COLLAPSIBLE CRATE

Abstract: A bin comprises a collapsible wall over a pallet. The collapsible wall comprises a pair of side walls and a pair of end walls interconnected by vertical hinges with the end walls having additional intermediate vertical hinges whereby the end walls are collapsible to fold between the side walls to form a flat collapsed pack. A plurality of collapsed packs stack vertically side-by-side over a vertical stack of nested pallets. The pallets have nestable legs which inter-relate with indentations of a lid for the bin. The pallet and lid can have charge and discharge openings with closures thereto. The bin parts are in expanded foam for light weight.

Description: TITLE: "COLLAPSIBLE CRATE" FIELD OF THE INVENTION THIS INVENTION relates to a collapsible bin or crate, and, in particular, to the style of collapsible bin or crate wherein, in the process of collapsing, side panels fold along a vertical axis. BACKGROUND OF THE INVENTION Various forms of collapsible bins or crates have been devised. Most usually, the collapsing involves panels that are folded together along hinges established along a combination of vertical or horizontal edges. In some prior designs, the bin or crate is collapsed by folding of various panels along hinge lines that bisect the panels. In these latter arrangements, the hinge line can be located in either of a vertical or a horizontal direction. Prior Australian Patent Specification Nos. 68129/87 and 46290/85 set out descriptions of collapsible crates in which side panels fold along horizontal hinge lines. In prior Australian Patent Specification No. 44120/85, the crate collapses by folding along vertically aligned hinge lines that bisect opposed side panels. Whilst a wide range of collapsible bins or crates have been devised in the past, none have proved to be totally satisfactory. In the transport of fruit and vegetables, bulk bins or crates have been employed for the more solid fruits and vegetables, but of what is in standard use, few of these is collapsible to realise the advantage of the collapsible concept providing for return and reuse. Some fruits and vegetables, being soft, etc., cannot be packed into crates of any great depth. One single size of crate has limited utility. What construction techniques have been used to date do not lend themselves to creation of a range of depths in crate volumes which crates can be stacked conveniently to take advantage of available height on transports, in stores, etc. OBJECT OF THE INVENTION It is an object of the present invention to provide a collapsible bin or crate capable of cost effective use in the transport of bulk quantities of fruit, vegetables, grains and other like commodities. Other objects, and various advantages, will hereinafter become apparent. NATURE OF THE INVENTION The present invention achieves its object in the provision of: side walls for containing goods therebetween, said side walls being collapsible on vertical hinge lines into a flat pack; and a pallet to support the side walls thereover providing a floor thereto to contain produce therein; characterised in that: a plurality of the said pallets are stackable one above the other; and a respective plurality of collapsed side walls are so dimensioned that in a side by side assembly of a predetermined number of vertically stood flat side walls, said side-by-side assembly nests in a stable configuration on the uppermost pallet of the pallet stack. The configuration of stacked pallets and walls, works irrespective of wall height. Prior systems of collapsed crates lay the walls flat and in this configuration, the walls may not have a height dimension which relates in any workable way with the dimensions of the pallet to produce a stack with the same uniformity as is now realised. In this specification the terms "bin" and "crate" are used interchangeably to denote a form of container which is provided with at least side walls and bottom whereby various products such as fruit, vegetables, grains, etc. may be held for transportation. The height of the walls of the collapsible crate may be varied by selection of an appropriate assembly of panels depending upon what is to be stored therein with lower vertical heights when the collapsible crate is to be used to contain objects that cannot be loaded onto each other to too great a depth. The bin or crate of this invention can comprise walls of a chosen height over a pallet which is stackable and dimensioned to receive a set number of collapsed walls stacked side by side over a vertical stack of their respective pallets. This arrangement reduces the volume of the bins to a particularly useful degree, creating a collapsed pack which is readily handled. The wall panels and other parts, pallet, covers, etc. for a crate of the above kind can each be produced as a single moulding of desired dimension from a polyethylene structural foam in the form of an extended plate form panel