FOLDABLE CONTAINER

The invention provides a foldable container wherein: the container comprises: a base; a pair of opposing first side walls; a pair of opposing second side walls; each of the side walls is attached to the base by a separate hinge joint; the foldable container is made from a polymer; further comprising: a pair of foldable flaps, each attached to an upper edge of each of the first side walls by a hinge joint; repeatable locking mechanism configured to lock each of the foldable flaps against at least one side walls; wherein at least one first side wall is each attached to an adjacent second side wall by a mechanical transmission; and, wherein each foldable flap clamps at least one mechanical transmission against at least one side wall, by the repeatable locking mechanism in the deployed state.

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Description
FIELD OF THE INVENTION

The invention relates to a foldable container and more particularly a foldable container that can be reused. The foldable container may be suitable for holding goods in the deployed state and after the goods have been unloaded from the foldable container, the volume of the foldable container can be reduced by folding the container into a collapsed state, which is preferably essentially flat.

BACKGROUND OF THE INVENTION

Foldable containers, such as a foldable box or foldable crate, already exist in the art. However, these foldable containers require many manipulations to fold the container form a deployed state to a collapsed state and vice versa. The weight that the foldable container can hold is often limited, this by the construction of the foldable container or by the mechanism holding the foldable container in the deployed state. Often, these foldable containers are made from different parts, which complicate construction. Often, the connection between two different parts is a weak point in the container, and extra care in the design, use or construction need to be taken to overcome these weaknesses. Often, the foldable container can lose its stability in the deployed state when lifted, when the load is too heavy or the load moves inside the container.

Because of these shortcomings with the current foldable containers, foldable containers are hardly used in industrial settings or retail setting, especially where a durable, steady container is required to hold heavier loads.

SUMMARY OF THE INVENTION

There is a demand for foldable container which can be reused multiple times; which is durable; which is robust; which can hold heavy loads; which is easy to manipulate; which can be folded from a collapsed state to a deployed state, or vice versa, with a limited number of manipulations, preferably in one fluent movement; which can be folded from a collapsed state to a deployed state, or vice versa, without having to change the grip during the folding process; which are stable in the deployed state; which are essentially flat in the collapsed state; which can be easily manufactured; which can be manufactured in a single piece. Especially for retail, like vegetable retail, there is a demand for a reusable container, which can be folded flat and be sent back to the supplier after the good have been sold or unloaded. However, such a foldable container need to be stable, can hold heavy loads and need to be able to be folded with a minimum of manipulations, and this with only applying a small force to change from the deployed state to the collapsed state, or vice versa, ensuring a high user comfort for a professional who will have to use many of these container when carrying out his job.

It is accordingly one of the objects of the present invention to overcome or ameliorate one or more of the aforementioned disadvantages present in the market, or to meet any of the demands that are present in the market.

The present inventors have now surprisingly found that one or more of these objects can be obtained by providing a foldable container, having a collapsed state (2) and a deployed state (1), said container having a substantially cuboid form in the deployed state (1) wherein:

    • the container in the deployed state (1) comprises:
      • a base (3);
      • a pair of opposing first side walls (4, 5), extending from the base (3);
      • a pair of opposing second side walls (6, 7), extending from the base (3);
      • an container opening (31) opposed to the base (3); and,
    • each of the side walls (4, 5, 6, 7) is attached to the base (3) by a separate hinge joint.

In some embodiments, the foldable container is preferably made from a polymer, preferably a synthetic polymer, more preferably polypropylene (PP), polyethylene (PE), acrylonitrile butadiene styrene (ABS), polyvinylchloride (PVC), polystyrene (PS), polymethylmethacrylate (PMMA), and/or polylactic acid (PLA).

In some embodiments, the foldable container further comprises:

    • a pair of foldable flaps (8, 9), each attached to an upper edge (10, 11) of each of the pair of first side walls (4, 5) by a hinge joint;
    • repeatable locking mechanism configured to dismountably lock each of the foldable flaps (8, 9) against at least one side walls (4, 5, 6, 7), thereby stabilising the deployed state (1).

More particularly, the above mentioned objects can be obtained by providing a foldable container, having a collapsed state (2) and a deployed state (1),

said container having a substantially cuboid form in the deployed state (1) wherein:

    • the container in the deployed state (1) comprises:
      • a base (3);
      • a pair of opposing first side walls (4, 5), extending from the base (3);
      • a pair of opposing second side walls (6, 7), extending from the base (3);
      • an container opening (31) opposed to the base (3);
    • each of the side walls (4, 5, 6, 7) is attached to the base (3) by a separate hinge joint;
    • the foldable container is made from a polymer, preferably a synthetic polymer, more preferably polypropylene (PP), polyethylene (PE), acrylonitrile butadiene styrene (ABS), polyvinylchloride (PVC), polystyrene (PS), polymethylmethacrylate (PMMA), and/or polylactic acid (PLA);
    • further comprising:
      • a pair of foldable flaps (8, 9), each attached to an upper edge (10, 11) of each of the first side walls (4, 5) by a hinge joint;
      • repeatable locking mechanism configured to dismountably lock each of the foldable flaps (8, 9) against at least one side walls (4, 5, 6, 7), thereby stabilising the deployed state (1);

wherein at least one first side wall (4, 5), preferably both first side walls (4, 5) is each attached to an adjacent second side wall (6, 7) by a mechanical transmission (22, 23, 24, 25) for transfer of force from the pair of opposing first side walls (4, 5) to the pair of opposing second side walls (6, 7) during transition between the collapsed state (2) and the deployed state (1); and,

wherein each foldable flap (8, 9) clamps at least one, preferably at least two mechanical transmission (22, 23, 24, 25) against at least one side wall (4, 5, 6, 7), when said foldable flap is locked against at least one of the sidewalls (4, 5, 6, 7), by the repeatable locking mechanism in the deployed state (1).

