U.S. patent application number 11/530986 was filed with the patent office on 2007-03-15 for collapsible container for air shipment cargo and method of use.
This patent application is currently assigned to BRADFORD COMPANY. Invention is credited to Timothy A. Bublitz, Brian T. Dobrinski.
Application Number | 20070056967 11/530986 |
Document ID | / |
Family ID | 39184450 |
Filed Date | 2007-03-15 |
United States Patent
Application |
20070056967 |
Kind Code |
A1 |
Dobrinski; Brian T. ; et
al. |
March 15, 2007 |
Collapsible Container For Air Shipment Cargo and Method of Use
Abstract
A collapsible container for air shipment cargo comprises a base,
a top and collapsible side walls integral with each other to form a
ring. Front and rear walls are hingedly secured to the base. Each
of the side walls has upper and lower wall panels hinged together
so as to enable each side wall to collapse inwardly. A door may be
hinged to one of the side walls. Flaps having fasteners are hinged
to the side walls and used to assemble and erect the container.
Portions of the top have fasteners which are used to secure the
front and rear walls to the top. One of the front and rear walls
has upper and lower portions forming an obtuse angle with each
other when the container is erected.
Inventors: |
Dobrinski; Brian T.;
(Zeeland, MI) ; Bublitz; Timothy A.; (Grand Haven,
MI) |
Correspondence
Address: |
WOOD, HERRON & EVANS, LLP
2700 CAREW TOWER
441 VINE STREET
CINCINNATI
OH
45202
US
|
Assignee: |
BRADFORD COMPANY
13500 Quincy Street P.O. Box 1199
Holland
MI
|
Family ID: |
39184450 |
Appl. No.: |
11/530986 |
Filed: |
September 12, 2006 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
11227738 |
Sep 15, 2005 |
|
|
|
11530986 |
Sep 12, 2006 |
|
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Current U.S.
Class: |
220/6 |
Current CPC
Class: |
B65D 11/1826 20130101;
B65D 88/524 20130101; B65D 88/14 20130101; B65D 90/008
20130101 |
Class at
Publication: |
220/006 |
International
Class: |
B65D 6/00 20060101
B65D006/00 |
Claims
1. A collapsible container comprising: a base; a top having two
opposed flanges; a front wall hingedly secured to said base; a rear
wall hingedly secured to said base; side walls integral with said
base and top, each of said side walls being collapsible inwardly;
flaps hinged to said side walls, wherein said flaps and said
flanges of said top may be secured to said front and rear wall
panels to erect said container.
2. The collapsible container of claim 1 wherein said front and rear
walls each have a strap secured thereto to aid in assembly of said
container.
3. The collapsible container of claim 1 further comprising a
collapsible door hinged to one of said walls.
4. The collapsible container of claim 1 wherein said flaps and said
flanges of said top may be secured to said front and rear walls
with fasteners.
5. The collapsible container of claim 1 wherein each of said side
walls has an upper portion integral with a lower portion.
6. The collapsible container of claim 1 wherein at least some of
said flaps are integral with said side walls.
7. The collapsible container of claim 1 wherein at least some of
said flaps are secured to said side walls with hinges.
8. A collapsible container comprising: a base; a top having two
opposed flanges; a front wall secured to said base with a hinge; a
rear wall having a upper portion and a lower portion, said lower
portion being secured to said base with a hinge and forming an
obtuse angle with said upper portion of said rear wall when said
container is erected; side walls integral with said base and said
top, each of said side walls having integral upper and lower
portions hinged together so as to enable said side wall to hinge
and collapse inwardly; flaps integral with said side walls for
securing said side walls to said front and rear walls when said
container is erected.
9. The collapsible container of claim 8 wherein at least some of
said flaps have fasteners attached thereto which may pass through
openings in said front and rear walls for assembly of said
container.
10. The collapsible container of claim 8 further comprising a
collapsible door.
11. The collapsible container of claim 9 further comprising
fasteners attached to said flaps for erecting the container.
12. The collapsible container of claim 10 wherein said door has an
upper portion integral with a lower portion.
13. A collapsible container comprising: a base; a top; a front wall
hingedly secured to said base; a rear wall hingedly secured to said
base; side walls integral with said base and top, each of said side
walls having integral upper and lower portions hinged together and
being collapsible inwardly; flaps for securing said side walls to
said front and rear walls to erect said container.
14. The collapsible container of claim 13 wherein each of said
flaps has latches thereon which pass through said front and rear
walls and are used to assemble the container.
15. The collapsible container of claim 13 wherein said top has
opposed flanges, each of said flanges having latches thereon which
pass through said front and rear walls and are used to assemble the
container.
16. The collapsible container of claim 13 further comprising hinges
joining said front and rear walls to said base.
17. The collapsible container of claim 13 further comprising a door
having an upper portion hinged to a lower portion.
18. A method of erecting a collapsible container, the method
comprising the steps of: providing a collapsed container; lifting a
top of the collapsed container, thereby erecting side walls of the
collapsed container; lifting front and rear walls hingedly secured
to a base of the collapsed container; securing the top of the
container to the front and rear walls of the container; securing
flaps hinged to said side walls of the container to the front and
rear walls of the container.
19. The method of claim 18 wherein securing the top of the
container to the front and rear walls of the container comprises
passing rotatable latches through openings in the front and rear
walls of the container and rotating the latches to prevent the
latches from passing through the openings in the front and rear
walls of the container.
20. The method of claim 18 wherein lifting said front and rear
walls of the collapsed container comprises pulling on a strap
secured to each of said front and rear walls.
