110 is not itself visible when the central hinge 74a-d is opened.
The extension spring 110 is preferably mounted so that it is under
tension regardless of the position of the supports 16a-d. In use,
opening of the central hinge 74a-d causes the distance between
opposite ends of the lift assist to increase, thereby stretching
the extension spring 100 and applying an increased biasing force to
the support 16a-d. As a result, the extension spring 110 has the
effect of lessening the apparent weight of the top 104 making it
easier to control collapsing and raising of the container. The
extension spring can be replaced by other lift assist devices,
including both internal and external devices. For example, the lift
assist may alternatively include other elastic or resilient
components, such as an alternative extension spring, a compression
spring, a bungee chord, a rubber strap, a torsion spring, a
bendable rod or a gas-assist cylinder. These alternative lift
assist mechanism may be disposed within the tube or mounted to the
exterior of the tube as required. In some applications, the lift
assist may be mounted between the top and the base rather than
directly to the supports, for example, a gas assist cylinder (not
shown) may be mounted between the top and base. In some
applications, it may be desirable to incorporate the lift assist
into the hinges, for example, by replace the hinges described above
with spring-loaded hinges.
[0031] An alternative lift assist is shown in FIGS. 7 and 8. In
this alternative embodiment, a pair of conventional compression
springs 10a-b' are disposed within one or more of the supports
16a-d to bias the corresponding support 16a-d toward the raised
position. As shown, a first compression spring 110a' is mounted
within the upper folding section 36a and a second compression
spring 110b' is mounted within the lower folding sections 38a. Each
compression spring 110a-b' includes a fixed end 111 that is fixedly
mounted to the support 16 and a free end 113 that extends freely
into the support 16 in a direction away from the central hinge 74.
A cable 112' or other flexible element is mounted between the free
ends 113 of the two compression springs 110a-b'. The cable 112'
preferably extends from the free ends 113 through the center of
each compression spring 110a-b'. In this embodiment, the cable 112'
is connected to the free ends 113 of each spring 110a-b' by a
washer 150 and a stop sleeve 152. The washer 150 preferably
includes an outer diameter that is greater than the inner diameter
of the compression springs 110a-b' to prevent the washer 150 from
being pulled into the center of the springs 110a-b'. The stop
sleeve 152 is preferably crimped or otherwise secured to the cable
112' to lock the washer 150 in place. The cable 112' may be secured
to the compression springs 110a-b' using alternative techniques and
apparatus. As the support 16 is collapsed, the central hinge 74
swings open, thereby increasing the effective distance between the
free ends 113 of the two compression springs 110a-b'. Because the
cable 112' is secured between the springs 110a-b' at a fixed
length, the collapsing action causes the cable 112' to compress the
two compression springs 110a-b'. This compression biases the
support 16 in the raised (or unfolded) position, thereby bearing at
least a portion of the weight of the collapsing portions of the
container 10. Although this embodiment is described with two
compression springs 110a-b' (one in each folding section), the lift
assist may alternatively include only a single compression spring
located in one of the two folding sections. In this "one-spring"
alternative, one end of the cable is secured to the free end of the
compression spring and the other end is secured to the folding
section that does not include the compression spring. When the
support 16 is collapsed, the single compression spring is
compressed to provide the desired lift assist. The precise
characteristics of the compression springs, cable and other
elements of the alternative lift assist will vary from application
to application depending primarily on the weight of the container
and the desired amount of list assist.