In some embodiments, the locking mechanism comprises two pairs of repeatable catches, RC, each comprising a first RC element (13) and second RC element (12), wherein:

    • an application of an external force stabilises (or destabilises) an attachment of the first RC element (13) to second RC element (12),
    • the first RC elements (12) are provided on each foldable flap (8, 9),
    • the second RC elements (13) are provided on the at least two of the side walls (4, 5, 6, 7), preferably on at least two opposing side walls (4,5; or, 6,7),
    • the first RC element (13) and second RC element (12) are configured such that they are stably mutually attached when the foldable flaps (8, 9) are folded or pivoted inwardly.

In some embodiments, the second RC element (12) comprises a receiving element (16) and the first RC element (13) comprises a complementary protruding element (17), and the receiving element (16) is dismountably attachable (or detachable) with the complementary protruding element (17) by application of an external force (29).

In some embodiments, each side wall (4, 5, 6, 7) comprises at least one, preferably at least two guiding elements (32), wherein in the deployed state (1) each guiding element (32) engages with a guiding element (32) of the neighbouring side wall (4, 5, 6, 7).

In some embodiments, the receiving element (16) comprises an opening, suitable for receiving the protruding element (17), preferably pointing upwards in the deployed state (1). In some embodiments, the receiving element (16) comprises a solid section, said solid section preferably spanning the lower half of the receiving element (16), the lower half being defined in the deployed state (1). In some preferred embodiments, the receiving element comprises an open slot, preferably wherein the opening of the slot is oriented upwards when the container is in the deployed state (1). A lower portion of the slot dismountably engages with the protruding element (17) for instance by friction, or using a spring latching mechanism. This way, the direction of opening the locking mechanism is opposite to the direction of the gravitational pull when lifting up the container. This way, the gravitational pull is not able to open the locking mechanism. This allows for a locking mechanism that can be opened by a light force, essentially opposite of the gravitational pull, but where the container itself can hold a heavy load. In a preferred embodiment, the pair of opposing second side walls (6, 7) each comprise the receiving element (16) and the handles or handle openings (20, 21), preferably the receiving element is a bracket.

In some embodiments:

    • the base (3),
    • the pair of opposing first side walls (4, 5),
    • the pair of opposing second side walls (6, 7), and
    • optionally the pair of foldable flaps (8, 9),

are made from a single piece and the hinge joints are preferably living hinges.

This facilitates the construction of the foldable container. It also joins the joints permanently to the base and side walls, resulting in a stronger construction, making it possible to carry heavier load inside the container.

In some embodiments, the single piece is an injection moulded piece. Multiple injection points may be use to injection mould the single piece. The single piece may be a sheet-like structure.

In some embodiments, the injection moulding is single shot injection moulding.

In some embodiments, the side walls (6, 7) of the pair of second side walls comprise handles or handle openings (20, 21).

In some embodiments, the foldable container is configured such that upon transitioning from the deployed state (1) to the collapsed state (2) the pair of opposing first side walls (4, 5) fold outwards and the pair of opposing second side walls (6, 7) fold inwards.

In some embodiments, the foldable container is configured such that movement of the pair of opposing first side walls (4, 5) relative to the base (3) around the connecting hinge actuates movement of the pair of opposing second side walls (6, 7) around the connecting hinge relative to the base (3).

In some embodiments, at least one first side wall (4, 5), preferably both first side walls (4, 5) is each attached to an adjacent second side wall (6, 7) by a mechanical transmission (22, 23, 24, 25) for transfer of force from the pair of opposing first side walls (4, 5) to the pair of opposing second side walls (6,7), or vice versa, during transition between the collapsed state (2) and the deployed state (1). This allows that the container can be transitioned between the collapsed state and the deployed state by only manipulating one pair of side walls, and preferably by one fluent manipulation. The mechanical transmission may also reinforce the foldable container.

In some embodiments, each transmission (22, 23, 24, 25) comprises a non-elastic member attached at one end to a first side wall (4, 5) and at the other end to an adjacent second side wall (6, 7).

In some embodiments, the collapsed state (2) has a flattened form, optionally rectangular, such as oblong or square.

In some embodiments, the foldable container in the deployed state (2) is stackable with another foldable container in the deployed state (2).

In some embodiments, locating lugs protrudes from the collapsed state making the foldable container stackable in the collapsed state.

In some embodiments, the locating lugs prevent sliding of foldable containers relative to each other when these containers are stacked on top of each other in the collapsed state.

The invention further provides a method for manufacturing a foldable container, comprising the steps of:

    • injection moulding a single piece, wherein said single piece comprises a base (3), and two pairs of opposing side walls (4, 5, 6, 7), mechanical transmission (22, 23, 24, 25) and optionally foldable flaps (8, 9); wherein the side walls (4, 5, 6, 7) are attached to the base (3) via hinges, preferably living hinges (26) and each mechanical transmission is attached to a side wall via hinge, preferably a living hinge;
    • attaching, preferably irreversible attaching, the mechanical transmission (22, 23, 24, 25) to an adjacent side wall (4, 5, 6, 7).

Preferably, the method is suitable for manufacturing a foldable container according to an embodiment of the invention.

Preferred embodiments of the invention are disclosed in the detailed description and appended claims. In the following passages different aspects of the invention are defined in more detail. Each aspect so defined may be combined with any other aspect or aspects unless clearly indicated to the contrary. In particular, any feature indicated as being preferred or advantageous may be combined with any other feature or features indicated as being preferred or advantageous. (Preferred) embodiments of one aspect of the invention are also (preferred) embodiments of all other aspects of the invention.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 provides a view of the foldable container in the deployed state (1) according to an embodiment of the invention.

