COLLAPSIBLE CONTAINER

Abstract

A collapsible container for storing and transporting content is provided. The container has the strength to hold up to one hundred and fifty pounds of contents while being stacked up to eight high. The container may be loaded in a flattened configuration and then erected to enclose the contents. The container is also collapsible for ease of storage and transport. In some embodiments, the container includes wings that attach the end walls to the front and back walls and maintain the container in an upright configuration.

Description

TECHNICAL FIELD

This invention relates generally to collapsible containers, and more particularly to a collapsible container for receiving, storing, transporting, and discharging products.

BACKGROUND

Historically, cardboard, wood, or synthetic containers have been used for receiving, storing, transporting, and discharging products of all types. These containers are typically constructed in square, rectangular, or circular shapes with lift straps attached to each of the uppermost corners of the container. Content is placed over the side of a container until the container is full. The high sides of the containers make automation of container loading difficult because content must be lowered into the container.

Typically, cardboard, wood, or synthetic containers store large volumes of content. When loaded with content, the containers can be costly to transport because of their weight. Many containers are not collapsible because of the difficulty in designing a container that can both support the weight of the contents and also collapse for ease of storage and return shipping. Often designing a container that can collapse for storage makes the container too weak to efficiently transport content.

Some shippers include cardboard dividers to separate containers into smaller compartments but this approach has multiple drawbacks. First, the cardboard dividers are often not reusable because they are deformed during transport, which raises costs. Second, the cardboard dividers introduce box dust that can cause problems in manufacturing facilities as well as be a source of contamination in pharmaceutical and food-grade contents. Third, standard cardboard dividers have a greater x and y dimension than the containers when folded flat, causing problems in storage and return shipping.

Thus, there is a need for a strong collapsible container that can be loaded while the container is in a flattened position but that can also efficiently transport content.

SUMMARY OF INVENTION

The present invention relates generally to a collapsible container that provides improved storage, stacking ability, and strength. The containers are designed to store content such as manufacturing line products, pharmaceutical and personal hygiene products, food-related products, plastic parts and/or injection molded plastic parts, and the like. In general, the containers are manufactured of polyethylene or polypropylene fabric; have four walls, a base, and optionally a lid; and include stiffening panels in pockets formed in the four walls. In some embodiments, the containers include wings attached to end walls that allow the end walls to reversibly secure to the front and back wall and maintain the container in an upright position.

The containers are designed to collapse to a substantially flat position, which allows the containers to be easily loaded as well as easily stored and transported. In an embodiment, the containers are loaded with content while in a flattened configuration, erected into a box-shaped configuration, and efficiently transported in a stack. The containers can be unloaded in a flattened configuration or while still in a box-shaped configuration and then collapsed for ease in return shipping. The containers save money for shippers by providing efficient transport, ease of return, and re-usability.

In one embodiment, the container includes a base, a rigid front wall, a rigid back wall, and a pair of end walls defining four corners. The end walls include a first section, a second section, and a pair of wings, wherein the wings maintain the container in an upright position by reversibly attaching to the front wall and the back wall. In an embodiment, the wings include attachment devices, such as Velcro, adhesive, or other attachment devices for reversibly mating with attachment devices on the front wall and the back wall.

In a still further embodiment, the container includes a first lid portion attached to the back wall and a second lid portion attached to the front wall. The first lid portion and second lid portion are configured to fold over the base to a position substantially parallel with the base and to reversibly attach to one another, thereby enclosing the contents of the container when the container is erected. The lid portions can be detached from one another when the container is collapsed.

In further embodiments, the container includes an access door in the front wall and/or the back wall, wherein the access door can be sealed shut to store contents in the container or the access door can be opened to allow easy removal of contents in the containers. The access door is advantageous when the walls of the container are too high for convenient access from the side. In some embodiments, the container includes a girdle that reduces deflection in the front wall and the back wall. The girdle is attached to either wall and reversibly attaches to a point attached to the opposing wall. In still further embodiments, the container includes a partition that is able to separate the container into smaller compartments. The partition can be set up on the container when the container is in a flattened configuration. When the product is loaded onto the container, the partition will confine the content into smaller compartments that are formed when the walls of the container are raised.