21. The method of claim 18 wherein said step of securing flaps
hinged to said side walls of the container to the front and rear
walls of the container comprises passing rotatable latches located
on the flaps of the container through openings in the front and
rear walls of the container and rotating the latches.
22. A method of erecting a collapsible container, the method
comprising the steps of: providing a collapsed container having a
top with opposed flanges, each of said flanges having at least one
latch thereon; raising the top of the collapsed container, thereby
erecting collapsed side walls of the collapsed container, each of
the side walls having flaps hinged thereto and at least one of the
side walls having a collapsible door formed therein; lifting front
and rear walls hingedly secured to a base of the collapsed
container; passing said latches located on the flanges of the top
of the container through openings in the front and rear walls of
the container; securing the top of the container to the front and
rear walls of the container with the latches; passing latches
located on the flaps of the container through openings in the front
and rear walls of the container; securing the flaps of the
container to the front and rear walls of the container using the
latches.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of U.S. patent
application Ser. No. 11/227,738 filed Sep. 15, 2005 entitled
"Collapsible Container For Air Shipment Cargo and Method of Use",
which is fully incorporated by reference herein.
FIELD OF THE INVENTION
[0002] The present invention relates to a collapsible container for
use in an aircraft cargo hold.
DESCRIPTION OF THE PRIOR ART
[0003] Special containers are used on aircrafts for storing fragile
parcels containing breakable or perishable goods, or for storing
passenger luggage. Due to the limited space available in aircraft
cargo holds, the shape of such a container is generally designed to
fit the shape of the walls of the aircraft cargo hold or luggage
compartment. One of the most important factors airlines use in
selecting a suitable container for use in an aircraft cargo hold is
gross weight. The heavier the container, the heavier the airplane
and the more fuel must be used to fly a predetermined distance.
[0004] In order to reduce the space occupied by such a container
once it has been emptied, such a container has been designed to
collapse. For example, U.S. Pat. No. 5,890,612 discloses a
collapsible aircraft container which has a rigid base frame
supporting an accordion folding frame. The collapsible container
has sides made of canvas and sheet metal plates. The frames are
made of steel. Therefore, the container is heavy, even when
empty.
[0005] Another collapsible aircraft container is disclosed in U.S.
Pat. No. 5,941,405. This collapsible aircraft container has a base,
support posts and roof made of aluminum and flexible side walls
formed from light weight fabric. Again, due to the support posts,
the container is heavy, even when empty.
[0006] In each of these collapsible aircraft containers, the less
the weight the better, as long as the container is sturdy enough to
handle normal wear and tear of such use. Consequently, there is a
need for a light weight, collapsible airline container which does
not include a frame or support posts, thereby reducing its
weight.
SUMMARY OF THE INVENTION
[0007] The collapsible container of the present invention comprises
a base, a top, front and rear wall panels hingedly secured to the
base and side walls hingedly secured to the base and top. Each of
the side walls comprises upper and lower wall panels hinged
together so as to enable each side wall to collapse inwardly. A
hinged door is formed in one of the side walls for access to the
interior of the erected container.
[0008] Once the container is erected, a person may load product(s)
or luggage into the interior of the container for shipping
purposes. Likewise, prior to collapsing the container, product(s)
or luggage may be removed from the interior of the container out
the opening or openings formed in one or both of the side walls of
the container which may be closed doors or other similar
structure.
[0009] Although the collapsible container of the present invention
is intended for use inside airplane cargo holds or luggage
compartments, it may used in any desired environment and is not
intended to be limited in its use.
[0010] In one embodiment of the present invention, the top of the
collapsible airline container is one piece or panel of material
having two opposed flanges which may be bent downwardly
perpendicular to the generally planar main portion of the top.
Fasteners are secured to these flanges in any suitable manner and
in one embodiment comprise rotatable latches adapted to pass
through openings in the front and rear wall panels or walls of the
container during assembly of the container. Of course, any other
suitable fasteners may be used to secure the top to the collapsible
front and rear wall panels of the assembly during assembly.
[0011] The front wall panel of the container in one embodiment
comprises one generally rectangular piece or panel of plastic
material. However, the front wall panel or front wall may be made
of multiple pieces secured together of any suitable material.
[0012] The rear wall panel in one embodiment comprises one
generally rectangular piece or panel of plastic material. The rear
wall panel has a living hinge extending from one side edge to the
other side edge which separates the rear wall panel into a
generally planar upper portion or section and a generally planar
lower portion or section and enables the rear wall panel to be
folded into a collapsed position when the container is collapsed.
These upper and lower portions or sections of the rear wall panel
form an obtuse angle with each other when the container is
assembled and lay on top of one another when the container is
collapsed. If desired, the rear wall may be made of multiple pieces
secured together of any suitable material.
[0013] The collapsible airline container further comprises plastic
flaps hingedly secured to the side walls. These flaps are secured
to the front and rear wall panels of the container during assembly
of the container. In one embodiment, three flaps are hingedly
secured to one edge of each side wall for securing the side wall to
the rear wall panel and two flaps are hingedly secured to an
opposing edge of the side wall for securing the side wall to the
front wall panel. At least one fastener is secured to each of the
flaps. In one embodiment these fasteners comprise rotatable latches
adapted to pass through openings in the front and rear wall panels.
Of course, any other suitable fasteners may be used to secure the
flaps to the collapsible front and rear wall panels.
