METHOD AND APPARATUS FOR COLLAPSIBLE CONTAINER

Abstract

A hollow container or box formed from a top panel, a first side panel, a second side panel, opposed end panels, and a base panel placing the container or box in a fully assembled position. The second side panel is releasably coupled to the base panel and each of the other panels are hingedly coupled to one another. Upon rotating each of the opposed end panels, the top panel, the first side panel, and the second side panel relative to one another and various axis rotation in combination with releasably detaching the second side panel from the base panel, the container or box is transitioned from a fully assembled position into a flat, parallel orientation, fully collapsed position.

Description

I. CROSS-REFERENCE TO RELATED APPLICATION

Not applicable.

II. FIELD OF THE INVENTION

The present invention relates to shipping containers and, more particularly, to a method and apparatus for collapsing shipping containers.

III. DESCRIPTION OF THE PRIOR ART

Shipping containers have continuously and for a long time been used for the storage and movement of materials and products within a global containerized intermodal freight transport system. The term “intermodal” is used herein to refer to, for example, a container that can be moved from one mode of transport to another (e.g., from ship, to rail, to truck) without unloading and reloading the contents of the container. Lengths of such shipping containers, having a unique ISO 6346 reporting mark, can vary from 8 to 56 feet (2.438 to 17.069 m) and heights from 8 feet (2.438 m) to 9 feet 6 inches (2.896 m), or be in the form of a lighter IATA-defined container for air freight.

The shipping containers are typically filled or packed with materials and products from an originating location and then shipped within the intermodal freight transport system anywhere throughout the world to a desired destination or location. For example, a shipping container may originate in China, be transported by ship to an entry port in the United States, and then transported by rail or truck to the desired destination or location in any city in the United States. At the desired destination or location, the materials and products are removed from the shipping container. The shipping container is then often transported and/or returned empty from the desired destination or location city back to the entry port. As it is not cost effective to ship small numbers of empty shipping containers, these empty shipping containers are typically then stored at the entry port location. The entry port continues to likewise store any and all other incoming empty shipping containers being returned to the entry port. The cost to store all of these empty shipping containers and dedicate areas or land to store these empty shipping containers is extremely expensive especially considering such empty shipping containers may reach well into the hundreds or more. The empty shipping containers received in this entry port are then stored until such time as there is enough empty shipping containers to completely fill a ship, or a ship is available, to return these empty shipping containers from the entry port in the United States back to the originating location of China. As these shipping containers being returned to China are empty and no materials and products are being transported in this shipment, the expensive cost for the use of the ship and this shipment is a expense that is borne by the applicable shipping companies.

Applicant recognizes that, although this process will likely continue to require these empty shipping containers to be transported in such shipments back to the originating location, the total number of empty shipping containers that can be shipped back per shipment is currently limited by the totality of the full sizes of each of the shipping containers and the type of ship used.

As a result, Applicant has solved this current problem and designed a method and apparatus for collapsing shipping containers. With each of these empty shipping containers collapsed, the total number of empty shipping containers that can be shipped back per shipment is now limited only by the totality of the collapsed sizes of each of the empty shipping containers and the type of ship used. This number of collapsed sized, empty shipping containers that can be transported per ship far exceeds the total number of fully sized, empty shipping containers. As a result, the total number of shipments of empty shipping containers transported from the entry ports back to the originating locations is significantly less, achieving:

(1) a cost savings to the entry ports as the empty shipping containers may be stored in its collapsible position resulting in less area or land dedicated for such storage;

(2) a cost savings to the entry ports as a significantly larger number of empty shipping containers can be shipped back to the originating location per shipment resulting in less empty shipping containers to store at the entry port; and

(3) a cost savings to the applicable shipping companies as significantly more empty shipping containers can be shipped back per shipment resulting in much less shipments.

Thus, there is a need and there has never been disclosed Applicant's unique method and apparatus for collapsing shipping containers.

IV. SUMMARY OF THE INVENTION

The present invention is a hollow container or box formed from a top panel, a first side panel, a second side panel, opposed end panels, and a base panel placing the container or box in a fully assembled position. The second side panel is releasably coupled to the base panel and each of the other panels are hingedly coupled to one another. Upon rotating each of the opposed end panels, the top panel, the first side panel, and the second side panel relative to one another and various axis rotation in combination with releasably detaching the second side panel from the base panel, the container or box is transitioned from a fully assembled position into a flat, parallel orientation, fully collapsed position.

V. BRIEF DESCRIPTION OF THE DRAWINGS

The Description of the Preferred Embodiment will be better understood with reference to the following figures:

FIG. 1 is a top perspective view of Applicant's inventive collapsible container.

