Collapsible Container For Air Shipment Cargo and Method of Use
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.
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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 INVENTIONThe present invention relates to a collapsible container for use in an aircraft cargo hold.
DESCRIPTION OF THE PRIOR ARTSpecial 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.
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.
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.
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 INVENTIONThe 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.
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.
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.
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.
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.
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.
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.
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® 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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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
Referring to the drawings and particularly to
As best illustrated in
As shown in
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.
As shown in
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
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
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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.
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
As shown in
As best shown in
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
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.
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
As shown in
Referring to
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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
As best illustrated in
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
As illustrated in
As shown in
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.
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
As best seen in
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
As seen in
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As best shown in
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
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.
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
As shown in
Referring to
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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.
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.
Referring to
As shown in
As shown in
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
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.
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.
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.
Type: Application
Filed: Sep 12, 2006
Publication Date: Mar 15, 2007
Applicant: BRADFORD COMPANY (Holland, MI)
Inventors: Brian Dobrinski (Zeeland, MI), Timothy Bublitz (Grand Haven, MI)
Application Number: 11/530,986
International Classification: B65D 6/00 (20060101);