The features, functions, and advantages that have been discussed may be achieved independently in various embodiments of the present invention or may be combined with yet other embodiments, further details of which can be seen with reference to the following description and drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1A and 1B show perspective views of a collapsible container in one aspect of the present invention, wherein FIG. 1A shows a top view of the collapsible container and FIG. 1B shows a bottom view of the collapsible container according to an embodiment.

FIG. 2 shows a perspective view of a collapsible container when the back wall is raised and attached to an end wall according to one embodiment.

FIG. 3 shows a perspective view of a collapsible container when the front wall and back wall are raised and attached to an end wall according to one embodiment.

FIG. 4 shows a perspective view of a collapsible container when the front wall and back wall are attached to opposing end walls according to one embodiment.

FIGS. 5A and 5B show perspective views of a collapsible container with a lid in a second aspect of the present invention, wherein FIG. 5A shows a top view of the collapsible container and FIG. 5B shows a bottom view of the collapsible container according to an embodiment

FIG. 6 shows a perspective view of a collapsible container when the lid is sealing the container.

FIG. 7 shows a perspective view of a collapsible container having an access door according to one embodiment.

FIG. 8 shows a perspective view of a collapsible container having a fold-down access door according to one embodiment.

FIG. 9 shows a perspective view of a collapsible container having a fold-to-the-side access door according to one embodiment.

FIGS. 10, 10a, and 10b show perspective views of a collapsible container having a girdle according to one embodiment.

FIGS. 11 and 12 show perspective views of a partition for use in a collapsible container according to an embodiment.

FIGS. 13 and 14 show perspective views of a partition for use in a collapsible container according to one embodiment.

DETAILED DESCRIPTION

The present invention generally relates to collapsible containers, methods for transporting and storing content in collapsible containers, and uses of collapsible containers. It is to be understood that the collapsible container described herein can be compatible with and may be used for storing and transporting any type of content. The collapsible container is easily loaded with content and allows convenient transport of the content. In an embodiment, the collapsible container is configured to receive content from an assembly line and then the walls swing up to enclose the content. In this manner, the content is not crushed or distorted during transport. Additionally, the containers are designed to be stackable, reusable, and collapsible. Surprisingly, the containers may be stacked up to eight high while containing loads of up to one hundred and fifty pounds each. Plastic rigid panels support less weight per square inch than plywood rigid panels, but both types of panels are appropriate for the content stored within these containers. The containers are designed for collapsible storage of up to about 150 lbs. It should be understood that varying the strength of the rigid panels will also affect the weight the panels are able to support. The container easily meet the minimum federal requirements of a 5:1 safe stacking factor for single use and the 6:1 safe stacking factor for reusable containers.

The design of the container minimizes bulging sides caused by heavy loads. Additionally, the containers weigh less than metal, wood, or plastic containers but can store products and be transported with at least the same level of efficiency. Further, the synthetic material used to manufacture the walls eliminates concerns related to cardboard or plywood such as dust that can contaminate pharmaceutical, food and personal hygiene products or damage sensitive equipment.

Any type of product may be transported in the containers. For example, solids or liquids can be transported in the collapsible containers. Solids can include, but are not limited to, powders, pre-formed components, and semi-solids. Liquids can include, but are not limited to, heavy oils, cooking fluids, and other viscous, semi-viscous, or non-viscous fluids. Specific examples of types of content than can be transported and stored in the containers include, but are not limited to, injection molded plastic parts, pharmaceuticals, personal hygiene components, and food products. Advantageously, the container may be laid flat at the end of an assembly line and products can be pushed onto the base of the container. Once the container is fully loaded, the walls of the container can be folded up and secured so that the products will be enclosed in the collapsible container and conveniently transported.

Thus, the present application provides a simple apparatus and method for reusable collapsible containers.