FIG. 2 is a top perspective view of the container and, in particular, illustrating the pair of doors in a first locked position when the container is in the fully assembled position.

FIG. 2A is a top perspective view of one of a plurality of first latches locking one of the pair of doors to a first side panel of the container.

FIG. 2B is a side perspective view of the latch and, in particular, illustrating the latch in the locked position.

FIG. 3 is a cross-sectional view, taken along line 3-3 of FIG. 2, of the hinge means connecting the pair of doors to a second side panel when the container is in the fully assembled position.

FIG. 4 is a top perspective view of the container in the first phase of collapsing the container and, in particular, illustrating the pair of doors being rotated through ninety degrees (90°) and then through one hundred and eighty degrees (180°) from the first locked position when the container is in the fully assembled position and in the process toward a second locked position as the container is being collapsed toward a fully collapsed position.

FIG. 5 is a cross-sectional view, taken along line 5-5 of FIG. 4, of the hinge means connecting the pair of doors to the first side panel of the container when the pair of doors is rotated ninety degrees (90°) from the first locked position when the container is in the first phase of collapsing the container.

FIG. 6 is a cross-sectional view, taken along line 6-6 of FIG. 4, of the hinge means connecting the pair of doors to the second side panel of the container when the pair of doors is rotated one hundred and eighty degrees (180°) from the first locked position when the container is in the first phase of collapsing the container.

FIG. 7 is a top perspective view of the collapsible container and, in particular, illustrating the pair of doors in the second locked position when the container is in the first phase of collapsing the container.

FIG. 7A is a top perspective view of one of a plurality of second latches locking one of the pair of doors to the second side panel of the container.

FIG. 8 is a cross-sectional view, taken along line 8-8 of FIG. 7, of the hinge means connecting the pair of doors to the second side panel of the container when the pair of doors is rotated through two hundred and seventy degrees (270°) and situated in the second locked position when the container is in the first phase of collapsing the container.

FIG. 9 is top perspective view of the of the hinge means connecting the pair of doors to the second side panel of the container when the pair of doors is rotated through two hundred and seventy degrees (270°) and in the second locked position when the container is in the first phase of collapsing the container.

FIG. 10 is a top perspective view of the securing means for securing the second side panel to the base panel of the container.

FIG. 10A is a bottom perspective view of the tubular extension and, in particular, illustrating the inward taper of each of the sides.

FIG. 11 is a top perspective view of the container in the second phase of collapsing the container.

FIG. 12 is an end perspective view of the container as the container continues to be collapsed during the second phase of collapsing the container.

FIG. 13 is an end perspective view of the container in the third and final phase of collapsing the container.

FIG. 14 is an end perspective view of the container as the container continues to be collapsed during the third and final phase of collapsing the container.

FIG. 15 is a side perspective view of the container in the third and final phase of collapsing the container.

VI. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Turning first to FIG. 1, there is illustrated Applicant's inventive collapsible container 20 (also referred to herein as “container 20”). In the preferred embodiment, the container 20 is an intermodal shipping container or box and, in particular, a container used for the storage and movement of materials and products within a global containerized intermodal freight transport system. The term “intermodal” is used herein to refer to a container that can be moved from one mode of transport to another (e.g., from ship, to rail, to truck) without unloading and reloading the contents of the container. Lengths of containers, having a unique ISO 6346 reporting mark, can vary from 8 to 56 feet (2.438 to 17.069 m) and heights from 8 feet (2.438 m) to 9 feet 6 inches (2.896 m). Alternatively, the container 20 may be a lighter IATA-defined container for air freight and/or any other type, size, or shape of container known to one skilled in the art provided that the container is assembled, collapsed, and used in the manner described herein.

In the preferred embodiment, the container 20 comprises a top panel 22, a base panel 24 (see also FIG. 4), a first side panel 26 (see also FIG. 4), a second side panel 28, and end panels 30 and 32. At the corners of the container 20 are castings 34 each having a plurality of openings 36 for twistlock fasteners to lock the container 20 into place on a ship, railway train, or truck; and/or for lifting of the container 20 by container cranes and sidelifters when collapsing the container from a fully assembled position to a fully collapsed position as described in more detail herein.

The container 20 is preferably manufactured of a reusable steel and the first side panel 26, the second side panel 28, and the end panels 30 and 32 are preferably each substantially constructed of a corrugated weathering steel 38. A representation illustrating the corrugated weathering steel 38 is illustrated in FIG. 1. Alternatively, it is contemplated that the container 20 and the top panel 22, the base panel 24, the first side panel 26, the second side panel 28, and the end panels 30 and 32 may each be manufactured of any material known to one skilled in the art provided that the material used for each is of sufficient strength and durability to accomplish Applicant's invention described herein.