with upstanding flanges about the periphery and traversed across the surface of the panel to provide a desired rigidity. The hinges may comprise integrally moulded hinge parts spaced to interdigitate when two panels are butted to receive a hinge pin therethrough. Use of structural foams and appropriate strengthening ribs enables a bin or crate to be realised in weight ranges of 28 to 40 kg having standard pallet floor dimensions. The ribbing is preferably provided outside the box structure so that fruits, etc., therein are not damaged by the ribs. The same techniques can be applied to walls of a range of heights so that a small number of wall panels can be produced over a desired range to permit shallow depths when fruits, etc., cannot be packed to any great depth. The bin or crate is readily produced with pallets able to be stood over crates below to gain useful storage volumes with the full height of a transport, etc., able to be used by stacking of crates. The use of foam as a material of construction allows the use of lower pressure tooling in moulding which is cheaper than other higher pressure tooling. Strength is achieved by adding framing and flanges to the panel, pallet, etc. BRIEF DESCRIPTION OF THE DRAWINGS The invention will now be described with reference to the accompanying drawings, in which: FIG. 1 is a perspective view of a bin or crate in accordance with the present invention showing how the walls may be collapsed; FIG. 2 is a plan view of the side walls of the crate or bin of FIG. 1; FIG. 3 is a view of one side wall of the crate or bin of FIGS. 2 and 3; FIGS. 4 and 5 are detailed views of wall panel components as might be used in the crate or bin of FIGS. 1 to 3; FIGS. 6 to 8 are detailed views of a corner hinges of a crate or bin as in FIGS. 1 to 3; FIGS. 9 to 11 are plan and sectional views of a pallet which may be employed as the base of a bin or crate in accordance with the present invention. FIG. 12 shows how a plurality of bins or crates might be collapsed and shipped; FIG. 13 shows a detailed view of how walls might be mounted to a pallet; FIGS. 14 to 19 illustrate features of a lid which might be used with the bin and pallet of the above figures; and FIGS. 20 to 23 show features of a cap which might be used with the lid of FIGS. 14 to 19. PREFERRED EMBODIMENTS In FIG. 1, a bin or crate may be formed with vertical interconnected walls 10 supported over a pallet or tray bottom (not shown). Side walls 11 and 12 collapse towards each other when side walls 13 and 14 are each collapsed about hinges 15 and 16 respectively. By this means the bin or crate may be collapsed for return and reuse. In the plan view of FIG. 2 the crate or bin 10 is provided with corner hinges 22 to 25 which open to 90° to form a square or rectangular shape. Hinges 26 and 27 open to 180° to form side walls that are collapsible onto themselves between the other two connecting walls to form a flat collapsed pack. Side walls are formed by identical sections 32 and 33 and 34 and 35 differing only in length. The lugs such as 110 provided around the crate walls are to engage in slots in a perimeter flange of the pallet bellow as described below with reference to FIG. 13. In construction of the above bin or crate, plastic technology may be utilised and the bin or crate can be established from a small range of parts. In FIG. 3, a side wall is shown between corner hinges 24 and 25 with mid-side panel hinge 27 therebetween. The central fold line comprises the hinge axis of hinge 27. FIG. 4 is a section through the lower end of a corner of a bin or crate showing an internal detail of the formation of a hinge. The hinge part 69, and each successive hinge part thereabove (not shown) are strengthened by a star section hinge pin locator 70. The hinge pin 71 is threaded therethrough and the bottom can be plugged by a plug 72 to retain a hinge pin or rod 71 therein. The extra ring of material adds to strength vertically to assist in supporting against downward loads. It also provides a buffer against impacts which might otherwise damage the hinge pin and its hinge parts. A bent pin would adversely affect the operation of the crate. In FIG. 5 is seen the section A-A of FIG. 4 to show in section the shape of hinge pin locator 70 which exists in hinge part 69 on panel 72 to locate hinge pin 71 therein. FIGS. 6 and 7 show a mid-panel hinge in greater detail. The panels 60 and 61 are provided with hinge parts arrayed at regular spacings along their vertical edge. Hinge parts 58 and 59 only are drawn for convenience. The hinge parts and their attached panels 60 and 61 are connected by a pin or rod 71 extended therethrough up the height of the bin or crate. In FIG. 8 is seen how hinge parts come together to be connected by a pins at 64. Panels 54 and 55 may comprise sheet form plates which are ribbed thereover to strengthen them. At their periphery they may have a perpendicular flange thereabout which