[0014] Each of the wall panels and flaps is preferably made of
plastic but may be made of any suitable material. In one embodiment
of the present invention, each of the wall panel is made of a
plastic material sold under the mark CON-PEARL.RTM. by Friedola
Gebr. Holzapfel Gmbh & Co. of Germany. The panel material may
be selected as appropriate to protect or prevent surface damage to
the products being stored and/or shipped in the erected
container.
[0015] The method of assembling the collapsible airline container
comprises multiple steps. Although the method is described with
respect to one preferred embodiment, the method may be used with
any of the embodiments contemplated by this invention.
[0016] In one instance, a collapsed container as described above is
first provided. Two operators first lift a top of the collapsed
container, thereby erecting side walls of the collapsed container
including a collapsed door. The operators then lift, pivot or raise
the front and rear wall panels of the collapsed container by
pulling on straps secured to these panels of the collapsed
container.
[0017] One of the assemblers then enters the interior of the
container via the open door of the partially erected container. The
first assembler located outside the partially erected container
passes rotatable latches located on the flanges of the top of the
container through openings in the front and rear wall panels of the
container. The assembler located inside the container then rotates
the latches to prevent the latches from passing back through the
openings in the front and rear wall panels of the container. The
second assembler located outside the container also passes the
fasteners in the form of rotatable latches located on the flaps of
the container through openings in the front and rear wall panels of
the container. The assembler located inside the container then
rotates the latches to prevent the latches from passing back
through the openings in the front and rear wall panels of the
container and secure the flaps to the front and rear wall panels of
the container.
[0018] After the interior of the erected container is loaded with
product, one of the assemblers may close and lock the door of the
container in a closed position.
[0019] In this manner, the container may be quickly and
inexpensively assembled or erected. For purposes of this document,
the term "fastener" refers to any type of fastener including a
rotatable latch.
[0020] In order to disassemble the container, a person enters the
interior of the erected container and rotates the rotatable latches
to open them so that the flaps may be separated from the front and
rear wall panels and the top may be separated from front and rear
wall panels by a second operator located outside the container.
After the person previously inside the interior of the container
exits the container via the opening where the door is located, the
other person pulls the flaps away from the front and rear wall
panels and collapses the front and rear wall panels after the top
has been separated from the front and rear wall panels. After the
rear wall panel has been collapsed, the front wall panel is
collapsed then the side walls are collapsed. The container is now
fully collapsed.
[0021] An alternative embodiment of collapsible container comprises
a base, a top, side walls hinged to the base and top with living
hinges. The side walls are integral with the top and base so as to
form an integral ring or loop which results in enhanced strength
and integrity of the container. Each of the side walls comprises
upper and lower portions hinged together with a living hinge so as
to enable each side wall to collapse inwardly.
[0022] The collapsible container further comprises front and rear
walls hingedly secured to the base. The rear wall may have an upper
portion and a lower portion, the lower portion being pivotally or
hingedly secured to the base with a hinge. This lower portion may
form an obtuse angle with the upper portion of the rear wall when
the container is erected. A door may be hinged to one of the walls
for access to the interior of the erected container. Alternatively,
a door may be formed in one of the walls.
[0023] This embodiment further comprises flaps hinged to the side
walls. At least some of these flaps, if not all, may be integral
with the side walls. Others may be secured to the side walls with
hinges. To erect the container and keep it in an erected condition,
the flaps are secured to the front and rear walls of the container
with fasteners or any other suitable securement. In one embodiment,
three flaps are hinged to one edge of each side wall for securing
the side wall to the rear wall and two flaps are hinged to an
opposing edge of the side wall for securing the side wall to the
front wall. At least one fastener is located on each of the flaps
for such securement. Each fastener may comprise a rotatable latch
adapted to pass through an opening in one of the front and rear
walls. Of course, any other suitable fasteners may be used to
secure the flaps to the collapsible front and rear walls.
[0024] In this embodiment, the top of the collapsible airline
container may have two opposed flanges which may be bent downwardly
from the generally planar main portion of the top. The flanges in
one embodiment are integral with the main portion of the top but
may be separate pieces hinged to the main portion or body of the
top of the container. Fasteners may be used to secure these flanges
to the front and rear walls of the container in aid in the erection
of the container. The fasteners may assume numerous configurations
or types and in one embodiment comprise rotatable latches adapted
to pass through openings in the front and rear walls of the
container before being rotated during erection of the container. Of
course, any other suitable fasteners may be used to secure the top
to the collapsible front and rear walls of the container.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] FIG. 1 is a perspective view of the container of the present
invention in an erected condition;
[0026] FIG. 2 is a perspective view of the container of the present
invention in a collapsed condition;
[0027] FIG. 3 is a perspective view of the collapsed container of
FIG. 2 illustrating the side walls being erected;
[0028] FIG. 4 is a perspective view of the container of FIG. 3
illustrating the side walls fully erected;
[0029] FIG. 5 is a perspective view of the container of FIG. 4
illustrating the front and rear wall panels being erected;
[0030] FIG. 6 is a perspective view of the container of FIG. 5
illustrating the flaps being secured to the front wall panel of the
erected container;
[0031] FIG. 7A is a perspective view of one of the rotatable
latches used in accordance with the present invention in an
unlocked position;
[0032] FIG. 7B is a perspective view of the rotatable latch of FIG.