The top panel 22 is hingedly connected to the first side panel 26 by a first hinge means 40. In the preferred embodiment, the first hinge means 40 comprises a double hinge 44 as described in further detail herein. In the non-limiting example as illustrated, there are five (5) double hinges 44, equally spaced apart, that are used to hingedly connect the top panel 22 to the first side panel 26. Alternatively, the total number of double hinges 44 used to connect the top panel 22 to the first side panel 26 may be more or less depending upon the type, size, or shape of container 20 used.

The top panel 22 is also hingedly connected to the second side panel 28 by a second hinge means 42. In the preferred embodiment, the second hinge means 42 is a single hinge 46. The single hinge 46 is preferably a butt hinge or any other type of single hinge that may be used in the manner as described herein. In the non-limiting example as illustrated, there are five (5) single hinges 46, equally spaced apart, that are used to hingedly connect the top panel 22 to the second side panel 28. Alternatively, the total number of single hinges 46 used to connect the top panel 22 to the second side panel 28 may be more or less depending upon the type, size, or shape of container 20 used.

The first side panel 26 is hingedly connected to the base panel 24 by a third hinge means 120 (as illustrated in FIG. 4). In the preferred embodiment, the third hinge means 120 comprises a double hinge 122 as described in further detail herein. In the non-limiting example as illustrated, there are five (5) double hinges 122, equally spaced apart, that are used to hingedly connect the first side panel 26 to the base panel 24. Alternatively, the total number of double hinges 122 used to connect the first side panel 26 to the base panel 24 may be more or less depending upon the type, size, or shape of container 20 used. As a further alternative, the third hinge means 120 may be a single hinge provided that it accomplishes the use as described herein.

Doors 48 (see also FIG. 4) and 50 preferably form each of the end panels 30 and 32, respectively, and extend substantially the length 52 (see also FIG. 4) between the top panel 22 and the base panel 24. In the preferred embodiment, each of the doors 48 and 50 are secured to the first side panel 26 by a first latching means 54. In the preferred embodiment, the first latching means 54 is more clearly illustrated in FIGS. 2A and 2B.

The first latching means 54, as illustrated in FIGS. 2A and 2B, comprises a bracket 56, a latch chamber 58, a latch lever 60, a latch bolt 62, and a receiving cylinder 64. In the preferred embodiment, a weld 66 secures the bracket 56 to the first side panel 26. Alternatively, the means for securing the bracket 56 to the first side panel 26 may include but is not limited to being integrally molded or manufactured into the first side panel 26 or any other means known to one skilled in the art.

The latch chamber 58 is fixedly secured to the bracket 56 and is an elongated cylindrical member having an internal hollow passageway 72 and a slot 68 extending along the exterior of the latch chamber 58. The slot 68, as illustrated in FIG. 2B, also provides recesses 78 and 80. The latch lever 60 is an elongated, cylindrical member of sufficiently smaller size to be contained within the hollow passageway 72 of the latch chamber 58 and provides a latch head 70 that extends from the latch lever 60 outwardly and through the slot 68 of the latch chamber 58.

In use, the latch lever 60 is manually articulated between a locked position 76 and an unlocked position 74 relative to the latch chamber 58, as illustrated in FIG. 2B. To lock the doors 48 and 50 to the first side panel 26, the latch lever 60 is articulated through the hollow passageway 72 of the latch chamber 58. As the latch lever 60 is articulating through the hollow passageway 72, the latch head 70 is likewise traversing along the slot 68. When the latch head 70 reaches adjacent to the recess 80, the latch lever 60 is rotated axially within the hollow passageway 72 such that the latch head 70 is appropriately positioned and received into the recess 80. When this occurs, the latch bolt 62, which is an extension of the latch lever 60, is extended outwardly from the latch chamber 58 and received into the receiver cylinder 64 which is fixedly secured to the exterior side of the door 50. In this manner, the first latching means 54 locks or secures the doors 48 and 50 to the first side panel 26 and is referred to herein as the locked position 76.