engages against the flat section of each hinge part such as 65 to limit the degree of opening of the panels to 90° or 180° as desired. FIGS. 9 to 11 show details of a pallet that might be employed with the above described walls. FIG. 10 is a sectional view on A-A in FIG. 9. FIG. 11 is a sectional view on B-B in FIG. 9. The pallet has an upper deck 71 supported above a ground surface on legs or feet such as 72, 73 and 74. The deck 71 is ribbed and boxed as described below to the depth 75 (in FIG. 10) to leave space thereunder into which lifting forks may be fitted in the usual way. The dotted lines represent flanges beneath to strengthen the deck. The feet 72 to 74 are open topped and hollow such that a plurality of pallets may be stacked, nested into each other to save space on a return journey. The upper deck 71 may have an upstanding lip 76 (see FIG. 10) about its periphery. In use, the collapsible walls nest against the inside of this lip to provide support to the side walls against outward pressures. The feet of the pallet may be indented as seen in FIGS. 10 and 11 to enable stacking of bins or crates on atop the other as at point marked 77. The centre of the pallet may be provided with an opening 82 (see FIG. 11) through which pallet contents may be discharged. Granular materials might be stored in a liner which may be punctured or opened from below to enable discharge. The boxing which strengthens the pallet may comprise downwardly projected flanges which cross the bottom of the pallet being provided in an orthogonal pattern as indicated by the dotted lines in FIG. 9. The use of four legs to stand the pallet off a ground beneath provides four way access to the pallet by fork lifts, etc. The legs of the pallet can have a recess in the bottom to assist and locate the pallet when it sits on another crate. FIG. 12 shows how a plurality of crates may be collapsed and stacked for return and reuse. Pallets are shown stacked one above the other with their respective collapsible walls collapsed and stacked side by side over the top of the top pallet. FIG. 13 is a detail at the edge of a pallet showing a wall edge detail. A pallet 83 with upstanding edge 84 has a strengthening flange 85. Wall edge 86 of a vertical wall is shown with a special locating lug 87 received in a slot 88 of pallet 83. The lug 87 may be repeated at regular intervals around the lower ends of the vertical walls. In FIG. 14 is shown a lid 83 which might be used with the aforementioned bins or crates. Lid 83 comprises a cover 84 with indentations 85 and a central hole 86. The indentations 85 are proportioned and shaped to complement the pallet feet so as to enable a pallet to be stood on the lid of a crate below with its feed located by the indentations. The hole 86 is constructed, as desired below, so as to receive a cap therein. FIG. 15 is a section on BB of the lid of FIG. 16. In FIG. 15, the material of the lid 83 provides a continuous cover 84 with indentations 87 to 89 to receive pallet feet therein. The lid 83 has a downward projected edge 90 to overlap a crate or bin 91 therebeneath. FIG. 16 is a section through the centre of a pallet 92 to show how the lid 83 complements and supports it. The pallet 92 of FIG. 16 is on the same section as that of FIG. 17. In FIG. 16 the feet 95 and 96 are received in the indentations 97 and 98 of FIG. 17. The hole 94 in the central foot of pallet 92 overlies the hole 86 in lid 83 (see FIG. 17). FIG. 17 is a section on AA of the lid of FIG. 14. In FIG. 17, the central hole 86 is provided with screw threads 99 and 100 whereby a cap, described below, may be removably held. FIG. 18 is a section at the edge of lid 83 in FIG. 14 at 103. FIG. 19 is the section CC of lid 83 of FIG. 18. In FIGS. 18 and 19, lid 83 has a downward edge flange 90 which has tabs 101 projected inwards to engage under the upper lip 102 of bin or crate 91. A number of tabs or lugs 101 around the edge of the lid 83 provide a means whereby the lid 83 is removably held to the bin or crate beneath. In FIG. 20 is seen a plan view of a cap 104 shown from the top. The cap 104 is provided with indentations 105 and 106 which create a ridge 107 which provides a means whereby the cap can be held and turned so as to either lock it in place or remove it. FIG. 21 is a section DD of the cap 104 of FIG. 20. In FIG. 21, edge 108 of cap 104 is provided with channels such as 109 in separated segments about the periphery. The channels 109 receive the screw threads of FIG. 17 therein. The separated segments are angularly extended a short distance only being limited so as to slot into the gaps between the thread in the hole of lid 83. FIG. 22 is the section EE of cap 104 of FIG. 20. FIG. 23 is the section FF of FIG. 20. By use of the above techniques, a bin or crate of desired size might be assembled from a basic inventory of parts. It will be clear from the foregoing that other elements may be usefully added to these.