7A in a locked position;
[0033] FIG. 8 is a perspective view of the erected container of
FIG. 1 illustrating the base of the container;
[0034] FIG. 9 is a rear elevational view taken along the line 9-9
of FIG. 2;
[0035] FIG. 10 is a perspective view of the erected container of
FIG. 1 illustrating products being placed into the interior of the
container;
[0036] FIG. 11 is a view taken along the line 11-11 of FIG. 8;
[0037] FIG. 12 is a perspective view of an alternative embodiment
of container in an erected condition;
[0038] FIG. 13 is a perspective view of the container of FIG. 12 in
a collapsed condition;
[0039] FIG. 14 is a perspective view of the collapsed container of
FIG. 12 illustrating the side walls being erected;
[0040] FIG. 15 is a perspective view of the container of FIG. 12
illustrating the side walls but not the container fully
erected;
[0041] FIG. 16 is a perspective view of the container of FIG. 12
illustrating the front and rear walls being erected;
[0042] FIG. 17 is a perspective view of the container of FIG. 12
illustrating the flaps being secured to the front wall;
[0043] FIG. 18 is a perspective view of the erected container of
FIG. 12 illustrating the base of the container;
[0044] FIG. 19 is a rear elevational view taken along the line
19-19 of FIG. 13;
[0045] FIG. 20 is a perspective view of the erected container of
FIG. 12 illustrating products being placed into the interior of the
container;
[0046] FIG. 21A is a perspective view of one of the rotatable
latches used in accordance with the present invention in an
unlocked position; and
[0047] FIG. 21B is a perspective view of the rotatable latch of
FIG. 21A in a locked position.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0048] Referring to the drawings and particularly to FIG. 1, there
is illustrated a collapsible container 10 movable between an
erected condition or position illustrated in FIGS. 1 and 8 and a
collapsed condition or position illustrated in FIGS. 2 and 9. The
collapsible container 10 is designed for use inside an aircraft
luggage hold but may be used in another environment or for any
other purpose.
[0049] As best illustrated in FIG. 8, the collapsible container 10
comprises a generally rectangular and generally planar base 12
having an upwardly directed flange 13 around the periphery thereof.
The base 12 is preferably made of one piece of plastic material.
However, other materials or other configurations may be used
without departing from the present invention.
[0050] As shown in FIG. 1, a pair of side walls 14 are hingedly
secured to the base 12 and more particularly to upwardly directed
flanges 13 located around the periphery of the base 12 with
horizontally oriented hinges 16 shown in FIG. 9. Each hinge 16 is
preferably a co-extruded plastic hinge made by the Bradford Company
of Holland, Mich. but may be any other type of hinge.
[0051] Each side wall 14 comprises a lower wall panel 18 hingedly
secured to an upper wall panel 20 with a horizontally oriented
hinge 22. Each hinge 22 is preferably a co-extruded plastic hinge
like hinges 16, but may be any other type of hinge. Each wall panel
18, 20 is preferably made of one piece of plastic material, but may
be multiple pieces or made with any other suitable material.
Although the wall panels 18, 20 of each side wall 14 are preferably
made of the same material, they may be different materials.
[0052] As shown in FIGS. 3 and 9, hinges 22 enable each side wall
14 to fold or collapse inwardly so that the upper wall panel 20
overlays or lays on top of the lower wall panel 18 when the
container 10 is collapsed. As shown in FIG. 9, each hinge 22, as
well as each hinge 16, comprises a pair of U-shaped receptacles 23
and a flexible joining member 25 joining the receptacles 23 and
enabling them to move relative to one another.
[0053] As shown in the figures, at least one of the side walls 14
has a collapsible door 24 adapted to cover an opening 26 formed in
the side wall. See FIG. 10. The door 24 is hingedly joined to the
side wall 14 with a vertically oriented hinge 28 and movable
between a closed position as shown in FIG. 1 and an open position
as shown in FIG. 10. The door 24 has an upper portion or section 30
and a lower portion or section 32 separated by hinge 22. In the
illustrated embodiment, each section 30, 32 comprises one piece of
plastic; however, other materials of any desired size may be used
for the door sections.
[0054] Each section 30, 32 of door 24 may be latched or locked in a
closed position with a latch 34a, 34b, respectively. As seen in
FIG. 6, a portion of each latch 34a, 34b is located on the door
section 30, 32 and another portion of the latch 34a, 34b is located
on one of the side wall panels 20, 18. See FIG. 10. In one
embodiment, each latch 34a, 34b is manufactured by McMaster-Carr of
Aurora, Ohio. Latch 34a is sold as Part No. 10425 A86 and latch 34b
is sold as Part No. 10425 A84. See www.mcmaster.com. Either of the
latches may be locked if desired. However, latches 34a, 34b may be
any other suitable latching or locking members.
[0055] FIG. 11 illustrates hinge 28 in further detail. In one
embodiment, hinge 28 is a 270 degree hinge extrusion manufactured
by Filtrona Extrusion of Athol, Mass. and sold as Part No. 1440.
See www.filtrona.com. However, hinge 28 may be any other suitable
hinge. Hinge 28 comprises a pair of generally U-shaped receptacles
29, retaining lower wall panel 18 and the lower section 32 of the
door 24, respectively in any desired manner. The hinge 28 further
comprises a joining member 31 which enables movement of the
receptacles 29 and their contents relative to one another.
[0056] As best seen in FIG. 3, flaps 36a, 36b and 36c are hingedly
secured to side edges 38a, 38b and 38c, respectively, of each side
wall 14. More particularly, upper flaps 36a are hingedly secured to
side edges 38a of upper wall panels 20 with hinges 40a. Similarly,
middle flaps 36b are hingedly secured to side edges 38b of lower
wall panels 18 with hinges 40b. Lastly, lower flaps 36c are
hingedly secured to side edges 38c of lower wall panels 18 with
hinges 40c.