FIG. 2 provides a view of the foldable container in the collapsed state (2) according to an embodiment of the invention.

FIG. 3 provides a view of the foldable container in the extruded state (27) according to an embodiment of the invention.

FIG. 4 illustrates the opening of the locking mechanism of the foldable container according to an embodiment of the invention.

FIG. 5 illustrates the transition of the foldable container according to an embodiment of the invention from the deployed state (1) to the collapsed state (2).

FIG. 6 provides a detail view of the locking mechanism.

FIG. 7 provides a view of the foldable container in the deployed state (1) according to an embodiment of the invention.

FIG. 8 provides a view of the foldable container in the collapsed state (2) according to an embodiment of the invention.

FIG. 9 provides a view of the foldable container in the extruded state (27) according to an embodiment of the invention.

FIG. 10 provides a cross section of a locking mechanism in sidewall (5).

 DETAILED DESCRIPTION OF THE INVENTION

When describing the invention, the terms used are to be construed in accordance with the following definitions, unless a context dictates otherwise.

Reference throughout this specification to “one embodiment” or “an embodiment” means that a particular feature, structure or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, appearances of the phrases “in one embodiment” or “in an embodiment” in various places throughout this specification are not necessarily all referring to the same embodiment, but may. Furthermore, the particular features, structures or characteristics may be combined in any suitable manner, as would be apparent to a person skilled in the art from this disclosure, in one or more embodiments. Furthermore, while some embodiments described herein include some but not other features included in other embodiments, combinations of features of different embodiments are meant to be within the scope of the invention, and form different embodiments, as would be understood by those in the art.

As used in the specification and the appended claims, the singular forms “a”, “an,” and “the” include plural referents unless the context clearly dictates otherwise. By way of example, “a container” means one container or more than one container.

Unless defined otherwise, all technical and scientific terms used herein have the same meaning as is commonly understood by one of skill in the art. All publications referenced herein are incorporated by reference thereto.

Throughout this application, the term ‘about’ is used to indicate that a value includes the standard deviation of error for the device or method being employed to determine the value.

The recitation of numerical ranges by endpoints includes all integer numbers and, where appropriate, fractions subsumed within that range (e.g. 1 to 5 can include 1, 2, 3, 4 when referring to, for example, a number of elements, and can also include 1.5, 2, 2.75 and 3.80, when referring to, for example, measurements). The recitation of end points also includes the end point values themselves (e.g. from 1.0 to 5.0 includes both 1.0 and 5.0). Any numerical range recited herein is intended to include all sub-ranges subsumed therein.

In the present description, reference is made to the accompanying drawings that form a part hereof, and in which are shown by way of illustration only of specific embodiments in which the invention may be practiced. Parenthesized or emboldened reference numerals affixed to respective elements merely exemplify the elements by way of example, with which it is not intended to limit the respective elements. It is to be understood that other embodiments may be utilised and structural or logical changes may be made without departing from the scope of the present invention. The following detailed description, therefore, is not to be taken in a limiting sense.

The invention provides in a foldable container, having a collapsed state (2) and a deployed state (1), said container having a substantially cuboid form in the deployed state (1) wherein:

    • the container in the deployed state (1) comprises:
      • a base (3);
      • a pair of opposing first side walls (4, 5), extending from the base (3);
      • a pair of opposing second side walls (6,7), extending from the base (3);
      • an container opening (31) opposed to the base (3);
    • each of the side walls (4, 5, 6, 7) is attached to the base (3) by a separate hinge joint.

More particularly, the invention provides a foldable container, having a collapsed state (2) and a deployed state (1),

said container having a substantially cuboid form in the deployed state (1) wherein:

    • the container in the deployed state (1) comprises:
      • a base (3);
      • a pair of opposing first side walls (4, 5), extending from the base (3);
      • a pair of opposing second side walls (6, 7), extending from the base (3);
      • an container opening (31) opposed to the base (3);
    • each of the side walls (4, 5, 6, 7) is attached to the base (3) by a separate hinge joint;
    • the foldable container is made from a polymer, preferably a synthetic polymer, more preferably polypropylene (PP), polyethylene (PE), acrylonitrile butadiene styrene (ABS), polyvinylchloride (PVC), polystyrene (PS), polymethylmethacrylate (PMMA), and/or polylactic acid (PLA);
    • further comprising:
      • a pair of foldable flaps (8, 9), each attached to an upper edge (10, 11) of each of the first side walls (4, 5) by a hinge joint;
      • repeatable locking mechanism configured to dismountably lock each of the foldable flaps (8, 9) against at least one side walls (4, 5, 6, 7), thereby stabilising the deployed state (1);

wherein at least one first side wall (4, 5), preferably both first side walls (4, 5) is each attached to an adjacent second side wall (6, 7) by a mechanical transmission (22, 23, 24, 25) for transfer of force from the pair of opposing first side walls (4, 5) to the pair of opposing second side walls (6, 7) during transition between the collapsed state (2) and the deployed state (1); and,

wherein each foldable flap (8, 9) clamps at least one, preferably at least two mechanical transmission (22, 23, 24, 25) against at least one side wall (4, 5, 6, 7), when said foldable flap is locked against at least one of the sidewalls (4, 5, 6, 7), by the repeatable locking mechanism in the deployed state (1).

The term “foldable container” refers to a container which can be folded into a deployed state (1) starting from a collapsed state (2) and vice versa and this multiple times, preferably there are reversible stabilisation means, such as a reversible locking mechanism which stabilise the foldable container in the deployed state (1). Preferably, the foldable container is a foldable box or a foldable crate.