FIGS. 1A and 1B are perspective top and bottom views, respectively, of a collapsible container 100 in one aspect of the present invention. The container includes a square or rectangular base and four wall panels connected to an edge of the base, the four wall panels consisting of a front wall 102, a back wall 104, and a pair of end walls 105. When the four wall panels are raised up to a position substantially perpendicular to the base, the four wall panels connect to form a square or rectangular-shaped box. In an embodiment, the containers are produced in base dimensions from as small as 10 inches by 10 inches to as large as 48 inches by 96 inches. In some embodiments, the containers have a height from between 5 inches and 200 inches tall, more preferably between 20 inches and 96 inches. The containers, however, may be produced in any size including those sizes designed to fit standard or custom pallet measurements. For example, the containers can be 40×48 inches, 40×40 inches, 42×42 inches, or 48×48 inches in length and width dimensions. In another example, the containers can be sized to correspond to international pallet dimensions, such as 1000×1200 millimeters, 800×1200 millimeters, or 800×600 millimeters. In one embodiment, the container is designed to be less in each length and width dimension than the pallet, e.g., about one inch less, so that the container can be easily placed on the pallet and expand to the pallet's edges when filled.

The containers are constructed of materials such as woven polypropylene, polyethylene, PVC vinyl, urethane vinyl, or any other fabric or film of appropriate strength. For example, woven polypropylene fabric having a weight of between 3 to 10 ounces per square yard or 6-35 mil film, preferably between 4 to 8 ounces per square yard, and most preferably of about 6.5 ounces per square yard can be used to construct the containers.

In one embodiment, a wall panel is a single sheet of fabric or film. This type of wall panel has no rigidity. The single sheet of fabric may bulge when the container is filled. In an embodiment, the single sheet of fabric is under pressure by being stretched from the corners when the container is erected. Advantageously, wall panels that are manufactured from a single sheet of fabric are flexible and can be folded inward easily when the container is collapsed.

In another embodiment, the container is constructed by sewing two layers of woven polypropylene or woven polyethylene fabric together to create a wall panel having a pocket between the layers. In another embodiment, the wall panels are welded together to eliminate needle holes and create the pocket. Advantageously, welding provides a sealed environment in the container suitable to meet sterile and/or food storage standards.

The material can be welded together by any type of welding including hot gas welding, freehand welding, speed tip welding, extrusion welding, contact welding, hot plate welding, high frequency welding, ultrasonic welding, friction welding, laser welding, and solvent welding.

The pockets in the wall panels are designed to receive panels that provide rigidity and support to the container. Each wall can have a single pocket or multiple pockets. If the wall is designed with multiple pockets, each pocket can be defined by a sewn or welded seam. In one embodiment, the pockets have the panels placed therein and are then sealed shut (e.g., sewn or welded shut) to prevent the panel from falling out. In another embodiment, the pockets are open at one end or are reversibly sealable, such as by Velcro, a zipper, or other attachment means. Pockets that open allow the panels to be easily removed for transport or replacement.

The rigid panels can be made of plastic, engineered wood product, corrugated paperboard, or other suitable materials. The plastic can be corrugated or flat. Corrugated plastic can be between 4 mil and 25 mil thick, preferably between 10 mil and 16 mil thick, most preferably about 13 mil thick. Optionally, plywood can be from ⅛ inch thick to 2 inches thick, preferably from ¼ inch thick to 1 inch thick, most preferably about ½ inch thick. Additionally, different weight panels can be used for different parts of the container. For example, the panels in the front wall and back wall can be ½ inch plywood while the panels in the end walls 105 can be 13 mil corrugated plastic such as Interpro™.

In an exemplary embodiment of the container depicted in FIGS. 1-4, the container 100 includes a square or rectangular base 101, a front wall 102, a back wall 104, and end walls 105. Each of the four walls attach to one of the sides of the base at a seam or weld line. The seam or weld lines are constructed in the aforementioned manner and allow flexibility in moving the walls relative to the base. In an embodiment, the base and each of the four walls have a single pocket enclosing a rigid panel. It should be understood that many variations of rigid wall panels and flexible wall panels are possible by combining wall panels that have a pocket for receiving a rigid panel and wall panels composed of a single sheet of fabric.

In the embodiment depicted in FIGS. 1-4, the end walls 105 include a first section 106, a second section 107, and a pair of wings 108. In some embodiments, the first section 106, second section 107, and wings 108 are separated by seams or weld lines. The first section 106 is configured to be substantially the same height as the front wall 102 and the back wall 104 when the front wall 102, back wall 104, and first section 106 of the end walls 105 are positioned substantially perpendicular to the base 101. The first section 106 may also lay flat and in the same plane as the base 101 in another configuration, thereby allowing the container to be collapsed and conveniently stored. In an exemplary embodiment, the first section 106 includes a rigid panel within a pocket.