To unlock the doors 48 and 50 from the first side panel 26, the latch lever 60 is lifted to release the latch head 70 from the recess 80, rotated axially, and in the opposite direction, within the hollow passageway 72 and then articulated through the hollow passageway 72 of the latch chamber 58 in a direction away from the recess 80. As the latch lever 60 is articulating through the hollow passageway 72, the latch head 70 is likewise traversing along the slot 68. When the latch head 70 reaches adjacent the recess 78, the latch lever 60 is again rotated axially within the hollow passageway 72 such that the latch head 70 is appropriately positioned and received into the recess 78. When this occurs, as the latch lever 60 is articulating through hollow passageway 72 of the latch chamber 58 toward the location of the recess 78, the latch bolt 62, which is an extension of the latch lever 60, is retracted back into the latch chamber 58 and thereby removed from the receiver cylinder 64. In this manner, the first latching means 54 unlocks the doors 48 and 50 from the first side panel 26 and is referred to herein as the unlocked position 74.

Referring back to FIG. 1, in the non-limiting example as illustrated, there are three (3) first latching means 54, equally spaced apart, that are used to secure (i.e, lock and unlock) each of the doors 48 and 50 to and from the first side panel 26. Alternatively, the total number of first latching means 54 used to secure either of the doors 48 and 50 to and from the first side panel 26 may be more or less depending upon the type, size, or shape of container 20 used.

Each of the doors 48 and 50 are hingedly connected to the second side panel 28 by a fourth hinge means 82. In the preferred embodiment, the fourth hinge means 82 comprises a double hinge 84 as described in further detail herein. The double hinge 84 is preferably the exact same as the double hinge 44 and the double hinge 122. In the non-limiting example as illustrated, there are three (3) double hinges 84, equally spaced apart, that are used to hingedly connect each of the doors 48 and 50 to the second side panel 28. Alternatively, the total number of double hinges 84 used to connect the doors 48 and 50 to the second side panel 28 may be more or less depending upon the type, size, or shape of container 20 used.

The fourth hinge means 82 comprising the double hinge 84 is more clearly illustrated in FIG. 3. As illustrated in FIG. 3, the double hinge 84 comprises a first pin 124, a first mounting bracket 126, a second pin 128, a second mounting bracket 130, and an interconnecting bracket 132. Preferably, the first pin 124 and the second pin 126 comprise a pin 134 rotatably secured within a barrel 136 to form a knuckle. Alternatively, the first pin 124 and the second pin 126 may be any other type of rotatable pin provided that it is used in the manner described herein.

In the preferred embodiment, the first mounting bracket 126 and the second mounting bracket 130 are each fixedly secured to the door 48 and the second side panel 28, respectively, by welding. Alternatively, the means for fixedly securing the first mounting bracket 126 and the second mounting bracket 130 to the door 48 and the second side panel 28, respectively, may include but is not limited to being integrally molded or manufactured into the door 48 and the second side panel 28, respectively, or any other means known to one skilled in the art.

In the preferred embodiment, a mortise 138 is provided in each of the door 48 and the second side panel 28 to receive and fixedly secure the double hinge 84. In this manner, the double hinge 84 is recessed within the container 20 and, more particularly, the first pin 124 and the second pin 128 remain inside the mortise 138 and preferably flush and aligned with the exterior of the door 48 and second side panel 28 without extending outwardly or beyond of the exterior of the door 30 or second side panel 28.

The second side panel 28 is secured to the base panel 24 by a securing means 86. In the non-limiting example as illustrated, there are five (5) securing means 86, equally spaced apart, that are used to secure or releasably attach the second side panel 28 to the base panel 24. Alternatively, the total number of securing means 86 used to connect the second side panel 28 to the base panel 24 may be more or less depending upon the type, size, or shape of container 20 used.

As the securing means 86 is more clearly illustrated in FIG. 10, reference is made to this FIG. 10 to describe the securing means 86. The securing means 86 comprises an external tubular extension 88 fixedly secured to the second side panel 28, a tubular support post 90 contained within the base panel 24, and a securing pin 92.

The tubular extension 88 is preferably rectangular in shape having sides 94 forming substantially the same square cross-section as the tubular support post 90. Each of the sides 94 are designed to taper inwardly from a proximal end 96 to a distal end 98 and is provided with holes 100 situated through two of the opposed sides 94.

The tubular support post 90 is likewise preferably rectangular in shape having interior perpendicular sides 102 and providing a hollow center 104. The tubular support post 90 is situated within or inside a C-shaped channel 106 in the base panel 24. Holes 112 are also situated in the tubular support post 90 between two of the opposed interior perpendicular sides 102. In the preferred embodiment, the holes 112 are situated on the interior perpendicular sides 102 corresponding with the opposed sides 94 containing the holes 100 in the tubular extension 88.