The fact that the side walls are connected to the base each via a hinge joint has the advantage that a strong connection can be established between the side walls and the base. This avoids connection of the side walls to the base via locking mechanisms, as in other foldable containers in the art. This allows for the container being able to hold heavier loads, as the load is no longer limited by the strength of the locking mechanism, but by the strength of the hinge joint. In some embodiments the hinge joints are non-dismountable, whereas the locking mechanism in the prior art is often repeatably engageable, and hence more subjective to opening under the load carried in the container.

In some embodiments, the foldable container is made at least partially, preferably entirely from a polymer, preferably a synthetic polymer, more preferably polypropylene (PP), polyethylene (PE), acrylonitrile butadiene styrene (ABS), polyvinylchloride (PVC), polystyrene (PS), polymethylmethacrylate (PMMA), and/or polylactic acid (PLA). This makes it possible to use the foldable container in multi way applications.

The term “cuboid” refers to a rectangular box, which can be oblong or square, rectangular cuboid, right cuboid or a rectangular hexahedron all fall under the more general term “cuboid”.

In some embodiments, the foldable container may be repeatably transitionable between the collapsed state (2) and the deployed state (1) by application of an external force (29).

In some embodiments, the base (3) is planar preferably the base (3) is rectangular. In some embodiments, each first side wall (4, 5) is planar, preferably each first side wall (4, 5) is rectangular. In some embodiments, each second side wall (6, 7) is planar, preferably each second side wall (6, 7) is rectangular.

In some embodiments, the base (3), each side wall (4, 5) of the pair of opposing first side walls and each side wall (6, 7) of the pair of opposing second side walls are all planar, preferably the base (3), each side wall (4, 5) of the pair of opposing first side walls and each side wall (6, 7) of the pair of opposing second side walls are all rectangular.

In some embodiments, the base comprises reinforcement elements, preferably in a grid like pattern, more preferably in a grid like pattern, wherein the grid is made up of straight lines in one direction and Curved lines in the other direction.

In some embodiments, the sidewalls may comprise openings and/or cut-outs.

In some embodiments, the foldable container further comprises:

    • a pair of foldable flaps (8, 9), each attached to an upper edge (10, 11) of each first side wall (4, 5) of the pair by a hinge joint;
    • repeatable locking mechanism configured to dismountably lock the each of the foldable flaps (8, 9) against each second first wall (4,5), thereby stabilising the deployed state (1).

In some embodiments, the foldable container further comprising:

    • a pair of foldable flaps (8, 9), each attached to an upper edge (10, 11) of each first side wall (4, 5) of the pair by a hinge joint;
    • repeatable locking mechanism configured to dismountably lock the each of the foldable flaps (8, 9) against each second side wall (6, 7), thereby stabilising the deployed state (1).

The term “repeatable” refers to the ability of elements to be attached and detached a plurality of times.

The term “dismountable” refers to the attachment between elements being temporary but stable. The elements can be detached by the application of force.

In some embodiments, when the foldable flaps (8, 9) are folded over or in the container opening (31), and the locking mechanism engaged, the foldable flaps (8, 9) may only partially occlude the container opening (31) in the deployed state. A lid may be provided attached the foldable flaps or to a side wall which occludes the container opening (31). Alternatively, a lid may be provided that is not attached to any parts of the foldable container, but fits inside the container opening (31) or fits over the container opening (31), or fits over the upper section of the foldable container.

In some embodiments, the repeatable locking mechanism comprises one, two, three, four or more repeatable catches (RC). In a more preferred embodiment, the repeatable locking mechanism comprises two or four repeatable catches.

The term “foldable flap” may refer to a longitudinal body, which is preferably rigid. Reinforcement elements, such as ribs, ridges or honeycomb structures, may be present on the foldable flap to provide rigidity. The foldable flap may be a bar or preferably a plate material, this last one having the advantage that the container opening is not partially blocked in the deployed state (1).

In some embodiments, the foldable flap (8, 9) is ridged. In some embodiments, the foldable flaps (8, 9) span the length of a first side wall (4, 5).

Is some embodiments, a first RC element (13) a second RC element (12) form the RC. The first and second RC element may be configured such that they are stably mutually attached when the foldable flap (8, 9) is folded or rotated inwards, inwards meaning that the foldable flaps are folded or rotated over and/or in the container opening (31).

In some embodiments, the first RC element (13) and second RC element (12) are configured such they are become mutually detached when the foldable flap (8, 9) is folded or rotated outwards. The term “deployed state (1) of the container” refers to the state wherein the container is intending to fulfil its function of holding goods. In the deployed state the base, the pair of opposing first side walls and the pair of opposing second side walls define a holding volume, which may be used to hold goods. The container has a container opening (31) opposed to the base (3), opposed to the base through which goods are passed into the holding volume. “Up” “upwards” or “upper” refers to the direction of the container opening (31) in the deployed state. “Down” or “lower” refer to the direction of the base in the deployed state (1).

The “upper edge of a side wall”, is preferably the upper 25%, more preferably the upper 20%, even more preferably the upper 15%, yet more preferably the upper 10% and most preferably the upper 5% of a side wall in the deployed state.

The term “folding inwards” refers to the side walls folding towards the inside of the internal volume of the container defined in the deployed state.

The term “folding outwards” refers to the side walls folding towards the outside of the internal volume of the container defined in the deployed state.

The term “opposing side walls” refers to side walls that face each other in the deployed state. The opposing side walls may be perpendicular to each other in the deployed state. Side walls that are opposing side walls in the deployed state are herein still called opposing side walls in the collapsed state or any intermediate state between the collapsed state and deployed state. There are preferably two pairs of opposing side walls, a pair of opposing first side walls (4, 5) and a pair of opposing second side walls (6, 7). Preferably, a first side wall (4, 5) is adjacent to a second side wall (6, 7) in the deployed state (1).