[0057] As seen in FIGS. 3 and 4, on the other end of each side wall
14, flaps 36d and 36e are hingedly secured to side edges 38d and
38e, respectively, of each side wall 14. More particularly, flaps
36d are hingedly secured to side edges 38d of upper wall panels 20
with hinges 40d. Similarly, flaps 36b are hingedly secured to side
edges 38e of lower wall panels 18 with hinges 40e.
[0058] Preferably, each flap 36a-36e is a single piece of plastic
material. However, any of the flaps may be made of any number of
pieces of any suitable material and of any desired size.
[0059] In one embodiment, hinges 40a-40e, all used to secure flaps
to side wall panels 18, 20, are 270 degree hinge extrusions like
hinge 28 used on the door 24, shown in detail in FIG. 11 and
manufactured by Filtrona Extrusion of Athol, Mass. and sold as Part
No. 1440. See www.filtrona.com. However, these hinge may be any
other suitable hinges.
[0060] As shown in FIG. 6, the collapsible container 10 further
comprises a front wall panel 42 hingedly joined to base 12 with
horizontally oriented hinge 44. Hinge 44 in the embodiment shown is
the same hinge as hinges 16 and 22 shown in detail in FIG. 9 and
described above. As best shown in FIGS. 3 and 4, front wall panel
42 has at least one hole or opening 46 therethrough at the end of
the front wall panel 42 opposite where it is joined to base 12 with
hinge 44. This end becomes the top of the front wall panel 42 when
the container 10 is erected. Similar holes or openings 48 through
the front wall panel 42 are located along the sides of the front
wall panel 42. As shown in FIG. 6, a nylon strap 50 is secured at
its upper end 52 to the outside surface 54 of the front wall panel
42 and used for raising the front wall panel 42 from a horizontal
collapsed position shown in FIGS. 3 and 4 to an erected or raised
position shown in FIG. 6.
[0061] As best shown in FIGS. 1 and 8, the collapsible container 10
further comprises a rear wall panel 56 hingedly joined to base 12
with horizontally oriented hinge 58. Hinge 58 in the embodiment
shown is the same hinge as hinges 16 and 22 shown in detail in FIG.
9 and described above. (also the same as hinge 44 shown in FIG. 6).
As best shown in FIG. 5, rear wall panel 56 has a living hinge,
crease or fold 60 separating the rear wall panel 56 into an upper
portion or section 62 and a lower portion or section 64. As best
illustrated in FIG. 8, when the container 10 is erected, the upper
portion 62 is vertically oriented and forms an obtuse angle 66 with
the lower portion 64. As best illustrated in FIG. 5, when the
container 10 is collapsed, the upper portion 62 lays on top of the
lower portion 64.
[0062] Like the front wall panel 42, the rear wall panel 56 has at
least one hole or opening 68 therethrough at the end of the rear
wall panel 56 opposite where it is joined to hinge 58. This end
becomes the top of the rear wall panel 56 when the container 10 is
erected. Similar holes or openings 70 through the rear wall panel
56 are located along the sides of the rear wall panel 56 to aid in
erecting the container 10. See FIG. 5. As shown in FIG. 5, a nylon
strap 72 is secured at one end 74 to the outside surface 76 of the
rear wall panel 56 and used for raising the rear wall panel 56 from
a horizontal collapsed position shown in FIGS. 3 and 4 to an
erected or raised position shown in FIGS. 1 and 8. As shown in FIG.
5, when the rear wall panel 56 is collapsed, an inner surface 78 of
the upper portion 62 of the rear wall panel 56 is upwardly directed
while an inner surface 78a of the lower portion 64 of the rear wall
panel 56 is downwardly directed.
[0063] It is within the contemplation of the present invention that
other devices other than nylon straps 50, 72 may be used to raise
the front and rear wall panels 42, 56, respectively.
[0064] The collapsible container 10 further comprises a top or top
panel 80 hingedly joined to the upper wall panels 20 of the side
walls 14 with horizontally oriented hinges 82. Hinge 82 in the
embodiment shown is the same hinge as hinges 16 and 22 shown in
detail in FIG. 9, hinge 44 shown in FIG. 6 and hinge 58 shown in
FIG. 8, described above. Any other suitable hinge may be used if
desired. As best shown in FIGS. 3 and 4, top 80 has a pair of
flanges 84 extending downwardly from a main portion 85 of the top
80.
[0065] As shown in FIG. 7A, at least one fastener in the form of a
rotatable latch 86 is secured to each flange 84 of the top 80. The
rotatable latch 86 may be riveted or secured in any suitable manner
to an inside surface 88 of flange 84. The rotatable latch 86
comprises a stationary portion 90 and a rotatable portion 92. See
FIGS. 7A and 7B. One fastener or rotatable latch which has proven
satisfactory is manufactured by Friedola Tech Holzapfel Gmbh of
Germany and sold as Part No. M931020. However, any other suitable
latch or fastener may be used.
[0066] Referring to FIG. 5, in order to secure the rear wall panel
56 to the flange 84 of the top 80, the rotatable portion 92 of the
latch 86 is passed through opening 68 in the rear wall panel 56 in
its position shown in FIG. 7A and then rotated to a locked position
shown in FIG. 7B.