The second section 107 is configured to fold towards the center of the base 101 at a seam, weld, or fold line when the first section 106 is substantially perpendicular to the base 101. In an embodiment, the second section 107 folds toward the center of the base 101 until the second section 107 is substantially parallel to the base 101. In some embodiments, a tab 112 is placed over the seam, weld line, or fold line, and the tab supports the second section 107 in a position substantially parallel to the base 101. In other embodiments, however, a tab 112 is not present and the second section 107 is free to fold into the container formed by the base 101 and the four walls. In some embodiments, the second section 107 includes a rigid panel. In other embodiments, however, the second section 107 is flexible material without a rigid panel.

The wings 108 are designed so that they are reversibly movable into a position substantially adjacent to the front wall 102 and the back wall 104. As used herein, the term “substantially adjacent” means positioned next to and contacting or coming close to contacting. In some embodiments, the wings 108 comprise an attachment device 109, such as Velcro™, that attaches to matching attachment devices 109 (shown in FIG. 3) on the front wall 102 and the back wall 104. Adhesive, hook and loop fasteners, zippers, pressure lock buckles, pinch clips, or the like, may be used instead of Velcro™. When the wings 108 are positioned substantially adjacent to and secured to the front wall 102 and the back wall 104 by the attachment devices 109, the container is maintained in an upright position. In some embodiments, the wings 108 are elastic and can be stretched prior to attaching to the front wall 102 and the back wall 104 to tightly secure the walls together. When the wings 108 are substantially adjacent to the front wall 102 and the back wall 104, the container is freestanding, able to receive content, supports stacking, and is able to be box dumped without collapsing.

In an embodiment, the base 101 includes a rigid panel, such as enclosed within a pocket in the base 101. In another embodiment, the base 101 is not rigid and the bottom of the container is physically supported by resting on a rigid surface, such as a pallet. In another embodiment, a cassette (not shown) can be positioned in the container to provide rigid support for the flexible base 101. In this embodiment, the container can be used with or without a pallet because the bottom of the container is already supported and will not flex or bulge when the container is filled. For example, a container with a cassette supporting the bottom portion can be pushed or pulled off of a pallet and onto a truck, rail car, or ocean container. The cassette also allows the container to retain its shape when the container is tipped over and the contents are poured out.

The cassette is constructed from two layers of material creating a pocket and a rigid panel is inserted into the pocket, as described herein. In one embodiment, the rigid panel is sewn into the pocket and in another embodiment the pocket is reversibly sealed by Velcro™ or the like. In an embodiment, the cassette is placed in the container as the container is erected and removed from the container when the container is going to be collapsed. In some embodiments, the cassette includes a lanyard (not shown) for ease of movement. For example, the cassette may include a 0.5 inch to 2 inch wide strip of webbing sewn to the free end of the cassette. This webbing can be made into a handle so that it is easier to move the cassette to various positions within the container.

In operation, the container of FIGS. 1-4 can be transported to a manufacturing facility in a flat configuration. Content can be placed on the base 101 and the front wall 102, back wall 104, and end walls 105 can be raised up to a position substantially perpendicular to the base 101, thereby enclosing the content. The second portion 107 can be folded toward the center of the base 101 so that the second portion 107 is substantially parallel to the base 101 and the wings 108 can be attached via attachment devices 109 to the front wall 102 and back wall 104. In this manner, the container 100 is moved from a flat configuration to a configuration that encloses, protects, and assists in transportation of the content.

FIGS. 5 and 6 depict an embodiment of the present invention wherein the collapsible container includes an integral lid. FIG. 5A depicts a top view of the collapsible container and FIG. 5B depicts a bottom view of the collapsible container. In an embodiment, the collapsible container includes the square or rectangular base 101, front wall 102, back wall 104, and end walls 105 having a first section 106, second section 107, and wings 108. The front wall 102, back wall 104, and wings 108 include attachment devices 109, as described herein. The collapsible container also includes a first lid portion 116 attached to the back wall 104 and a second lid portion 118 attached to the front wall 102. The first lid portion 116 is flexibly attached to the back wall 104, such as by means of a weld or seam as described herein, so that the first lid portion 116 can fold over the square or rectangular base 101. Similarly, the second lid portion 118 is flexibly attached to the front wall 102 so that the second lid portion 118 can also fold over the base 101. The first lid portion 116 and the second lid portion 118 may include stiffening panels, as disclosed herein. As shown in FIG. 5A, the first lid portion 116 includes an attachment device 109 configured to mate with an attachment device 109 in the second lid portion 118, as shown in FIG. 5B.