In some embodiments, the foldable flap (8, 9) comprises at least one longitudinal rib, preferably is the foldable flap attached to the hinge joint at the upper edge of the side wall. In some embodiments, the foldable flap (8, 9) hinged around one of its longitudinal ribs.

In some preferred embodiment, when the foldable flaps (8, 9) are folded or rotated inwards to engage the locking mechanism, a protruding element (17) enters a receiving element (16) from the opposite direction of the gravitational pull or perpendicular to the gravitational pull when the container is held by the handles or handle openings in the deployed state (1). Therefore, gravity pulls in the wrong direction to unlock the locking mechanism when the container is handled, preferably in an upright orientation or handled by both handles.

In some embodiments, the foldable flap comprises at least one or two first RC elements (13), which comprises a protruding element (17), such as a pin, a node, a hook, or a bar. In some embodiments, side walls (4, 5, 6, 7) from at least one pair each comprises at least one or two second RC elements (12), which comprises the receiving element (16), such as a bracket, clamp, an opening or a clip. In some embodiments, the foldable flap comprises the first RC element (13) which comprises a protruding element (17) and the second side walls (6, 7) comprises the second RC element (12), which comprises the receiving element (16). In some alternative embodiments, the foldable flap comprises the first RC element (13) which comprises a protruding element (17) and the first side walls (6, 7) comprises the second RC element (12), which comprises the receiving element (16).

In some embodiments, each foldable flap (8, 9) comprises at least one repeatable catch (RC), wherein at least one RC element is configured to latch onto a RC element on one side wall (6) of the pair of opposing first side walls, preferably the side wall where the foldable flap is attached to.

In some embodiments, each foldable flap (8, 9) comprises at least two repeatable catches (RC), wherein at least one RC element is configured to latch onto a RC element on one side wall (6) of the pair of opposing second side walls and at least one RC element is configured to latch onto a RC element on the opposing side wall (7) of the pair of opposing second side walls. This way, manipulating the foldable flaps results in opening or closing at least two RCs.

In a preferred embodiment, manipulation, preferably rotation or folding, of both the foldable flaps (8, 9) results in locking or unlocking all RCs. In some embodiments, manipulation, rotation or folding of the foldable flaps (8, 9) inwards results in locking all the RCs; manipulation, rotation or folding of the foldable flaps (8, 9) outwards results in unlocking all the RCs. An operator can transition the foldable container from the deployed state (1) to the collapsed state (2) by applying an external force (29) to the foldable flaps (8, 9), thereby manipulating, rotating or folding the foldable flaps (8, 9) outwards, this will destabilises the RC and unlock the locking mechanism. The foldable flaps (8, 9), which are attached to the side walls (4, 5) of the pair of opposing first side walls, can be brought outwards (29); this allows the side walls (4, 5) of the pair of opposing first side walls to move outwards (30) and allows for the foldable container to enter the collapsed state (2). In some embodiments, a mechanical transmission is provided, whereby a movement of the pair of opposing first side walls (6, 7) is transferred to the pair of second side walls, resulting that the pair of second side walls are also brought in the collapsed state (2). Preferably, the operator does not have to change his grip to manipulate (30) the foldable container from the deployed state (1) to the collapsed state (2). To bring the container into the deployed state (1) starting from the collapsed state (2), an operator can grab the foldable flaps, manipulate, rotate or fold them upwards, bringing the side walls in the deployed state, followed by a further manipulation, rotation or folding of the foldable flaps inwards to lock the locking mechanism. The operator is able to do this without changing his grip to the foldable flaps.

In some embodiments, each side wall (4, 5, 6, 7) comprises at least one, preferably at least two guiding elements (32), wherein in the deployed state (1) each guiding element (32) engages with a guiding element (32) of the neighbouring side wall (4, 5, 6, 7). Because these guiding elements engage with each other in the deployed state, the sidewalls lock with each other preventing deformation of the container due to an uneven load in the container. The guiding elements may stabilise the foldable container in the deployed state.

In some embodiments, the guiding elements may be protrusions and/or slots.

In some embodiments, the first receiving elements (13) are positioned along the length of the foldable flaps (8, 9), preferably halfway along the length of the foldable flaps (8, 9).

In some embodiments, the second receiving elements (12) are positioned on or in the side walls (4,5) of the pair of opposing first side walls, the first receiving elements (13) are positioned along the length of the foldable flaps (8, 9), preferably halfway along the length of the foldable flaps (8, 9).

In some embodiments, in the collapsed state (2) the foldable flaps can be reversibly engaged with a side wall of the pair of opposing first side walls (4, 5), thereby restricting, preferably locking, the mechanical transmission (22, 23, 24, 25) against a side wall of the pair of opposing first side walls (4, 5).

In some embodiments, the thickness of the reinforcement elements in or on the side walls, preferably the side walls of the pair of opposing first side walls, increases at the intersection with the base (3).

In some embodiments, each foldable flap (8, 9) clamps at least one, preferably at least two mechanical transmission (22, 23, 24, 25) against at least one side wall (4, 5, 6, 7), when said foldable flap is locked against at least one of the sidewalls (4, 5, 6, 7), by the repeatable locking mechanism in the deployed state (1). This causes extra rigidity and prevents movement between the different sidewalls.

In some embodiments, each foldable flap (8, 9) clamps at least one, preferably at least two mechanical transmission (22, 23, 24, 25) against at least one side wall (4, 5, 6, 7), when said foldable flap is locked against at least one of the sidewalls (4, 5, 6, 7), by the repeatable locking mechanism in the collapsed state (2). This ensures that in the collapsed state the container is in a flat configuration, what makes it easier for stacking and storing containers in the collapsed state.

