FLAT PACK BOX

Abstract: The invention provides a box (1) comprising four side panels (2) which are injection-moulded from a suitable rigid plastics material and further comprises a plurality of complementary locating members (10a-10f) integrally moulded with first and second sides (8, 9) of the wall member (3). The locating members (10) have a recess (11) through which a peg member (12) is positioned to hold the locating members in position. Each locating member has a front face (103) with a tab (105) integrally molded with side faces (101, 102) and extending across the front face (103) and a back face (104) having a cut out section (106) which corresponds to the tab (105). When the panels (2) are positioned adjacent one another, the locating members (10) are interposed between one another fitting together in alternate arrangement. A peg member (12) is pushed down through the space through the locating members (10) to hold the locating members rigidly in position and thereby to secure the two adjacent panels (2) together.

Description: FLAT PACK BOX The invention relates to flat pack boxes, especially boxes made by injection moulding plastics material, particularly, though not exclusively to flat pack boxes for use as access chambers e.g. for cable television or for street furniture such as pole mounting sockets, traffic lights, bollards, signs and associated cables. When assembled, these boxes have to be rigid and to be able withstand substantial loads, for example up to at least 12.5 tonnes, a requirement for access chambers for cable television and other utilities, which often are placed in the roadway or pavement. The assembled boxes are positioned in the ground to form access chambers for connections between main underground electric cables and distributor cables to adjacent premises or for street furniture. It is desirable for the boxes to be packed flat for transportation and storage as die assembled boxes are large. Presently available flat pack boxes comprise a one piece box that can be unfolded and erected to form a rigid access chamber or box. It is desirable to have different sizes of box available for different applications. There are practical limits to the size of box which can be moulded from plastics material. To overcome this, it is sometimes desirable to construct the boxes modularly to make different sizes of box from a single unit. However, satisfactory, modular flat pack boxes, presently are not available. It is an object of the invention to provide a flat-pack box made from moulded plastics material that has substantial strength, particularly in a vertical direction. It is a further object of the invention to provide a box that is sufficiently rigid when assembled. Another object of the invention is to provide a box that can be assembled simply and easily on site without special tools or fittings. Yet another object is to provide a box that is suitable for modular assembly. The invention provides a flat-pack box comprising a plurality of panels moulded from plastics material and a plurality of peg members, each panel comprising: a wall member comprising a front face, a rear face, a top, a bottom, a first side and a second side; and at least one complementary locating member fom-ing a channel for locating a peg member therein on each of the first and second sides of the wall member; characterised in that the locating members comprise a U-shaped member having a first side integrally moulded with a side of the wall member, a second side opposed to the first side, a back face and an open front face and wherein the locating member further comprises a tab integrally moulded with at least one side of the U-shaped member and extending across the open front face of the locating member and the back face has a cut out section opposed to the tab and of at least the same dimensions as the tab. Advantageously die peg members are injection moulded of suitable rigid plastics material but diey may be made in any suitable manner. For example, the peg members may be fabricated from a suitable metal e.g. steel. Advantageously the complementary locating members each comprise a channel of square or rectangular cross-section, though any suitable cross-section may be used. Advantageously the tab is integrally moulded with both sides of the U-shaped member. Alternatively the tab may extend only part way across the front face of the U-shaped member. In this arrangement, the tab advantageously extends further across the open front face than the width of the side of die wall member so that the wall member does not slip into the void of the U-shaped member. Preferably the cut out section in the back face of the U-shaped member is of me same dimensions as the tab. Alternatively, it may be larger than the tab. Preferably the side walls of die U-shaped member are set back from the face of the wall member to which the tab is adjacent by the deptii of the tab. Preferably the peg members each comprise an elongate rigid member that extends dirough a plurality of locating members. Advantageously die peg members may have a point at the base and a corresponding socket at the top. Thus, when one peg is positioned on top of anodier peg the point of one peg fits into the socket on die other peg and load on die box is transferred effectively through the pegs. Advantageously d e locating members further comprise peg retaining members, such as one or more ridges integrally moulded in the interior of the locating members. Advantageously die peg members each comprise a plurality of cross