FIG. 6 depicts the collapsible container with the integral lid in a box-shaped configuration wherein the first lid portion 116 and the second lid portion 118 are attached to one another by means of their respective attachment devices 109. The front wall 102 and the back wall 104 are folded so that they are substantially parallel to one another and then the first lid portion 116 and the second lid portion 118 are folded so that they are substantially parallel to the base 101. One skilled in the art would know to overlay the first lid portion 116 and the second lid portion 118 in such a manner so that their respective attachment devices 109 are able to mate and secure the lid over the base 101. The end walls 105 can then be folded up such that the first section 106 forms an end to the container and the second section 107 folds into a position substantially adjacent the lid. The wings 108 then fold down to the front wall 102 and the back wall 104 so that the attachment devices 109 on the wings can mate with the attachment devices 109 on the front wall 102 and the back wall 104.

In some embodiments, the first lid portion 116 includes a tab (not shown), similar to the tab between the first section 106 and the second section 107 of the end walls 105. The tab prevents the first lid portion 116 from extending more than substantially parallel to the base 101. The second lid portion 118 may have a similar tab.

It should be understood that the integral lid depicted in FIGS. 5 and 6 is only one embodiment of the lids that may be used with the collapsible container. In another embodiment, the first lid portion 116 or second lid portion 118 extends to the opposing wall and attaches to an attachment device 109 on the wall rather than to another lid portion. The first lid portion 116 and second lid portion 118 may also meet at a point in the center of the base 101 or at any point between the front wall 102 and the back wall 104. In a still further embodiment, the lid is separate from the collapsible container and placed on the container to secure the contents after the container is set up.

FIGS. 7, 8, and 9 show an access door 302 as it may be configured in any embodiment. The access door 302 can be opened to allow easy access to the interior of the container. For example, the access door 302 in FIG. 7 is in the front wall 102 of the container. The access door 302, however, can also be in the back wall 104 of the container. Typically, the access door 302 is of a slightly lower height (e.g., about 1 inch) than the wall panel portions on either side of it so that weight is not supported on the access door 302 when something (e.g., another container) is stacked on top of the container. As shown in FIG. 7, the access door 302 is sealed in a closed position by attachment means 308 such as Velcro tabs, zippers, pressure lock buckles, pinch clips, or the like. The access door can be off-centered in the wall. Further, the access door can have any width so long as the wall retains sufficient rigid materials on either side to support containers while stacked up to eight high. The access door 302 is manufactured from the same material as the wall panels. In one embodiment, the access door 302 is a single sheet of material. In another embodiment, the access door 302 is two pieces of material sewn or welded together and capable of receiving a rigid panel, as described herein.

In an embodiment shown in FIGS. 7 and 8, the access door 302 is constructed by placing two slits 304 in one of the wall panels and allowing the access door 302 to fold at a seam 306 substantially perpendicular to the two slits. The access door folds at the seam 306 located at some measurement down the wall. In an embodiment, the seam 306 is located above the midpoint of the wall, e.g., about one inch above the midpoint, so that when the access door is folded down it does not reach the bottom of the wall panel. In an embodiment, the access door 302 also defines three other panels in the wall panel: a first panel 320 on one side of the access door 302, a second panel 322 on a second side of the access door 302, and a third panel 324 below the access door 302. The first panel 320, second panel 322, and third panel 324 can be constructed of two sheets of fabric, as described herein, and have rigid panels providing support in them. Alternatively, a single piece of rigid material can be designed for the wall panel having the access door.

In another embodiment shown in FIG. 9, the access door 302 is configured to open to the left or the right. In this embodiment, a slit extending substantially vertically 310 and a slit extending substantially horizontally 312 define a side and bottom edge of the access door 302. A seam 314 defines the opposing edge of the access door. The attachment means 308 are also provided to secure the door in a closed position. The access door 302 that opens to the left or the right can have any height because the access door is not folding down towards the floor but rather to one of the edges where the wall panels meet.