[0067] As shown in FIG. 5, at least one fastener in the form of a
rotatable latch 86 is secured to an inside surface of each flap
36a-36e and adapted to pass through holes 70 in the rear wall panel
56. Similarly, at least one fastener in the form of a rotatable
latch 86 is secured to an inside surface of each flap 36d and 36e
and adapted to pass through holes 48 in the front wall panel
42.
[0068] Referring to FIG. 3, the method of assembling the
collapsible container 10 will now be described. Beginning with the
collapsed container 10 shown in FIG. 2, two operators or assemblers
94a and 94b are provided. Simultaneously, they lift the top 80 or
upper portions 20 of the side walls 14 up as shown in FIG. 3,
thereby erecting the side walls 14 of the container 10 including
the door 24. At this point, the front and rear wall panels 42, 56
of the container 10 are still in their collapsed condition or
position. See FIGS. 3 and 4. FIG. 4 shows the container with the
side walls 14 fully erect and the flaps 36a-36e located outside the
side walls 14 of the container.
[0069] As shown in FIG. 5, assemblers 94a and 94b grab straps 72,
50, respectively and pull them upwardly to raise or pivot upwardly
rear wall panel 56 and front wall panel 42, respectively. Front
wall panel 42 is raised first by operator 94b since it lays on top
of rear wall panel 56 when the front and rear wall panels 42, 56
are collapsed above base 12.
[0070] As shown in FIG. 6, after the front and rear wall panels 42,
56 are erected or raised, one of the assemblers 94a opens the door
24 and enters the interior of the partially erected container 10.
The other assembler 94b stays outside the container 10. The
assembler 94a passes the rotatable portions 92 of rotatable latches
96 secured to flanges 84 of top 80 through openings 46, 68 in the
front and rear wall panels 42, 56, respectively. See FIG. 7A. The
assembler 94a inside the container 10 then rotates the rotatable
portions of latches 96 as shown in FIG. 7B to secure the top 80 of
the container to the front and rear wall panels 42, 56 of the
container. Additionally, the assembler 94a passes the rotatable
portions 92 of rotatable latches 96 secured to flaps 36a-36e
through openings 48,70 in the front and rear wall panels 42, 56,
respectively. See FIG. 7A. The assembler 94a inside the container
10 then rotates the rotatable portions of latches 96 as shown in
FIG. 7B to secure the flaps 36a-36e of the container 10 to the
front and rear wall panels 42, 56 of the container 10, the flaps
36a-36e being outside the front and rear wall panels 42, 56 of the
container 10.
[0071] After the container 10 is fully assembled, the door may be
closed and locked, if necessary, after products or items 96 are
loaded inside the interior 98 of the container 10. See FIG. 10.
[0072] FIGS. 12-19 illustrate another embodiment of collapsible
container 110 movable between an erected condition or position
illustrated in FIGS. 12, 18 and 20 and a collapsed condition or
position illustrated in FIGS. 13 and 19. The collapsible container
110 is designed for use inside an aircraft luggage hold but may be
used in another environment or for any other purpose.
[0073] As best illustrated in FIGS. 12 and 18, the collapsible
container 110 comprises a base 112, a pair of collapsible side
walls 114 and a top 180 which are integrally joined together by
living hinges or folds in a continuous but yet collapsible loop or
ring of material 181. This collapsible ring 181 of the container
110 may be made of numerous pieces of material welded or otherwise
joined together. In one embodiment, the collapsible ring 181 of the
container 110 comprises multiple pieces of plastic material
butt-welded together.
[0074] The base 112 has a pair of upwardly directed flange portions
113 on opposed sides of the base 112 which may remain vertically
oriented when the container 110 is collapsed. See FIG. 19. These
flange portions 113 are integrally joined by living hinges 116 to
side walls 114. See. FIGS. 13 and 19. These living hinges 116
enable the collapsible side walls 114 to collapse inwardly on top
of the base 112 as shown in FIGS. 13 and 19. Similarly, the side
walls 114 and top 180 are integrally joined by living hinges 182
which enable the top 180 to collapse on top of the collapsed side
walls 114 as shown in FIGS. 13 and 19.
[0075] As illustrated in FIG. 14, each side wall 114 comprises a
lower wall portion 118 hinged to an upper wall portion 120 with a
horizontally oriented living hinge 122 such that the upper and
lower wall portions 120, 118 of each side wall 114 are integral
with each other. Such configuration of side walls 114 enables each
side wall 114 to collapse inwardly in a manner best illustrates in
FIG. 14 so that the upper wall portion 120 overlays the lower wall
portion 118 of each side wall 114 when the container 110 is
collapsed.
[0076] As shown in FIGS. 12-19, at least one of the side walls 114
has a collapsible door 124 adapted to cover an opening 126 formed
in the side wall. See FIG. 20. The door 124 is hingedly joined to
the side wall 114 with a vertically oriented hinge 128 and movable
between a closed position as shown in FIG. 12 and an open position
as shown in FIG. 20. Hinge 128 may be identical to hinge 28 shown
in FIG. 11 and described above. However, hinge 128 may be any other
suitable hinge. Hinge 128 is shown in detail in FIG. 22 and
comprises a pair of generally U-shaped receptacles 29 adapted to
receive one of the side wall portions 118, 120 on one side and a
portion of the door 124 on the other. The hinge 128 further
comprises a joining member 131 which enables movement of the
receptacles 129 and their contents relative to one another.
[0077] The door 124 has an upper portion or section 130 and a lower
portion or section 132 separated by a living hinge 123. In this
illustrated embodiment, the door 124 comprises one piece of plastic
collapsible or foldable due to living hinge 123. Although one type
of door is illustrated, other doors of any desired size or material
may be used.