In the preferred embodiment, the square cross-section of the tubular extension 88 (as measured from the exterior) preferably has a height and width which is slightly less than the height and width of the tubular support post 90 (as measured from the interior) or, in other words, is slightly less than the height and width of the hollow center 104 formed within the tubular support post 90 between the interior perpendicular sides 102. In this manner, the tubular extension 88 may releaseable traverse or freely move lengthwise into, within, and through the hollow center 104 of the tubular support post 90. Additionally, due to the minor tolerances or differences in height and width between these tubular members, the square cross-sectional shape of interior perpendicular sides 102 of the tubular support post 90 will forceably prevent the square cross-sectional shape of perpendicular sides 94 of the tubular extension 88 from laterally rotating or spinning within the tubular support post 90. In the alternative, should the tubular support post 90 be of any or different shape known to one skilled in the art, the tubular extension 88 should likewise be of substantially the same shape.

As the tubular extension 88 is provided with sides 94 that are inwardly tapered, as described above, this permits easier alignment with and insertion of the tubular extension 88 into the tubular support post 90. Upon the tubular extension 88 being received into the tubular support post 90, the tubular extension 88 releasably traverses or freely moves into, within, and through the hollow center 104 of the tubular support post 90 until the framing bar 108 of the second side panel 28 engages the framing bar 110 of the base panel 24 and the C-shaped channel 106. When this occurs, the tubular extension 88 is substantially situated inside or within the tubular support post 90 and the second side panel 28 is flush or, in direct engagement, with the base panel 24. Likewise, the holes 100 in the opposed sides 94 of the tubular extension 88 becomes aligned with the holes 112 in the opposed sides 102 of the tubular support post 90. Upon this alignment, the securing pin 92 is inserted through the hole 112 (in one of the opposed sides 102 of the tubular support post 90), through the hole 100 (in the adjacent opposed side 94 of the tubular extension 88), completely through the tubular extension 88 and hollow center 104 of the tubular support post 90, and into the corresponding holes 100 and 112 in both the tubular extension 88 and tubular support post 90 (in each of the other of the opposed sides 94 and 102, respectively). In this manner, the securing means 86 locks or secures the second side panel 28 to the base panel 24. Reversing this process thus unlocks the second side panel 28 from the base panel 24.

A guide post 114 is provided to (i) assist in the alignment of the securing pin 92 with the holes 100 of the tubular extension 88 and holes 112 of the tubular support post 90; (ii) provide a stop means to prevent the securing pin 92 from entering any further into the tubular extension 88 and tubular support post 90; and (iii) provide, in combination with a secondary post 116, a means for retaining the securing pin 92 within the C-shaped channel 106 when the second side panel 28 is unlocked from the base panel 24. In this manner, and regardless of what phase the container 20 is in between the fully assembled position and the fully collapsed position, the guide post 114 and secondary post 116 provide a gap 118 to retain the securing pin 92 to the container 20 such that the securing pin 92 is always available for use. Alternatively, any other means for retaining the securing pin 92 within the C-shaped channel 106 when the second side panel 28 is unlocked from the base panel 24 may be used as is known by one skilled in the art.

In the preferred embodiment, the container 20 can be transitioned (also referred to herein as “collapsed”) between a fully assembled position, as illustrated in FIGS. 1-3, through the process illustrated in FIGS. 4-13, to a fully collapsed position, as illustrated in FIGS. 14 and 15. In a non-limiting example, the process to transition or collapse the container 20 from the fully assembled position to the fully collapsed position is described herein in various phases: collectively, a first phase, a second phase, and a third phase. Alternatively, the process to transition or collapse the container 20 from the fully assembled position to the fully collapsed position, although using the same steps as set forth herein, can be referred to and identified as a single phase.

The process to transition or collapse the container 20 from the fully assembled position to the fully collapsed position begins with the first phase. In this first phase, the doors 48 and 50, that are initially locked or secured to the first side panel 26 in the fully assembled position, as illustrated in FIGS. 1 and 2, are unlocked from the first side panel 26. To accomplish this, the first latching means 54 is moved from the locked position 76 to the unlocked position 74, as illustrated in FIGS. 2A and 2B.

As illustrated in FIG. 4, the doors 48 and 50 are each then rotated about the fourth hinge means 82 and, in particular, the double hinge 84. As the doors 48 and 50 are rotated through ninety degrees (90°), as illustrated in FIG. 5: the first mounting bracket 126 remains fixedly secured to the doors 48 and 50 and is rotated through ninety degrees (90°), the doors 48 and 50 are each rotated about the first pin 124 ninety degrees (90°) (i.e., counterclockwise rotation for the door 48 and clockwise rotation for the door 50), the interconnecting bracket 132 remains fixedly secured to and rotating relative to both the first pin 124 and the second pin 128 within the mortise 138, and the second mounting bracket 130 remains fixedly secured in its initial position relative to the second side panel 28.