In some embodiments, each foldable flap (8, 9) clamps at least one, preferably at least two mechanical transmission (22, 23, 24, 25) against at least one side wall (4, 5, 6, 7), when said foldable flap is locked against at least one of the sidewalls (4, 5, 6, 7), by the repeatable locking mechanism in both the deployed state (1) and the collapsed state (2).

In some embodiments, the side walls (4,5, 6,7) may comprise one or more springs, preferably one or more leaf springs. Preferably, so that the sidewalls partially rise up from the collapsed state when the by unlocking the foldable flaps in the collapsed state. This makes it easier for a user to put his hands in the handles and to fond the container to its deployed state.

In some embodiments, the protruding element (17) comprises at the terminal end a cammed surface (33) that adjoins an abrupt groove (34), which functions as a hook, said hook being configured to latch on the a ridge (35) in an opening, said opening being the receiving element (16). Preferably, said receiving element (16) is an opening in the side wall of the pair of opposing first side walls (4, 5). Details of such a locking mechanism can be seen in FIG. 10.

In some embodiments: the hinges between:

    • the base (3),
    • the pair of opposing first side walls (4, 5),
    • the pair of opposing second side walls (6, 7), and
    • optionally the pair of foldable flaps (8, 9),

are living hinge.

As used herein the term “living hinge” is a preferably flexible hinge made from the same material as the two ridged pieces it connects. It is typically thinned or cut to allow the rigid pieces to bend along the line of the hinge.

In some embodiments:

    • the base (3),
    • the pair of opposing first side walls (4, 5),
    • the pair of opposing second side walls (6, 7), and
    • optionally the pair of foldable flaps (8, 9),

are made from a single piece.

In some embodiments, the protruding element (17) is mounted between two stop-faces (18, 19).

A “stop face” refers to a face that prevents the latching mechanism from unlocking in an unintended direction.

In some embodiments, the stability of the locking mechanism is unaffected by forces exercised directly on the side walls (4, 5, 6, 7) and/or base (3).

In some embodiments, the foldable container comprises clips to lock the side walls into the collapsed state. These clips ensures that the foldable container remains flat in the collapsed state, as the hinges can sometimes force the foldable container in an intermediate state between the collapsed state (2) end the deployed state (1), when no external pressure is applied to the foldable container.

In some embodiments, the side walls (4, 5, 6, 7) and/or the base (3) may comprise reinforcement elements (28), such as ribs, ridges or honeycomb structures.

The invention may also be described by the following statements or any combination of the following statements:

    • 1. Foldable container, having a collapsed state (2) and a deployed state (1), said container having a substantially cuboid form in the deployed state (1) wherein:
      • the container in the deployed state (1) comprises:
        • a base (3);
        • a pair of opposing first side walls (4, 5), extending from the base (3);
        • a pair of opposing second side walls (6, 7), extending from the base (3);
        • an container opening (31) opposed to the base (3);
      • each of the side walls (4, 5, 6, 7) is attached to the base (3) by a separate hinge joint;
      • the foldable container is made from a polymer, preferably a synthetic polymer, more preferably polypropylene (PP), polyethylene (PE), acrylonitrile butadiene styrene (ABS), polyvinylchloride (PVC), polystyrene (PS), polymethylmethacrylate (PMMA), and/or polylactic acid (PLA).
    • 2. Foldable container according to statement 2, further comprises:
      • a pair of foldable flaps (8, 9), each attached to an upper edge (10, 11) of each of the first side walls (4, 5) by a hinge joint;
      • repeatable locking mechanism configured to dismountably lock each of the foldable flaps (8, 9) against at least one side walls (4, 5, 6, 7), thereby stabilising the deployed state (1).
    • 3. Foldable container according to statement 2, wherein the locking mechanism comprises two pairs of repeatable catches, RC, each comprising a first RC element (13) and second RC element (12), wherein:
      • an application of an external force stabilises (or destabilises) an attachment of the first RC element (13) to second RC element (12),
      • the first RC elements (13) are provided on each foldable flap (8, 9),
      • the second RC elements (12) are provided on at least two of the side walls (4, 5, 6, 7), preferably on at least two opposing side walls (4,5; or, 6,7),
      • the first RC element (13) and second RC element (12) are configured such that they are stably mutually attached when the foldable flaps (8, 9) are folded or pivoted inwardly.
    • 4. Foldable container according to statement 3, wherein the second RC element (12) comprises a receiving element (16) and the first RC element (13) comprises a complementary protruding element (17), and the receiving element (16) is dismountably attachable (or detachable) with the complementary protruding element (17) by application of an external force (29).
    • 5. Foldable container according to statement 4, wherein each side wall (4, 5, 6, 7) comprises at least one, preferably at least two guiding elements (32), wherein in the deployed state (1) each guiding element (32) engages with a guiding element (32) of the neighbouring side wall (4, 5, 6, 7).
    • 6. Foldable container according to any one of statements 1 to 5, wherein:
      • the base (3),
      • the pair of opposing first side walls (4, 5),
      • the pair of opposing second side walls (6, 7), and
      • optionally the pair of foldable flaps (8, 9),
    • are made from a single piece and the hinge joints are living hinges.
    • 7. Foldable container according to statement 6, wherein the single piece is an injection moulded piece.
    • 8. Foldable container according to any one of statements 1 to 7, wherein the side walls (6, 7) of the pair of second side walls comprise handles or handle openings (20, 21).
    • 9. Foldable container according to any one of statements 1 to 8, configured such that upon transitioning from the deployed state (1) to the collapsed state (2) the pair of opposing first side walls (4, 5) fold outwards and the pair of opposing second side walls (6, 7) fold inwards.
    • 10. Foldable container according to any one of statements 1 to 9, configured such that movement of the pair of opposing first side walls (4, 5) relative to the base (3) around the connecting hinge actuates movement of the pair of opposing second side walls (6, 7) around the connecting hinge relative to the base (3).
    • 11. Foldable container according to any one of statements 1 to 10, wherein at least one first side wall (4, 5), preferably both first side walls (4, 5) is each attached to an adjacent second side wall (6, 7) by a mechanical transmission (22, 23, 24, 25) for transfer of force from the pair of opposing first side walls (4, 5) to the pair of opposing second side walls (6, 7) during transition between the collapsed state (2) and the deployed state (1).
    • 12. Foldable container according to any one of statements 1 to 11, wherein each transmission (22, 23, 24, 25) comprises a non-elastic member attached at one end to a first side wall (4, 5) and at the other end to an adjacent second side wall (6, 7).
    • 13. Foldable container according to any one of statements 1 to 12, wherein the collapsed state (2) has a flattened form, optionally rectangular, such as oblong or square.
    • 14. Foldable container according to any one of statements 1 to 13, wherein the foldable container in the deployed state (2) is stackable with another foldable container in the deployed state (2).