[0078] Each section 130, 132 of door 124 may be latched or locked
in a closed position with a latch or lock 134a, 134b, respectively.
As seen in FIG. 17, a portion of each latch 134a, 134b is located
on the door section 130, 132 and another portion of the latch 134a,
134b is located on one of the side wall portions 120, 118. See FIG.
20. The latches or locks 134a, 134b may be identical to latches
34a, 34b described above or may be different.
[0079] As best seen in FIGS. 14 and 15, flaps 136a and 136b are
integral with and hinged to upper and lower portions 120, 118,
respectively, of each side wall 114 by living hinges 138a, 138b,
respectively. More particularly, upper flaps 136a are hinged to
upper portions 120 of side walls 114 with living hinges 138a.
Similarly, middle flaps 136b are hinged to lower portions 118 of
side walls 114 with living hinges 138b. Thus, flaps 136a and 136b
are part of the side walls 114 and part of the loop or ring of
material 181 described above.
[0080] Lastly, lower flaps 136c are hingedly secured to side edges
138c of lower wall portions 118 of side walls 114 with hinges 140.
Each lower flap 136c is a separate piece of material, preferably
plastic. However, flaps 136c may be made of any suitable material
and of any desired size or configuration. Hinges 140, used to
secure flaps 136c to side walls 114 are 270 degree hinge extrusions
like hinge 28 used on the door 24, shown in detail in FIG. 11 and
described above. However, these hinges 140 may be any other
suitable hinges.
[0081] As seen in FIGS. 14 and 15, on the other end of each side
wall 114, flaps 136d and 136e are hinged to each side wall 114 and
integral with each side wall 114. More particularly, flaps 136d are
hinged to upper wall portions 120 of side walls 114 with living
hinges 138d. Similarly, flaps 136e are hinged to lower wall
portions 118 of side walls 114 with living hinges 138e. Thus, flaps
136d and 136e are part of the side walls 114 and part of the loop
or ring of material 181 described above.
[0082] As shown in FIG. 17, the collapsible container 110 further
comprises a front wall 142 hingedly joined to base 112 with
horizontally oriented hinge 144. Hinge 144 in the embodiment shown
is the same hinge as hinges 16 and 22 shown in detail in FIG. 9 and
described above. As best shown in FIGS. 14 and 15, front wall 142
has at least one hole or opening 146 therethrough at the end of the
front wall 142 opposite where it is joined to base 112 with hinge
144. This end becomes the top of the front wall 142 when the
container 110 is erected. Similar holes or openings 148 through the
front wall 142 are located along the sides of the front wall 142.
As shown in FIG. 17, a nylon strap 150 is secured at its upper end
152 to the front wall 142 and used for raising the front wall 142
from a horizontal collapsed position shown in FIGS. 14 and 15 to an
erected or raised position shown in FIG. 17. FIG. 17 shows the
strap 150 hanging outside the outside surface 154 of the front wall
142.
[0083] As best shown in FIG. 18, the collapsible container 110
further comprises a rear wall 156 hingedly joined to base 112 with
horizontally oriented hinge 158. Hinge 158 in the embodiment shown
is the same hinge as hinges 16 and 22 shown in detail in FIG. 9 and
described above. (also the same as hinge 44 shown in FIG. 6). As
best shown in FIGS. 16 and 18, rear wall 156 has a living hinge,
crease or fold 160 separating the rear wall 156 into an upper
portion or section 162 and a lower portion or section 164. As best
illustrated in FIG. 18, when the container 110 is erected, the
upper portion 162 is vertically oriented and forms an obtuse angle
166 with the lower portion 164 of the rear wall 156. As best
illustrated in FIG. 16, when the container 110 is collapsed, the
upper portion 162 lays on top of the lower portion 164.
[0084] Like the front wall 142, the rear wall 156 has at least one
hole or opening 168 therethrough at the end of the rear wall 156
opposite where it is joined to hinge 158. This end becomes the top
of the rear wall 156 when the container 110 is erected. Similar
holes or openings 170 through the rear wall 156 are located along
the sides of the rear wall 156 to aid in erecting the container
110. See FIG. 16. As shown in FIG. 12, a nylon strap 172 is secured
at one end 174 to the rear wall 156 and used for raising the rear
wall 156 from a horizontal collapsed position shown in FIGS. 14 and
15 to an erected or raised position shown in FIGS. 12 and 18. As
shown in FIGS. 16 and 17, when the rear wall 156 is collapsed, an
inner surface 178 of the upper portion 162 of the rear wall 156 is
upwardly directed while an inner surface 178a of the lower portion
164 of the rear wall 156 is downwardly directed. Thus, when the
rear wall 156 is collapsed, the upper portion 162 of the rear wall
156 is folded relative to of the lower portion 164 of the rear wall
156 and rests or resides on top of the lower portion 164 of the
rear wall 156.
[0085] It is within the contemplation of the present invention that
other devices other than flexible nylon straps 150, 172 may be used
to raise and lower the front and rear walls 142, 156,
respectively.
[0086] The collapsible container 110 further comprises a top 180
hinged to the upper wall portions 20 of the side walls 114 with
horizontally oriented living hinges 182 such that the top 180 is
integral with the side walls 114. As such the top 180 forms part of
the loop or ring 181 of the container 110. As best shown in FIGS.