As illustrated in FIG. 4, the doors 48 and 50 are each then continued to be rotated about the fourth hinge means 82 and, in particular, the double hinge 84. As the doors 48 and 50 are rotated through one-hundred and eighty degrees (180°), as illustrated in FIG. 6: the first mounting bracket 126 remains fixedly secured to the doors 48 and 50 and is rotated through one hundred and eighty degrees (180°), the doors 48 and 50 are each rotated about the first pin 124 one hundred and eighty degrees (180°) (i.e., further counterclockwise rotation for the door 48 and clockwise rotation for the door 50), the interconnecting bracket 132 remains fixedly secured to and rotating relative to both the first pin 124 and the second pin 128 within the mortise 138, and the second mounting bracket 130 remains fixedly secured in its initial position relative to the second side panel 28.

As illustrated in FIG. 7, the doors 48 and 50 are each then continued to be rotated about the fourth hinge means 82 and, in particular, the double hinge 84. As the doors 48 and 50 are rotated through two hundred and seventy degrees (270°), as illustrated in FIGS. 8 and 9: the first mounting bracket 126 remains fixedly secured to the doors 48 and 50 and is rotated through two hundred and seventy degrees (270°), the doors 48 and 50 are each rotated about the first pin 124 one hundred and two hundred and seventy degrees (270°) (i.e., further counterclockwise rotation for the door 48 and clockwise rotation for the door 50), the interconnecting bracket 132 remains fixedly secured to and rotating relative to both the first pin 124 and the second pin 128 and becomes adjacent to and parallel to the first mounting bracket 126 within the mortise 138, the second mounting bracket 130 remains fixedly secured in its initial position relative to the second side panel 28, and the doors 48 and 50 are aligned parallel with the second side panel 28.

In the preferred embodiment, each of the doors 48 and 50 are then secured to the second side panel 28 by a second latching means 140. In the preferred embodiment, the second latching means 140 is more clearly illustrated in FIG. 7A. The second latching means 140, as illustrated in FIG. 7A, comprises a second bracket 142, a second latch chamber 144, a second slot 152, a second latch lever 146, a second latch head 150, a second latch bolt 148, and a second receiving cylinder 154. In the preferred embodiment, the second latching means 140 is secured to the second side panel 28 and the components of the second latching means 140 are used in the same manner as the first latching means 54. In this manner, the second latching means 140 locks or secures the doors 48 and 50 to the second side panel 28 and is referred to herein as the second locked position 156. Alternatively, the second latching means 140 for locking or securing the doors 48 and 50 may be any means known to one skilled in the art.

In the non-limiting example as illustrated in FIG. 7, there is one (1) second latching means 140 that is used to secure (i.e, lock and unlock) each of the doors 48 and 50 to and from the second side panel 28. Alternatively, the total number of second latching means 140 used to secure either of the doors 48 and 50 to and from the second side panel 28 may be more or less depending upon the type, size, or shape of container 20 used.

This completes the first phase of the process to transition or collapse the container 20 from the fully assembled position to the fully collapsed position.

In the second phase, the second side panel 28, that is initially locked or secured to the base panel 24 in the fully assembled position, as illustrated in FIGS. 1 and 2, is unlocked from the base panel 24. To accomplish this, the securing means 86 is moved from the locked position to the unlocked position, as illustrated and described in FIG. 10, to releasably detach the second side panel 28 from the base panel 24.

As illustrated in FIG. 11, using a crane, sidelifter, or any other lifting device (not illustrated) as known to one skilled in the art, a cable 58 from the lifting device is secured or attached to the castings 34 located at the corners of the container 20 for lifting upwardly, in the direction of Arrow A, the top panel 22 and the second side panel 48 of the container 20. As the top panel 22 and the second side panel 48 are being lifted vertically upwardly, in the direction of Arrow A, the second side panel 48 remains in substantially the same vertical orientation as in the fully assembled position.

The top panel 22, however, is being rotated about the second hinge means 42 and, in particular, the single hinge 46, in the direction of Arrow B, toward the second side panel 28. The lifting device continues to lift the container 20 until the top panel 22 is rotated about the second hinge 46 through ninety degrees (90°) in relation to the second side panel 28, as illustrated in FIG. 12. At the same time, when this occurs, the other side of the top panel 22 is likewise rotated about the first hinge means 40 and, in particular, the double hinge 44, also in the direction of Arrow B. When the top panel 22 is rotated about the second hinge 46 through ninety degrees (90°), the other side of the top panel 22 is also rotated about the double hinge 44 in relation to the first side panel 26, as illustrated in FIG. 12. In this manner, upon this rotation, the top panel 22 engages the second side panel 28 and becomes aligned in parallel with and in the same vertical orientation with the second side panel 28.