In another embodiment depicted in FIGS. 10, 10a, and 10b, the container includes at least one girdle 406 configured to reduce deflection in the wall panel. When the container is storing a heavy load, the load presses against the interior walls and causes the wall panels to deflect outwards. The girdle 406 prevents this deflection from happening by providing support to the wall panels. A first piece of material 408 is sewn or welded to a wall panel, as described herein. In an embodiment, a second piece of material 410 is sewn or welded to the opposing wall. The two pieces of material reversibly attach to one another by attachment means 412 and provide support to both wall panels. For example, the first piece of material 408 may be sewn to the front wall 102 and include Velcro at one end. The second piece of material 410 is sewn to the back wall 104 and includes Velcro at a matching end. One skilled in the art would know to position the Velcro on the pieces of material so that the Velcro can secure the two pieces of the girdle, as well as that other types of attachment means may be used. For example, hook and loop, buttons, or adhesives may be used to connect the girdle. The two pieces of material can be any length so long as they are capable of connecting to one another. For example, the two pieces of material may overlap for some distance. Additionally, the two pieces do not need to be the same length and the attachment means do not need to connect at the midpoint of the opening of the container. To provide support to the wall panels, the first piece of material 408 and the second piece of material 410 are stretched towards one another and attached to provide resistance against stretching wall panels. The girdle 406 is reversible by detaching the attachment means 412 so that the container can be easily collapsed. In an embodiment, more than one girdle 406 is provided on the container. For example, two girdles may be included substantially parallel to one another to support a long wall panel.

FIG. 10A depicts a cross-section of the girdle 406 when the first piece of material 408 and the second piece of material 410 are not connected to one another by the attachment means 412. FIG. 10B depicts a cross-section of the girdle 406 when the first piece of material 408 and the second piece of material 410 are connected to one another by the attachment means 412. As can be seen in FIG. 10A, the girdle 406 connects the front wall 102 to the back wall 104 so that interior pressure in the container does not cause the front wall and back wall to bulge outwards.

In another embodiment, the girdle 406 includes a single piece of material having attachment means sewn or welded to a wall and corresponding attachment means attached to the opposing wall. The single piece of material is from one wall panels to an opposing wall panel and connected to the attachment means to prevent the wall panels from deflecting because of weight. The attachment means may be Velcro, hook and loop fasteners, zippers, pressure lock buckles, pinch clips, or the like.

FIGS. 11 and 12 depict a perspective view of a partition 700 for a collapsible container. In some embodiments, the partition 700 divides the container into smaller compartments. The partition 700 includes lateral walls 702 and a center wall 704. Seams 706 connect the lateral walls 702 to the center wall 704. The partition 700 may be constructed of the same material as the container or of different material. In an embodiment, the partition 700 is sewn or welded together, as disclosed herein, and includes stiffening panels in pockets in the lateral walls 702 and center wall 704 of the partition. In some embodiments, the stiffening panels are sewn or welded into the lateral walls 702 and center wall 704. In other embodiments, the stiffening panels are inserted into the pockets and then the pockets are sealed with Velcro, adhesive, tape, or other attachment devices.

The partition 700 may be sized to fit within the collapsible containers disclosed herein. In particular, the partition 700 may be sized so that the lateral walls 702 contact the front wall 102 and back wall 104 of the container and the center wall 704 contacts the end walls 105. In some embodiments (not shown), the lateral walls 702 and center wall 704 include attachment devices, such as Velcro or adhesive, that are configured to attach to matching attachment devices on the interior surfaces of the front wall, back wall, and end walls of the container. In this manner, the partition 700 may be reversibly secured in the container but easily removable. In an embodiment, the partition 700 has a height to substantially match the height of the container. In another embodiment, the partition 700 has a height that is less than the height of the container. For example, the partition 700 may be used with a cassette to define smaller compartments in a container.