pieces that coact with the peg retaining members to hold e peg in the locating members, so that it does not slip out when in use. The cross pieces also act to rigidify the peg members. The peg members advantageously each comprise two side pieces and a plurality of cross pieces at right angles forming square or rectangular sections or diagonally forming triangular sections between the side pieces. If tihe panels are to be used to make modular boxes of different heights, where the third and fourth sides respectively are positioned at the top and bottom, preferably one or more of the panels further comprise a plurality of complementary locating members on the top and bottom of the wall member. Alternatively the panels may comprise locating lugs and complementary slots in the top and bottom of the wall member. Alternatively heights may be varied by making suitable extension assemblies e.g. wing panels which can be assembled in the same way as the box to make an extension assembly of the same size as the boxes. In this case the panels may be made to form a gallery at the bottom edge portion, within which an upper edge portion of die extension assembly may be received to locate me assembly with its panels aligned widi the panels of die box so that loads are transferred directly through the panels. In assembling a box in accordance with the invention, die panels are arranged such that when a first panel is positioned adjacent a second panel, die locating members on me first side of the first panel are arranged in complementary positions, interposed between and aligned widi the locating members on the second side of die second panel and a peg member can be inserted dirough the peg locating means of the locating members to hold the panels rigidly togedier. In a second embodiment of the invention, the first element of me locking member preferably comprises a peg member on or adjacent me first and second sides of die wall member and die second element of the locking member comprises a plurality of collar members, the collar members each having peg locating means therethrough for fitting over the peg members. Preferably the collar member comprises a right angled collar having two elongated peg locating means therethrough and die peg members each comprise an elongated element integrally moulded widi the wall member rear face. Advantageously die peg members each have a trapezoidal cross section. For boxes for use as access chambers, advantageously die panels may be made with one or more removable sections to allow pipes, cables and connectors, for example, to be fitted dierethrough. Preferably the box when assembled can accept pipes and umbilicals from all directions by means of cut-out or punch-out portions in the panel which can be removed to make holes in desired positions. Preferably the panels are moulded in a selection of sizes. For larger size panels, die panels may advantageously be moulded in two sections, an outer, frame section forming a wall member having a hole dirough the front to rear faces and an inner section which is located in the hole in die outer section by retaining elements such as integrally moulded clips. This has the advantage of enabling the amount of plastics material required in a single moulding to be reduced. The inner section may, if desired, be adapted to connect a conduit (or flexible tube), referred to as an umbilical, to the box. The box advantageously comprises a base (or floor) panel similar to the panels forming the side walls. Alternatively, die panels may further comprise base retaining members, such as integrally moulded clips, and the box further includes a separate base panel, such that the retaining members securely hold die base panel in position. The clips may be merely lugs projecting inwardly from the panels, into the interior of the box and die base panel may be merely a flat panel resting on die lugs. The box advantageously further comprises a lid. Advantageously it may also have retaining members for fitting a lid or have a lid fitted to an internal or external frame. The invention further comprises a method of assembling the box of the first embodiment comprising steps of: locating a first panel adjacent a second panel, such that the complementary locating members on the first side of die first panel are arranged alternately with the complementary locating members on the second side of die second panel; and inserting a peg member through the peg locating means of me complementary locating members to hold the panels rigidly together. The invention further comprises a method of assembling die box of the second embodiment comprising steps of: locating a first panel adjacent a second panel; and fitting a collar member over the peg members such mat the peg locating means of me collar member fits over the peg members to hold the panels rigidly togedier. The invention will now be described, by way of example only, by reference to the accompanying drawings, of which: Figures la and lb show a side view and an end view respectively of a panel of a box according to a preferred embodiment of the invention; Figure 2 shows an end view of a box assembled from panels as shown in Figure 1 ; Figures 3a and 3b show side views of two alternative embodiments of peg members for use in die preferred embodiment of the invention; Figures 4a and 4b show a side view of an alternative panel and insert; and Figure 5 shows a perspective view of an alternative embodiment of die invention. As shown in Figures 1 and 2, die box 1 of the invention comprises four