Claims: CLAIMS 1. A collapsible bin or crate for transport of goods therein comprising: side walls for containing goods therebetween, said side walls being collapsible on vertical hinge lines into a flat pack; and a pallet to support the side walls thereover providing a floor thereto to contain produce therein; characterised in that: a plurality of the said pallets are stackable one above the other; and a respective plurality of collapsed side walls are so dimensioned that in a side by side assembly of a predetermined number of vertically stood flat side walls, said side-by-side assembly nests in a stable configuration on the uppermost pallet of the pallet stack. 2. A collapsible bin or crate as claimed in Claim 1 wherein said pallet comprises: a platform; hollow base supports beneath the platform to hold the platform in an elevated position above a ground; the base supports being open above the platform; the platform and base supports being configured for stacking with the base supports of an upper pallet nested within the base supports of a lower pallet. 3. A collapsible bin or crate as claimed in Claim 1 wherein: said pallet is formed with a peripheral upstanding flange thereabout to mate with the bottoms of said side walls, projections on the bottoms of said side walls being projected into slots in said flange. 4. A collapsible bin or crate as claimed in Claim 1 wherein: said pallet is formed with a hole therein in an upper surface thereof open into the bin or crate, said hole dimensioned to discharge produce, said hole having a removable lid fitted thereto to contain produce. 5. A collapsible bin or crate as claimed in Claim 1 wherein: the bin or crate is provided with a lid thereover, the lid having recesses therein in which the complementary shaped base of a pallet of another container is locked therein for stable stacking. 6. A collapsible bin or crate as claimed in Claim 1 wherein: the side walls are provided with hinge parts along vertical edges, respective hinge parts of adjoining panels being interdigitated with a hinge pin passed therethrough, the hinge pin passing through a bore in a central hub joined to a cage thereabout via spokes. 7. A collapsible bin or crate as claimed in Claim 1 wherein: the side walls are a structural foam with strengthening ribs thereto. 8. A collapsible bin or crate as claimed in Claim 1 wherein: the side walls have outward projected lugs at their base which lugs locks into slots in a perimeter flange of the pallet when the side walls are open and mounted on the pallet to form the crate, the pallet having a platform forming the base of the crate with supports thereunder to hold the platform elevated over a ground beneath, the supports being hollow and open at the top of the pallet to permit pallets to be nested in a stack . 9. A collapsible bin or crate as claimed in Claim 1 wherein: the pallet has a platform forming the base of the crate wherein exists a hole dimensioned to discharge produce, said hole being fitted with a removable closure whereby produce is retained in said crate, the crate being provided thereover with a complementary lid with recesses therein in which another crate thereover nests. 10. A collapsible bin or crate as claimed in Claim 1 wherein: the side walls are panels interconnected by interdigitated hinge parts with a hinge pin therethrough, the hinge parts including a surrounding protecting ring supporting a hub therein through which the hinge pin passes, the panels and hinge parts being integrally formed by a moulding process. 11. A collapsible bin or crate as claimed in Claim 1 wherein: the pallets are moulded with integral upper crate base and open topped, downwardly projected supports dimensioned for nested stacking of crates, the crate base having a removable cover to a discharge hole therein. 12. A collapsible bin or crate as claimed in Claim 1 wherein: the pallet is formed with an upstanding flange to abut the bottoms of the walls and a lid thereover has a downwards projected flange to overlap the upper edges of the walls. 13. A collapsible bin or crate as claimed in Claim 1 wherein: there is a lid thereover with an upper complementary configuration for receipt thereon of another crate in a locked configuration, the lid being moulded in a structural foam. 14. A collapsible bin or crate as claimed in Claim 1 wherein: there is a lid thereover, the walls, pallet and lid being moulded in a structural foam with walls and pallet having inner surfaces to the crate that are flat with outer flanges and/or ribs thereto.

Inventors: CIOBO ALLESSANDRO, CIOBO, ALLESSANDRO
Applicants: CIOBO ALEX & SONS PTY LTD, CIOBO ALLESSANDRO, ALEX CIOBO & SONS PTY. LTD.
Application year: 1993
Main classification: B65D19
IPC codes: B65D19