In an embodiment depicted in FIG. 12, the partition 700 is configured to fold down when the lateral walls 702 are folded at the seams 706. The partition 700 may be folded down to a substantially flat configuration while the stiffening panels are still within the pockets. In this manner, the partition 700 may be used to create compartments in the containers but when the containers are collapsed for storage or transport, the partitions may also be folded down to reduce the space requirements for transport. Additionally, the stiffening panels may be removed from the pockets in the lateral walls 702 and center wall 704 so that the partition 700 may be folded into an even smaller space than when folded substantially flat with the stiffening panels in the pockets.

FIGS. 13 and 14 depict another embodiment of a partition 800 that allows the user to divide a container into smaller compartments. The partition 800 is made of the same or similar material as the containers, as disclosed herein. The partition 800 includes a lateral wall 802 and a center wall 804, wherein the lateral wall 802 and the center wall 804 are sized so that when the lateral walls 802 and center wall 804 are mated together the partition is the size of the interior of a container. The lateral walls 802 and center wall 804 include slots 806 for mating the lateral walls 802 with the center wall 804. For example, the slots 806 in the lateral walls 802 may be configured to closely receive the slots 806 in the center wall 804. In an embodiment, the slots 806 are a consistent height and width, such as half the height of the lateral walls 802 and center wall 804. In another embodiment, the sum of the height of the slot 806 in the lateral walls 802 and the height of the slot 806 in the center wall 804 is about equal to the height of the center wall 804. Stiffening panels are included in pockets in the lateral walls 802 and the center wall 804, and may be removable. For example, the pockets may be sealed with Velcro, adhesive, or other attachment devices. In another embodiment, the pockets are sewn or welded shut. When the slot 806 in the lateral wall 802 is inserted into the slot 806 in the center wall 804, the lateral wall 802 and the center wall 804 are substantially perpendicular and the partition 800 is free-standing. The lateral walls 802 and the center wall 804 can be separated so that multiple flat panels are provided, rather than a free-standing partition. When the lateral walls 802 and the center wall 804 are separated, the partition 800 may be packed into a small space for shipping.

It should be understood that the partitions 700, 800 may be made with a wide variety of number of lateral walls 702, 802. While FIGS. 11 and 13 depict the partitions 700, 800 as including a single center wall and two lateral walls 702, 802 on either side of the center wall 704, 804, more than or less than two lateral walls may be included in the partition. In addition, multiple center walls 804 having slots 806 may be included such that when the slots in the center walls 804 and the lateral walls 802 are mated, the partition 800 is sized to fit within a container or on top of a cassette 612 for creating smaller compartments within a container.

In some embodiments, the containers include document pockets 122 or placards on the container, as depicted in FIGS. 1B, 3 and 4. The document pockets 122 are sewn or welded onto the container for placing removable material, such as identifying labels, on container. The document pockets 122 can be polyethylene sealable bags or they can be a single sheet attached to the container walls on three sides so that labels can be placed in the pocket created between the sheet and the wall.

In still further embodiments, the container includes bin handles (not shown) for use in moving the container. The bin handles can be attached by sewing or welding to the vertical seams or to the outside layer of the walls. In some embodiments, two to four loops made from webbing are sewn into the vertical seams so that the container can be picked up for stacking or to allow discharge of contents. In other embodiments, handles for picking up the empty container when erected or collapsed can be located anywhere on the container. The handles can be sewn or welded onto the material comprising the container.

In another embodiment, any of the containers described herein can include a liner (not shown) for storage of dry flowable parts. For example, a polyethylene film liner can be included in the container. The liner is easy to clean and allows the contents to be quickly removed from the container.

In another aspect of the invention, a method for storing content in collapsible containers is provided. In an embodiment, the method includes providing containers as described herein, loading content onto the flattened containers, erecting the containers around the content, unloading the content from the containers after storage and/or transport, and then collapsing the containers for easy transport. The containers can be stored and transported in a stacked position and because of the square or rectangular shape of the containers, storage spaces can be used efficiently with the containers. Collapsing the containers occurs as described herein and allows the containers to be reduced to a fraction of their size. The method provides several advantages over the previously known methods including that the containers are lightweight and reusable, that the containers are strong enough to be stacked up to eight high with heavy loads yet can be folded down when not needed, and that the method allows manufacturers to save money and time by having an efficient use of space when shipping the containers loaded and when shipping the empty containers.