side panels 2. The panel 2 comprises a wall member 3 having a front face 4, a rear face 5, a first side 8, a second side 9, a diird side 6, normally the top, and a fourth side 7, normally me bottom. The panel 2 is injection-moulded from a suitable rigid plastics material and further comprises a plurality of complementary locating members lOa-lOf integrally moulded with the first and second sides 8,9 of die wall member 3. The locating members 10 form U-shaped channels. The locating members 10 have a recess 11 tiirough which a peg member 12 (shown in Figure 3) is positioned to hold die locating members in position. Each locating member has two side faces 101, 102, a front face 103 and a back face 104. The front face 103 has a tab 105 integrally moulded widi the side faces 101 ,102 and extending across me front face 103. In the back face 104 is a cut out section 106 (shown in Figure 4a) which corresponds to ie tab 105. This arrangement has the advantage over solid locating channels, as known in the prior art, in diat it enables die panel 2 to be moulded in a simple two part mould without any need for further processing to bore out the channels for pegs 12 to be inserted dirough. As shown in Figure 2, when the panels 2 are positioned adjacent one anodier, the locating members 10 are interposed between one anodier fitting together in alternate arrangement. A peg member 12 is pushed down dirough die space dirough die locating members 10 to hold me locating members rigidly in position and to dierefore secure the two adjacent panels 2 together. The locating members 10 on each side of me panel 2 coact to prevent me peg 12 moving in a lateral direction. The locating members 10 have further retaining means in the form of ridges 13 which interact widi cross pieces 14 or 15 on die peg member 12. The construction is such as to allow die peg 12 to be easily pushed in. When die peg member has been inserted into die locating members 10 it is held in position by die ridges and cannot accidentally slip out. The peg members 12 may advantageously have a cap 16 to prevent ie peg 12 being inserted too far into the locating members 10. The peg members 12 are also moulded from a suitable rigid material and act to increase me rigidity and strengdi of the assembled box 1 , widi die cross pieces 14 or 15 serving also to provide greater rigidity and strengdi. The panels 2 can be moulded in a variety of sizes dependent on die size of box which is required, but d ey can also be moulded from a suitable single size mould, for example 150mm x 150mm, so that different size boxes of dimensions which are multiples of the panel sizes can be made using a different number of panels 2 connected togedier horizontally and vertically. The panels 2 may also have locating members 10 on the top 6 and bottom 7 of the wall member, for connecting the panels 2 vertically. Figures 4a and 4b show an alternative side panel 2. This panel 2 is moulded in two sections, an outer section 17 (Figure 4a) and an inner, insert, section 18 (Figure 4b). The outer section 17 has a hole 19 and a plurality of retaining clips 20. The inner section 18 is placed in die hole 19 during use and is held in position by die retaining clips 20. This reduces die amount of plastics material used in a single moulding operation, which is particularly useful for larger sizes of panel 2. A further feature shown in Figure 4a is a plurality of removable sections 21. These are formed as cut-out sections 22a,22b of two different sizes in the wall member 3. The smaller section 22a may be removed for, for example, allowing the insertion of cables (not shown), whereas bom sections 22a,22b may be removed to make a larger hole. In me embodiment shown in Figure 4a, die locating members 10 are arranged in opposite configuration with the tab 105 facing me inside of die box 1 on one side of me panel 2 and facing towards die outside of die box 1 on die odier side of die panel 2. In die embodiment shown in Figure 1 , the locating members 10 are arranged in the same configuration on bom sides of die panel 2, widi die tabs 105 facing the inside of the box 1 when die box 1 is assembled and dius contacting the side wall 8,9 of an adjacent panel 2 when die panels are assembled at right angles. The panel 2 shown in Figure 4a further includes complementary locating means of lugs 200 and slots 201 to enable the panels 2 to be arranged on top of one anodier. Figure 5 shows an alternative embodiment of the invention. In diis embodiment die panels 2 comprise wall members 51 integrally moulded widi peg members 50. A stud 52 on die first side 8 on one panel 2a locates in a recess 53 on die second side 9 of a second panel 2b and a moulded collar 54 slides over die peg members 50 to hold the panels 2 in position rigidly togedier. A box in accordance widi the present invention is stronger and more rigid dian prior art boxes of equivalent size. The box of the present invention also lends itself to modular assembly, thus enabling a variety of sizes of boxes to be achieved. The corner regions are especially strengthened by the structure, in the preferred embodiment the complementary locating members butting against one anodier and die peg members 12 giving very high strength especially in direction of insertion of the peg members 12, thus contributing to die load bearing capability. The box of the present invention can be moulded in a simple two part mould widiout additional moving parts. This makes the manufacmre of e boxes simpler and cheaper dian was possible for prior art boxes.