Additionally and contemporaneously therewith, the first side panel 26 is likewise rotated about the first hinge means 40 and, in particular, the double hinge 44, in the direction of Arrow B, in relation to the top panel 22, as illustrated in FIG. 12.

This completes the second phase of the process to transition or collapse the container 20 from the fully assembled position to the fully collapsed position.

In the third phase, the cable 58 from the lifting device, secured or attached to the castings 34 located at the corners of the container 20, is now lowered downwardly, in the direction of Arrow C. As this occurs, the second side panel 28, the top panel 22, and the first side panel 26 are each continued to be rotated, in the direction or Arrow D, about the double hinge 44, as illustrated in FIG. 13. At the same time, when this occurs, the other side of the first side panel 26 is likewise rotated about the third hinge means 120 and, in particular, the double hinge 122, also in the direction of Arrow D, in relation to the base panel 24, as illustrated in FIG. 13.

As the lifting device continues to be lowered downwardly, in the direction of Arrow C, the second side panel 28, the top panel 22, and the first side panel 26 are each continued to be rotated, in the direction or Arrow D, about the double hinge 44, as illustrated in FIG. 14. In this manner, upon this rotation, the second side panel 28, the top panel 22, the first side panel 26, and the base panel 24 all rotatably engaged to one another, and become aligned in parallel with and in the same horizontal orientation with respect to the base panel 24.

This completes the third and final phase of the process to transition or collapse the container 20 from the fully assembled position to the fully collapsed position. And, the container 20 is now illustrated in the fully collapsed position in FIGS. 14 and 15.

During this process to transition or collapse the container 20 from the fully assembled position to the fully collapsed position: (i) the doors 48 and 50 are each rotated about the fourth hinge means 82 and, in particular, the double hinge 84, through substantially two hundred and seventy degrees (270°); (ii) the top panel 22 is rotated about the second hinge means 42 and, in particular, the single hinge 46, through substantially ninety degrees (90°) in relation to the second side panel 28; (iii) the top panel 22 is further rotated about the first hinge means 40 and, in particular, the double hinge 44, through substantially one hundred and eighty degrees (180°) in relation to the base panel 24; (iv) the first side panel 26 is rotated about the first hinge means 40 and, in particular, the double hinge 44, through substantially ninety degrees (90°) in relation to the top panel 22; (v) the second side panel 28 is rotated about the first hinge means 40 and, in particular, the double hinge 44, through substantially ninety degrees (90°) in relation to the base panel 24; and (vi) the first side panel 26 is rotated about the third hinge means 120 and, in particular, the double hinge 122, through substantially ninety degrees (90°) in relation to the base panel 24.

Upon the container 20 reaching the fully collapsed position, as illustrated in FIGS. 14 and 15, each of the doors 48 and 50, the second side panel 28, the top panel 22, the first side panel 26, and the base panel 24 of the container 20 are also substantially stacked on top of one another in a vertical orientation.

In the preferred embodiment, as the first hinge means 40, the second hinge means 42, the third hinge means 120, the fourth hinge means 82, and securing means 86 are all contained or recessed within the container 20, none of these hinge means or the securing means 86 extend outwardly from the container 20 when the container 20 is in the fully assembled position nor when the container 20 is stacked in the vertical orientation in the fully collapsed position. The resulting benefit is that when this container 20 is transported within the global containerized intermodal freight transport system, possibly stacked on top of or adjacent to other containers 20 during transport, or being moved between other modes of transportation (e.g., from ship, to rail, to truck), in either the fully assembled position or the fully collapsed position, these recessed hinge means and the securing means 86 are not vulnerable to being sheared off, broken, and/or damaged due to engagement or stacking with the other containers 20.

Thus, there has been provided a method and apparatus for collapsing shipping containers. While the invention has been described in conjunction with a specific embodiment, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art in light of the foregoing description. Accordingly, it is intended to embrace all such alternatives, modifications and variations as fall within the spirit and scope of the appended claims.