The invention will be more readily understood by reference to the following examples, which are included merely for purpose of illustration of certain aspects and embodiments of the present invention and are not intended to limit the invention.

Examples

FIGS. 1 to 6 depict a specific embodiment of the invention. FIG. 1 shows the foldable container in the deployed state (1), whereas FIG. 2 shows the foldable container in the collapsed state (2) and FIG. 3 shows the foldable container in the extruded state (27).

The foldable container comprises a base (3), where to a pair of opposing first side walls (4, 5) and a pair of opposing second side walls are attached via a living hinge (26). To the upper edge (10, 11) of the pair of opposing first side walls, (4, 5), foldable flaps (8, 9), in the form of a bar, are attached also via a living hinge. The foldable flaps (8, 9) comprise the first repeatable catches (13). The pair of opposing second side walls (6, 7) comprises handles (20, 21), and the second repeatable catches (12), which are positioned near the upper edge (14, 15) of the pair of opposing second side walls (6, 7). In the deployed state (1) as shown in FIG. 1, the side walls and the base define in internal container volume. A container opening (31) is present on top of the foldable container, which is partially obscured by the foldable flaps (8, 9) in the deployed state (1).

In the collapsed state (2) depicted by FIG. 2, it can be seen that the pair of opposing first side walls (4, 5) folds outwards and the pair of opposing second side walls (6, 7) fold inwards, so that the collapsed state is essentially a rectangle. The mechanical transmission (22, 23, 24, 25) causes movement of the pair of opposing second side walls (6, 7), when the pair of first side walls (4, 5) are manipulated and vice versa.

The container may be manufactured as a sheet-like structure as shown in FIG. 3, the mechanical transmission (22, 23, 24, 25) is only connected to one pair of side walls, here the pair of opposing second side walls (6, 7). To allow a functioning foldable container, the mechanical transmission (22, 23, 24, 25) are subsequently melt welded or clipped on to the pair of opposing first side walls (4, 5).

As shown in FIG. 4 and FIG. 5, the manipulation (29) of the foldable flaps (8, 9) unlocks the locking mechanism, and without the need to change grip, the foldable flaps can be brought inwards (30) to arrive at the foldable container in the collapsed state (2). This can be done by an operator in one fluent motion. Transitioning from the collapsed state (2) to the deployed state (1) can also be performed by an opposite fluent motion.

As shown in FIG. 6, the locking mechanism comprises a second repeatable catch (12), which comprises a receiving element (16) and a first repeatable catch (12) which comprise a protruding element (17). The protruding element is mounted between two stop faces (18, 19), preventing the sideways opening of the locking mechanism. This way the locking mechanism can only open by twisting the foldable flaps (8, 9) upwards, hence the weight of the load inside the foldable container does not cause the locking mechanism to open.

FIGS. 7 to 9 depict a specific embodiment of the invention. FIG. 7 shows the foldable container in the deployed state (1), whereas FIG. 8 shows the foldable container in the collapsed state (2) and FIG. 9 shows the foldable container in the extruded state (27).

The foldable container comprises a base (3), where to a pair of opposing first side walls (4, 5) and a pair of opposing second side walls are attached via a living hinge (26). To the upper edge (10, 11) of the pair of opposing first side walls, (4, 5), foldable flaps (8, 9) are attached also via a living hinge. The foldable flaps (8, 9) comprise the first repeatable catches (13). The pair of opposing second side walls (6, 7) comprises handles (20, 21). The pair of opposing first side walls (4, 5) comprises the second repeatable catches (12). In the deployed state (1) as shown in FIG. 7, the side walls and the base define in internal container volume. A container opening (31) is present on top of the foldable container. Guiding elements (32) on both the first side walls (4, 5) and the second side walls (6, 7) engage in the deployed state (1).

In the collapsed state (2) depicted by FIG. 8, it can be seen that the pair of opposing first side walls (4, 5) folds outwards and the pair of opposing second side walls (6, 7) fold inwards, so that the collapsed state is essentially a rectangle. The mechanical transmission (22, 23, 24, 25) causes movement of the pair of opposing second side walls (6, 7), when the pair of first side walls (4, 5) are manipulated and vice versa. The foldable flaps (8, 9) are folded inwards in FIG. 8 and the locking mechanism is locked, this clamps the mechanical transmissions (22, 23, 24, 25) between the foldable flaps (8, 9) and the side walls (4, 5), maintaining a planar shape.