Claims: CLAIMS 1. A flat-pack box comprising a plurality of panels moulded from plastics material and a plurality of peg members, each panel comprising: a wall member comprising a front face, a rear face, a top, a bottom, a first side and a second side; and at least one complementary locating member forming a channel for locating a peg member therein on each of the first and second sides of die wall member; characterised in mat the locating members comprise a U-shaped member having a first side integrally moulded widi a side of title wall member, a second side opposed to die first side, a back face and an open front face and wherein the locating member further comprises a tab integrally moulded with at least one side of die U-shaped member and extending across the open front face of the locating member and die back face has a cut out section opposed to die tab and of at least die same dimensions as the tab. 2. A box according to claim 1 wherein the locating members each comprise a channel of square or rectangular cross-section. 3. A box according to claim 1 or claim 2 wherein the tab is integrally moulded widi bodi sides of die U-shaped member. 4. A box according to claim 1 or claim 2 wherein me tab extends part way across the front face of the U-shaped member. 5. A box according to any one of die preceding claims wherein the cut out section in the back face of the U-shaped member is larger than die tab. 6. A box according to any one of die preceding claims wherein the peg members each comprise an elongate rigid member that extends dirough a plurality of locating members. 7. A box according to claim 6 wherein die locating members further comprise peg retaining members. 8. A box according to claim 7 wherein the peg retaining members comprise one or more ridges integrally moulded in the interior of the locating members. 9. A box according to claim 7 or claim 8 wherein the peg members each comprise a plurality of cross pieces that coact with the peg retaining members to hold die peg in the locating members. 10. A box according to claim 9 wherein the peg members each comprise two side pieces and a plurality of cross pieces at right angles to the side pieces. 11. A box according to claim 9 wherein die peg members each comprise two side pieces and a plurality of cross pieces forming triangles between die side pieces. 12. A box according to any one of die preceding claims wherein one or more of the panels further comprise a plurality of complementary locating members on me top and bottom of the wall member. 13. A box according to any one of the preceding claims wherein the peg members are moulded from plastics material. 14. A box according to any one of me preceding claims wherein the panels are moulded widi one or more removable sections. 15. A box according to any one of die preceding claims wherein the panels are moulded in two sections, an outer section foπ-oing a wall member having a hole through die front to rear faces and including retaining elements, and an inner section which is located in the hole in the outer section by die retaining elements in die outer section. 16. A box according to any one of die preceding claims wherein the one of die panels comprises a base panel. 17. A box according to any one of claims 1 to 15 wherein die panels further comprise base retaining members and me box further comprises a base panel. 18. A box according to any one of die preceding claims, further comprising a lid. 19. A pole mounting access chamber comprising a box according to any one of die preceding claims. 20. A method of assembling a box according to any one of me preceding claims comprising steps of: locating a first panel adjacent a second panel, such diat the locating members on the first side of die first panel are arranged alternately with the locating members on me second side of the second panel; and inserting a peg member through the peg locating means of the locating members to hold die panels rigidly togedier. 21. A box panel moulded from plastics material, comprising: a wall member comprising a front face, a rear face, a top, a bottom, a first side and a second side; and at least one complementary locating member forming a channel for locating a peg member therein on each of the first and second sides of the wall member; characterised in that the locating member comprises a U-shaped member having a first side integrally moulded widi a side of die wall member, a second side opposed to the first side, a back face and an open front face and wherein the locating member further comprises a tab integrally moulded widi at least one side of the U-shaped member and extending across the open front face of the locating member and die back face has a cut out section opposed to die tab and of at least die same dimensions as die tab. 22. A flat-pack box comprising a plurality of panels and a plurality of locking members, wherein each panel comprises a wall member comprising a front face, a rear face, a top, a bottom, a first side and a second side; and die locking members comprise a first element and a second element, me first element being integral widi die wall member and me second element comprising a separate locating means for locating with the first element to form a rigid connection u erewith, wherein the first element of the locking member comprises a peg member on the first and second sides of die wall member and die second element of the locking member comprises a plurality of collar members, the collar members each having peg locating means therethrough for fitting over the peg members. 23. A box according to claim 22 wherein me collar member comprises a right angled collar having two elongated peg locating means -hereti--rough. 24. A box according to claim 22 or claim 23 wherein me peg members each comprise an elongated element integrally moulded widi the wall member rear face. 25. A box according to claim 24 wherein me peg members each have a trapezoidal cross section. 26. A method of assembling a box according to any one of claims 22 to 25 comprising steps of: locating a first panel adjacent a second panel; and fitting a collar member over the peg members such that the peg locating means of me collar member fits over the peg members to hold the panels rigidly together. 27. A box as hereinbefore described with reference to Figures 1 to 4 of die drawings. 28. A box as hereinbefore described widi reference to Figure 5 of the drawings.

Inventors: LAWRENSON ARTHUR JOHN, LEE JAMES ROTHWELL, LAWRENSON, ARTHUR, JOHN, LEE, JAMES, ROTHWELL
Applicants: LAWRENSON ARTHUR JOHN, LEE JAMES ROTHWELL, POLETECH SYSTEMS LTD, LAWRENSON, ARTHUR, JOHN, LEE, JAMES, ROTHWELL, POLETECH SYSTEMS LIMITED
Application year: 1998
Main classification: H02B1
IPC codes: B65D6, E02D29, H02G9