Claims

1. A collapsible container, comprising:

a top panel, a first side panel, a second side panel, opposed end panels, and a base panel forming a box in a fully assembled position and defining a hollow center;

a first hinge means for attaching the top panel to the first side panel and permitting the top panel to rotate through substantially one hundred and eighty degrees, and the second side panel to rotate through substantially ninety degrees;

a second hinge means for attaching the top panel to the second side panel and permitting the top panel to rotate through substantially ninety degrees;

a third hinge means for attaching the first side panel to the base panel and permitting the first side panel to rotate through substantially ninety degrees;

a fourth hinge means for attaching the opposed end panels to the second side panel and permitting the opposed end panels to rotate through substantially two hundred and seventy degrees; and

whereby, upon the rotation of the top panel, the first side panel, the second side panel, and the opposed end panels through the rotations about the first hinge means, the second hinge means, the third hinge means, and the fourth hinge means, the box is transitioned from the fully assembled position into a fully collapsed position.

2. The collapsible container of claim 1 wherein the first hinge means comprises a first double hinge.

3. The collapsible container of claim 2 wherein the second hinge means comprises a single hinge.

4. The collapsible container of claim 3 wherein the third hinge means comprises a second double hinge.

5. The collapsible container of claim 4 wherein the fourth hinge means comprises a third double hinge.

6. The collapsible container of claim 5 wherein the double hinge in the first double hinge, the second double hinge, and the third double hinge are substantially identical to one another.

7. The collapsible container of claim 1 wherein a first latching means releasably locks the opposed end panels to the first side panel in a first locked position.

8. The collapsible container of claim 7 wherein a second latching means releasably locks the opposed end panels to the second side panel in a second locked position.

9. The collapsible container of claim 1 wherein a securing means releasably locks the second side panel to the base panel.

10. A collapsible container, comprising:

a top panel, a first side panel, a second side panel, opposed end panels, and a base panel forming a box in a fully assembled position and defining a hollow center;

the top panel is hingedly coupled to the first side panel and defining a first axis of rotation;

the top panel is hingedly coupled to the second side panel and defining a second axis of rotation;

the first side panel is hingedly coupled to the base panel and defining a third axis of rotation;

the opposed end panels are hingedly coupled to the second side panel and defining a fourth axis of rotation;

whereby, the box is transitioned from the fully assembled position into a fully collapsed position by:

rotating each of the end panels through substantially two hundred and seventy degrees about the fourth axis of rotation;

rotating the top panel through substantially ninety degrees about the second axis of rotation;

rotating the top panel through substantially one hundred and eighty degrees about the first axis of rotation;

rotating the second side panel through substantially ninety degrees about the first axis of rotation; and

rotating the first side panel through substantially ninety degrees about the third axis of rotation.

11. The collapsible container of claim 10 wherein the second side panel is releasably coupled to the base panel.

12. The collapsible container of claim 10 wherein the first axis of rotation, the second axis of rotation, and the third axis of rotation are parallel to one another.

13. The collapsible container of claim 10 wherein the fourth axis of rotation is perpendicular to the first axis of rotation, the second axis of rotation, and the third axis of rotation.

14. A method for collapsing a container from a fully assembled position to a fully collapsed position, comprising the steps of:

providing a box in the fully assembled position and defining a hollow center formed from a top panel, a first side panel, a second side panel, and opposed end panels each hingedly coupled to one another, the first side panel hingedly coupled to a base panel, and the second side panel releasably coupled to the base panel;

rotating each of the opposed end panels about a first axis of rotation in relation to the second side panel and stacking each of the opposed end panels adjacent to and parallel to the second side panel;

rotating the top panel about a second axis of rotation in relation to the second side panel and stacking the top panel adjacent to and parallel to the second side panel on the opposite side of the opposed end panels;

rotating the top panel about a third axis of rotation in relation to the first side panel and rotating the first side panel about the third axis of rotation in relation to the top panel and stacking the first side panel adjacent to and parallel to the top panel on the opposite side of the second side panel;

rotating the first side panel about a fourth axis of rotation in relation to the base panel and stacking the first side panel adjacent to and parallel to the base panel;

defining the box in the fully collapsed position with the stacking of the opposed end panels on top of the second side panel on top of the top panel on top of the first side panel on top of the base panel.

15. The method of claim 14 and further comprising the step of rotating each of the end panels through substantially two hundred and seventy degrees about the first axis of rotation.

16. The method of claim 14 and further comprising the step of rotating the top panel through substantially ninety degrees about the second axis of rotation.

17. The method of claim 14 and further comprising the step of rotating the top panel through substantially one hundred and eighty degrees about the third axis of rotation.

18. The method of claim 14 and further comprising the step of rotating the first side panel through substantially ninety degrees about the third axis of rotation.

19. The method of claim 14 and further comprising the step of rotating the first side panel through substantially ninety degrees about the fourth axis of rotation.