The container may be manufactured as a sheet-like structure as shown in FIG. 9, the mechanical transmission (22, 23, 24, 25) is only connected to one pair of side walls, here the pair of opposing second side walls (6, 7). To allow a functioning foldable container, the mechanical transmission (22, 23, 24, 25) are subsequently melt welded of clipped on to the pair of opposing first side walls (4, 5).

It is to be understood that although preferred embodiments and/or materials have been discussed for providing embodiments according to the present invention, various modifications or changes may be made without departing from the scope and spirit of this invention.

REFERENCE SIGNS

1 Deployed state 2 Collapsed state 3 Base 4 Side wall of the pair of opposing first side walls 5 Opposed side wall of the pair of opposing first side walls 6 Side wall of the pair of opposing second side walls 7 Opposed side wall of the pair of opposing second side walls 8 First foldable flap 9 Second foldable flap 10 Upper edge of the side wall of the pair of opposing first side walls 11 Upper edge of the opposed side wall of the pair of opposing first side walls 12 Second RC element 13 First RC element 14 Upper edge of the opposed side wall of the pair of opposing second side walls 15 Upper edge of the side wall of the pair of opposing second side walls 16 Receiving element 17 Protruding element 18 First stop-face 19 Second stop face 20 First handle 21 Second handle 22 First mechanical transmission 23 Second mechanical transmission 24 Third mechanical transmission 25 Forth mechanical transition 26 Living hinge 27 Extruded state 28 Reinforcement element 29 Locking/unlocking motion 30 Manipulation to go from functional state to the collapsed state 31 Container opening 32 Guiding element 33 Cammed surface 34 Abrupt groove 35 Ridge

Claims

1. A foldable container, having a collapsed state and a deployed state, wherein at least one first side wall, preferably both first side walls is each attached to an adjacent second side wall by a mechanical transmission for transfer of force from the pair of opposing first side walls to the pair of opposing second side walls during transition between the collapsed state and the deployed state; and, wherein each foldable flap clamps at least one, preferably at least two mechanical transmission against at least one side wall, when said foldable flap is locked against at least one of the sidewalls, by the repeatable locking mechanism in the deployed state.

said container having a substantially cuboid form in the deployed state wherein:
the container in the deployed state comprises:
a base;
a pair of opposing first side walls, extending from the base;
a pair of opposing second side walls, extending from the base;
an container opening opposed to the base;
each of the side walls is attached to the base by a separate hinge joint;
the foldable container is made from a polymer, preferably a synthetic polymer, more preferably polypropylene (PP), polyethylene (PE), acrylonitrile butadiene styrene (ABS), polyvinylchloride (PVC), polystyrene (PS), polymethylmethacrylate (PMMA), and/or polylactic acid (PLA); further comprising:
a pair of foldable flaps, each attached to an upper edge of each of the first side walls by a hinge joint;
repeatable locking mechanism configured to dismountably lock each of the foldable flaps against at least one side walls, thereby stabilising the deployed state;

2. The foldable container according to claim 1, wherein the locking mechanism comprises two pairs of repeatable catches, RC, each comprising a first RC element and second RC element, wherein:

an application of an external force stabilises (or destabilises) an attachment of the first RC element to second RC element,
the first RC elements are provided on each foldable flap,
the second RC elements are provided on at least two of the side walls, preferably on at least two opposing side walls,
the first RC element and second RC element are configured such that they are stably mutually attached when the foldable flaps are folded or pivoted inwardly.

3. The foldable container according to claim 1, wherein the second RC element comprises a receiving element and the first RC element comprises a complementary protruding element, and the receiving element is dismountably attachable (or detachable) with the complementary protruding element by application of an external force.

4. The foldable container according to claim 3, wherein each side wall comprises at least one, preferably at least two guiding elements, wherein in the deployed state each guiding element engages with a guiding element of the neighbouring side wall.

5. The foldable container according to claim 1, wherein: are made from a single piece and the hinge joints are living hinges.

the base,
the pair of opposing first side walls,
the pair of opposing second side walls, and
optionally the pair of foldable flaps,

6. The foldable container according to claim 5, wherein the single piece is an injection moulded piece.

7. The foldable container according to claim 1, wherein the side walls of the pair of second side walls comprise handles or handle openings.

8. The foldable container according to claim 1, configured such that upon transitioning from the deployed state to the collapsed state the pair of opposing first side walls fold outwards and the pair of opposing second side walls fold inwards.

9. The foldable container according to claim 1, configured such that movement of the pair of opposing first side walls relative to the base around the connecting hinge actuates movement of the pair of opposing second side walls around the connecting hinge relative to the base.

10. The foldable container according to claim 1, wherein each transmission comprises a non-elastic member attached at one end to a first side wall and at the other end to an adjacent second side wall.

11. The foldable container according to claim 1, wherein the collapsed state has a flattened form, optionally rectangular, such as oblong or square.

12. The foldable container according to claim 1, wherein the foldable container in the deployed state is stackable with another foldable container in the deployed state.

13. A method for manufacturing a foldable container, comprising the steps of:

injection moulding a single piece, wherein said single piece comprises a base, and two pairs of side walls, mechanical transmission and optionally foldable flaps; wherein the side walls are attached to the base via hinges, preferably living hinges and each mechanical transmission is attached to a side wall via hinge, preferably a living hinges;
attaching, preferably irreversible attaching, the mechanical transmission to an adjacent side wall.
Patent History
Publication number: 20220048666
Type: Application
Filed: Nov 26, 2019
Publication Date: Feb 17, 2022
Inventor: Jan VANDEWIELE (Dottignies)
Application Number: 17/309,394
Classifications
International Classification: B65D 1/22 (20060101); B65D 6/18 (20060101);