14 and 15, top 180 has a pair of flanges 184 extending downwardly
from a main portion 185 of the top 180 and integral with the main
portion 185 of the top 180 via living hinges 183. Although two
flanges 184 are illustrated, any number of flanges of any desired
size may be integral with the main portion 185 of the top 180 via
living hinges. Alternatively, flaps (not shown) may be hinged to
the top 180 to secure the top 180 to the front and rear walls when
the container 110 is erected.
[0087] As shown in FIG. 21A, at least one fastener in the form of a
rotatable latch 186 like the one shown in FIG. 7A is secured to
each flange 184 of the top 180. The rotatable latch 186 may be
riveted or secured in any suitable manner to an inside surface 188
of flange 184. The rotatable latch 186 comprises a stationary
portion 190 and a rotatable portion 192. See FIGS. 21A and 22B. One
fastener or rotatable latch which has proven satisfactory is
manufactured by Friedola Tech Holzapfel Gmbh of Germany and sold as
Part No. M931020. However, any other suitable latch or fastener may
be used.
[0088] Referring to FIGS. 16, 21A and 21B, in order to secure the
rear wall 156 to the flange 184 of the top 180, the rotatable
portion 192 of the latch 186 is passed through opening 168 in the
rear wall 156 in its position shown in FIG. 21A and then rotated to
a locked position shown in FIG. 21B. The same procedure is used to
secure the front wall 142 to the opposite flange 184 of the top
180. Although only one fastener is illustrated securing the front
wall 142 to the top 180 and another one securing the rear wall 156
to the top 180 of the container 110, any number of fasteners may be
used.
[0089] As shown in FIG. 16, at least one fastener in the form of a
rotatable latch 186 is secured to an inside surface of each flap
136a-136c and adapted to pass through holes 170 in the rear wall
156. Similarly, at least one fastener in the form of a rotatable
latch 186 is secured to an inside surface of each flap 136d and
136e and adapted to pass through holes 148 in the front wall 142.
Any number of fasteners of any desired type or configuration may be
used to secure any of the flaps 136a-136e to either the front wall
142 or rear wall 156 of the container 110.
[0090] Although not illustrated, it is within the contemplation of
the present invention that any number of flaps be secured to or
integral with the front and rear walls 142, 156 of the container
110 instead of being secured to or integral with the side walls 114
of the container 110, as illustrated and described. In either
event, the flaps may be used to secure the front and rear walls
142, 156 of the container 110 to the collapsible side walls 114 of
the container 110 when the container 110 is erected.
[0091] The container 110 is preferably made of plastic material.
However, other materials or other configurations may be used
without departing from the present invention. Although reference is
made to made in this document to a front wall panel or front wall,
a rear wall panel or rear wall and side walls, it will be
appreciated that the collapsible container 10 or 110 may be
oriented in any direction so that, for example, the front wall
panel or front wall is actually at the rear of the erected
container.
[0092] Referring to FIG. 14, the method of assembling the
collapsible container 110 will now be described. Beginning with the
collapsed container 110 shown in FIG. 13, two operators or
assemblers 194a and 194b are provided. Simultaneously, they lift
the top 180 and/or upper portions 120 of the collapsed side walls
114 up as shown in FIG. 14, thereby erecting the side walls 114 of
the container 110 including the door 124. At this point, the front
and rear walls 142, 156 of the container 110 are still in their
collapsed condition or position. See FIGS. 14 and 15. FIG. 15 shows
the container 110 with the side walls 114 fully erect and the flaps
136a-136e located outside the side walls 114 of the container
110.
[0093] As shown in FIG. 16, assemblers 194a and 194b grab straps
172, 150, respectively and pull them upwardly to raise or pivot
upwardly rear wall 156 and front wall 142, respectively. Front wall
142 is raised first by operator 194b since it lays on top of rear
wall 156 when the front and rear wall 142, 156 are collapsed above
base 112.
[0094] As shown in FIG. 17, after the front and rear walls 142, 156
are erected or raised, one of the assemblers 194a opens the door
124 and enters the interior of the partially erected container 110.
The other assembler 194b stays outside the container 110. The
assembler 194a passes the rotatable portions 192 of rotatable
latches 186 secured to flanges 184 of top 180 through openings 146,
168 in the front and rear walls 142, 156, respectively. See FIG.
21A. The assembler 194a inside the container 110 then rotates the
rotatable portions of latches 186 as shown in FIG. 21B to secure
the top 180 of the container 110 to the front and rear walls 142,
156 of the container. Additionally, the assembler 194a passes the
rotatable portions 192 of rotatable latches 186 secured to flaps
136a-136e through openings 148, 170 in the front and rear walls
142, 156, respectively. See FIG. 21A. The assembler 194a inside the
container 110 then rotates the rotatable portions of latches 186 as
shown in FIG. 21B to secure the flaps 136a-136e of the container
110 to the front and rear walls 142, 156 of the container 110, the
flaps 136a-136e being outside the front and rear walls 142, 156 of
the container 110.
[0095] After the container 110 is fully assembled, the door 124 may
be closed and locked, if necessary, after products or items 96 are
loaded inside the interior 198 of the container 110. See FIG.
20.
[0096] Although the figures illustrate a known method of assembling
the collapsible containers of the present invention, any other
suitable known method may be used to assembly a collapsed container
built in accordance with the present invention.
[0097] While we have described several embodiments of our invention
in detail, we do not intend to be limited except by the scope of
the following claims. For example, wherever a living hinge is
illustrated and described, alternatively a separate hinge may be
used. Likewise, wherever a separate hinge is illustrated and
described, a living hinge may be used.
* * * * *
References