[0032] As noted above, the container 10 is raised during loading
and shipment of products, and can be collapsed to save space once
the container 10 is empty. The container 10 is specially configured
to permit a single individual to easily raise and collapse the
container one side at a time. The process of raising and collapsing
the container one side at a time will now be described in some
detail. Either side of the container 10 can be raised/collapsed
first. For purposes of this disclosure, the process will be
described by first raising the front of the container and then the
rear of the container. The collapsing process will be described in
reverse. To raise the front of the container, the individual
manipulates handle 52. As noted above, the handle 52 is connected
to the central hinges 74 of the corresponding supports 16a-b so
that manipulation of the handle 52 provides direct control over the
movement of the central hinges 74. By lifting upwardly on the
handle 52, the user causes the intermediate bends 72 to engage the
upper folding sections 36a-b, thereby provides an initial boost to
the lifting process. It should be noted that the lift assist 109
provides a force that assists in lifting the container 10 as
described above. As a result, the individual is not required to
lift the entire weight of the components to be raised at the front
of the container 10. By pulling outwardly and upwardly on the
handle 52 the central hinges 74 are lifted and drawn outwardly,
thereby causing the supports 16a-b to unfold, which in turn raises
the front of the top 14. During this motion, the nesting engagement
between the top 14 and base 12 at the rear of the container 10
helps to prevent the top 14 from shifting undesirably. Once the
supports 16a-b are fully unfolded, a locking sleeve 120 is secured
in place over the lower hinge 72 of preferably at least one of the
supports 16a-b. As noted above, the locking sleeve 120 preferably
drops down over the lower hinge 72 automatically by gravity as the
supports 16a-b reach the fully raised position. Additionally, the
central hinge 74 of preferably at least one of the supports 16a-b
is locked used a locking pin 122. In the illustrated embodiment,
the locking sleeve 120 will maintain the front of the container 10
in the raised position, thereby facilitating installation of the
locking pins 122. To further ease the locking process, the supports
16a-d may be configured to unfold to a position that is slightly
over-center. As a result, the weight of the top 14 will tend to
hold the central hinges 74 open and the supports 16a-d in the
raised position. Once locked in the raised position, the user
allows the handle 52 to swing down against the container 10 into a
resting position (See FIG. 1). Because of its unique configuration,
the handle 52 does not extend substantially into the space between
the supports 16a-b and therefore will not inhibit access to the
interior of the container 10. If desired, a strap, clasp, latch
(not shown) or other mechanism can be provided to retain the handle
52 in the resting position. The individual next raises the rear of
the container 10 by unfolding supports 16c-d through manipulation
of handle 54. Again, the handle 54 may be lifted to provide an
initial boost to the unfolding process. The handle 54 can then be
drawn outwardly and upwardly until the supports 16c-d are fully
unfolded. As when lifting the front of the container, the lift
assist 109 bears some of the weight of the portions of the
container 10 to be raised making it easier to lift the rear of the
container. Once raised, a locking sleeve 120 is secured in place
over the lower hinge 74 of at least one of the two supports 16c-d.
The central hinge 74 of preferably at least one of the supports
16c-d is locked by a locking pin 122. With the illustrated
embodiment, the process of raising the container 10 automatically
opens the flexible dunnage structure 200 that is mounted between
the top 14 and base 12. As a result, the raised container 10 is
ready to receive products. Loaded containers 10 are easily moved
using a fork lift or other similar machinery, and can be stacked
one on top of the other with the protrusions 30 of one container
nesting with the recesses of the other.
[0033] After the container 10 has been emptied, the container 10 is
easily collapsed so that it requires less space for shipping and
storage. The container 10 is collapsed in essentially the reverse
of the process described above. In short, the locking pin(s) 122 of
the rear supports 16c-d are removed and the locking sleeve(s) 120
are moved into the unlocked position so that the lower hinges 72
and central hinges 74 can move. The handle 54 is then pushed
inwardly causing the upper and lower folding sections 36c-d and
38c-d to fold inwardly. The process continues until the top 14 is
brought into contact with the base 14, and more specifically, until
the protrusions 31 are nested within the recesses 33. This nesting
interaction will help to maintain proper alignment between the top
14 and base 14 as the opposite side of the container 10 is
collapsed. During the collapsing process, the lift assist 109 will
bear a portion of the weight of the container 10 reducing the
weight that must be supported by the user. The front of the
container 10 is next collapsed through essentially the same
process: the locking pin(s) 122 are removed from the front supports
16a-d; the locking sleeve(s) 120 are moved to the unlocked
position; and the handle 52 is manipulated to cause the supports
16a-b to collapse at central hinges 74. As the container 10 is
collapsed, the flexible dunnage structure also collapses folding
onto itself so that it is contained within the collapsed container
10 ready for expansion when the container 10 is again raised.
Collapsed containers 10 are easily moved using a fork lift other
similar machinery. Like the raised containers, the collapsed
containers can be stacked one atop the other with the protrusions
30 of one container nesting with the recesses 32 of the other. If
desired, the container 10 may include bungee straps (not shown) or
other retaining devices to secure the container 10 in the collapsed
position.
[0034] The above description is that of a preferred embodiment of
the invention. Various alterations and changes can be made without
departing from the spirit and broader aspects of the invention as
defined in the appended claims, which are to be interpreted in
accordance with the principles of patent law including the doctrine
of equivalents. Any reference to claim elements in the singular,
for example, using the articles "a," "an," "the" or "said," is not
to be construed as limiting the element to the singular.
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