Although the invention has been variously disclosed herein with reference to illustrative embodiments and features, it will be appreciated that the embodiments and features described hereinabove are not intended to limit the invention, and that other variations, modifications and other embodiments will suggest themselves to those of ordinary skill in the art, based on the disclosure herein. The invention therefore is to be broadly construed, as encompassing all such variations, modifications and alternative embodiments within the spirit and scope of the claims hereafter set forth.

Claims

1. A collapsible container, the container comprising:

a base comprising a stiffening panel and four sides;

four walls, each of the walls comprising a stiffening panel and attached to one of the four sides of the base, the four walls comprising a front wall, a back wall, and two end walls, wherein the four walls are configured to move between a position substantially in the same plane as the base and a position substantially perpendicular to the base; and

attachment devices configured to reversibly secure the end walls to the front wall and back wall when the four walls are in the position substantially perpendicular to the base.

2. The container of claim 1, wherein the end walls comprise a first portion, a second portion, and a pair of wings, wherein the first portion is substantially the same height as the front wall and the back wall when the first portion, the front wall, and the back wall are positioned substantially perpendicular to the base.

3. The container of claim 2, wherein the second portion is configured to fold over the base to a position substantially parallel to the base.

4. The container of claim 3, wherein the pair of wings include an attachment device that is configured to reversibly mate with an attachment device on the front wall and the back wall when the second portion is positioned substantially parallel to the base.

5. The container of claim 1, wherein the container includes a girdle attached to two opposing walls, the girdle comprising a first material attached to a first wall and a second material attached to a second wall, wherein the first material and the second material are reversibly connectable.

6. The container of claim 1, wherein the front wall defines a pocket between two pieces of material welded together, and wherein the back wall defines a pocket between two pieces of material welded together.

7. The container of claim 1, wherein the stiffening panel is selected from the group consisting of plywood, corrugated plastic, metal, and cardboard.

8. The container of claim 1, wherein the container further comprises a first lid portion attached to the back wall and a second lid portion attached to the front wall, wherein the first lid portion and the second lid portion

9. The container of claim 8, wherein the first lid portion and the second lid portion are configured to reversibly attach to one another.

10. The container of claim 1, wherein the end walls comprise a seam between the first portion and the second portion and a stiffening panel in a pocket formed on either side of the central vertical seam.

11. The container of claim 10, wherein a tab connected to an exterior of each end wall across the seam prevents the second portion from extending into the container.

12. The container of claim 1 claims, further comprising an access door in at least one of the front wall and the back wall.

13. The container of claim 12, wherein the access door is of a lower height than a wall on either side of the access door so that pressure is not exerted on the door when pressure is applied to a top edge of the four walls of the container.

14. The container of claim 12, wherein the access door includes attachment means to secure the door in a closed position.

15. The container of claim 1, wherein the attachment device is selected from the group consisting of Velcro, adhesive, hook and loop fasteners, zippers, magnets, and buttons.

16. A collapsible container, the container comprising:

a base comprising a stiffening panel and four sides;

four walls, each of the walls comprising a stiffening panel and attached to one of the four sides of the base, the four walls comprising a front wall, a back wall, and two end walls, wherein the four walls are configured to move between a position substantially in the same plane as the base and a position substantially perpendicular to the base,

wherein the end walls comprise a first portion, a second portion, and a pair of wings, wherein the pair of wings is configured to reversibly attach to the front wall and the back wall when the first portion, the front wall, and the back wall are substantially perpendicular to the base.

17. The collapsible container of claim 16, further comprising a first lid portion and a second lid portion, wherein the first lid portion is attached to the back wall and the second lid portion is attached to the front wall.

18. The collapsible container of claim 16, further comprising a removable internal partition, wherein the removable internal partition divides the container into compartments when the front wall, back wall, and end walls are substantially perpendicular to the base.

19. The collapsible container of claim 16, wherein container is movable between a substantially flattened configuration and a substantially rectangular configuration.

20. A method for storing content in collapsible containers, the method comprising:

providing a container, the container comprising a base, a front wall, a back wall, end walls, and means for supporting the container in an upright position;

loading content onto the container when the container is in a flattened configuration;

erecting the container in an upright position using the means for supporting the container in an upright position;

unloading the content from the container;

reversing the means for supporting the container in an upright position; and

collapsing the container.