Abstract:
A container that is convertible between a collapsed configuration and deployed configuration. The container includes a lower base assembly having sides, and an upper base assembly that is removably coupled to the lower base assembly. A plurality of removable supports are removably erected between the lower base assembly and the upper base assembly when the container is in the deployed configuration, and stowed between the lower base assembly and the upper base assembly when the container is in the collapsed configuration. The container may further include a plurality of sidewalls disposed between the supports and the upper and the lower base assemblies. The sidewalls may each be hingedly coupled to a respective side of the base assembly such that the sidewalls are deployable between the collapsed configuration and a deployed configuration.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims the benefit of U.S. Provisional Application No. 61/104,485, filed on Oct. 10, 2008. The entire disclosure of the above application is incorporated herein by reference. 
    
    
     FIELD 
     The present disclosure relates to a collapsible container. 
     BACKGROUND 
     This section provides background information related to the present disclosure which is not necessarily prior art. 
     Containers may be used for a variety of purposes including storage and shipping. When the container is empty and not in use, however, the container may take up a significant amount of space in, for example, a warehouse. Moreover, an unused empty container is costly to transport due to the amount of space that it occupies, which may result in multiple trips to transport a plurality of the empty containers. Multiple trips may result in increased fuel costs needed to transport the containers. 
     SUMMARY 
     This section provides a general summary of the disclosure, and is not a comprehensive disclosure of its full scope or all of its features. 
     The present disclosure relates to a container deployable between a collapsed configuration and deployed configuration. The container includes a lower base assembly, and an upper base assembly that is removably coupled to the lower base assembly. A plurality of removable supports are erect between the lower base assembly and the upper base assembly when the container is in the deployed configuration, and stowed between the lower base assembly and the upper base assembly when the container is in the collapsed configuration. The container may further include sidewalls disposed between the supports and the upper and the lower base assemblies. The sidewalls may be hingedly coupled to one of the base assemblies such that the sidewalls are deployable between the collapsed configuration and the deployed configuration. 
     Further areas of applicability will become apparent from the description provided herein. The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure. 
    
    
     
       DRAWINGS 
       The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure. 
         FIG. 1  is a perspective view of a container in a collapsed configuration according to a principle of the present disclosure; 
         FIG. 2  is a perspective view of a container in a deployed position according to a principle of the present disclosure; 
         FIG. 3  is a bottom perspective view of a container according to a principle of the present disclosure; 
         FIG. 4  is a cross-sectional view a container according to the present disclosure; 
         FIG. 5  is an exploded perspective view of a container in a deployed configuration without sidewalls according to a principle of the present disclosure; 
         FIG. 6  is a perspective view of a container in a deployed configuration without sidewalls according to a principle of the present disclosure; 
         FIG. 7  is a perspective cross-sectional view of a joint between a pair of sidewalls and the floor of a container according to a principle of the present disclosure; 
         FIG. 8  is a cross-sectional view of a sidewall and hinge of a collapsed container according to a principle of the present disclosure; 
         FIG. 9  is a cross-sectional view of the sidewall and hinge of a container as the sidewall begins to move from the collapsed configuration to the deployed configuration according to a principle of the present disclosure; 
         FIG. 10  is a cross-sectional view of the sidewall and hinge of in a fully deployed configuration, according to a principle of the present disclosure; 
         FIG. 11  is a perspective view of a ramp assembly that may be used in conjunction with a collapsible container, according to a principle of the present disclosure; 
         FIG. 12  is a front perspective view of a pair of stacked containers in a deployed configuration, according to a principle of the present disclosure; and 
         FIG. 13  is a perspective view of a plurality of stacked containers in a collapsed configuration, according to a principle of the present disclosure. 
     
    
    
     Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings. 
     DETAILED DESCRIPTION 
     Example embodiments will now be described more fully with reference to the accompanying drawings. 
       FIGS. 1-6  illustrate a container  10  according to the present disclosure.  FIG. 1  illustrates container  10  in a collapsed configuration.  FIGS. 2-5  illustrate container  10  in a deployed configuration. Container  10  includes a lower base assembly  12  and an upper base assembly  14 . Lower base assembly  12  includes lower frame members  17 ,  18 ,  21 , and  23  that may be disposed along sides of container  10  that form a width W and a length L of container  10 . Width W and length L may each be about 7 feet in length. One skilled in the art, however, will readily acknowledge and appreciate that container  10  may be modified to include any width W and length L desired. Moreover, as will be described later, each of lower frame members  17 ,  18 ,  21 , and  23  include different heights. 
     Supporting lower frame members  17 ,  18 ,  21 , and  23  are a plurality of cross-beams  20 . Cross-beams  20  may each be spaced from each other at a distance that is satisfactory to accommodate tines of a fork-lift. In this manner, regardless of whether container  10  is in a deployed or collapsed configuration, container  10  may be easily transported or stacked. Disposed on cross-beams  20  and between lower frame members  17 ,  18 ,  21 , and  23  is a floor panel  19 . 
     As illustrated in  FIGS. 1 and 5 , upper base assembly  14  includes upper frame members  22 . Disposed between one set of opposed upper frame members  22  are one or more trusses  26 . Upper frame members  22  and trusses  26  may support a roof panel (not shown). To accommodate another container  10  stored thereon, upper base assembly  14  may include protrusions  24  that are formed at corners between upper frame members  22 . Protrusions  24  may be male mounting portions that are adapted to mount or engage with female mounting portions  25  ( FIG. 3 ) that may be formed at corners of lower base assembly  12 . Female mounting portions  25  may be formed at corners of the cross-beams  20 . 
     Container  10  also includes primary support members  32 . Primary supports  32  may be hollow, square or rectangular tubular members or, as shown in  FIG. 1 , may be substantially L-shaped. When container  10  is in the collapsed configuration, primary support members  32  are stowed between upper base assembly  14  and lower base assembly  12 . 
     When container  10  is in a deployed configuration, referring to  FIG. 2 , primary supports  32  mount between and to secondary supports  34  and upper frame members  22 . Secondary supports  34  are formed and attached to the lower base assembly  12  at joints located between lower frame members  17 ,  18 ,  21 , and  23 . As shown in  FIGS. 1 and 2 , secondary supports  34  are formed to have a height less than that of primary supports  32 . In this manner, when collapsible container  10  is in the collapsed configuration, container  10  may have a height that is substantially less than that of collapsible container  10  when in its deployed configuration. In particular, container  10  may have a height H 1  in a deployed configuration of about 7 feet. In the collapsed configuration, container  10  may have a height H 2  of about 16 to 24 inches, with a preferred height H 2  of about 19 to 20 inches. 
     Materials that may be utilized to fabricate upper base assembly  14 , lower base assembly  12 , primary supports  32 , secondary supports  34 , and trusses  26  include metal materials such as steel and aluminum, and rigid plastic materials as are known in the art. One skilled in the art will appreciate, however, that additional materials are contemplated and, therefore, the present disclosure should not be limited to the above-noted materials. 
     Now referring to  FIGS. 1 ,  2 ,  4  and  7 - 11 , container  10  includes a plurality of sidewalls  28 . Sidewalls  28  are shown collapsed in  FIG. 1 , while  FIG. 2  illustrates sidewalls  28  in a deployed configuration.  FIG. 4  illustrates sidewalls  28  that may include an outer panel  40  and an inner panel  42 , with a plurality of support brackets  44  therebetween to provide strength and rigidity to sidewalls  28 . Panels  40  and  42  of sidewalls  28  may be formed of materials such as plywood, plastic-coated plywood, corrugated aluminum, corrugated plastic, or any other material that may be desired depending on the use of container  10 . To provide access to an interior  50  of container  10 , a doorway  30  may be formed in one of sidewalls  28 . Doorway  30  may be provided with a handle  60  that may include locking mechanism  62  to secure contents stowed within container  10 . 
     To deploy container  10  from a collapsed configuration to a deployed configuration, upper base assembly  14  may be removed from lower base assembly  12 . Primary supports  32  may be then removed from storage on lower base assembly  12  and mated with secondary supports  34 . Once primary supports  32  are mated with secondary supports  34 , upper base assembly  14  may be mounted atop the free ends of primary supports  32 . 
     After primary supports  32  are mounted to secondary supports  34 , sidewalls  28  may be deployed. Sidewalls  28  may be deployed either prior to or after upper base assembly  14  is mounted atop secondary supports  34 . To deploy sidewalls  28 , referring to  FIGS. 6-9 , sidewalls  28  may be pivotably connected to respective sides of lower base assembly  12  by hinges  70 . In particular, sidewalls  28  may be hingedly connected to each of lower frame members  17 ,  18 ,  21 , and  23 . As best shown in  FIG. 6 , lower frame members  17  and  18  are formed to have different heights. Although not shown, lower frame members  21  and  23  are also formed to have different heights relative to each other, as well as to lower frame members  17  and  18 . Accordingly, sidewalls  28  hingedly connected to each of lower frame members  17 ,  18 ,  21 , and  23  each have a different height. Lower frame members  17 ,  18 ,  21 , and  23  each having a different height enables sidewalls  28  hingedly connected thereto to collapse inward without interfering with one another ( FIG. 1 ). 
     As best shown in  FIGS. 8-10 , outer panel  40  of sidewalls  28  may include a static seal  80  at a lower portion  82  thereof. As sidewalls  28  are lifted ( FIGS. 9-10 ), static seals  80  abut flanges  84  that axially extend from each of lower frame members  17 ,  18 ,  21 , and  23 . When static seals  80  abut axially extending flanges  84 , container  10  is made weather- and water-resistant. This enables container  10  to be used in a variety of manners including transporting goods at sea, storing goods outdoors, and the like. Although not illustrated in the Figures, it should be understood that static seal  80  may extend around an entire perimeter of outer panel  40  of sidewall  28  to engage surfaces of axially extending flange  84 , primary supports  32 , secondary supports  34 , and upper frame assembly  14  to provide container  10  with a weather- and water-resistant seal around the entire container  10 . In addition, as also shown in  FIGS. 8-10 , lower base assembly  12  further includes a floor support member  31  to which cross-beams  20  and lower frame members  17 ,  18 ,  21 , and  23  are secured. 
     To maintain sidewalls  28  in a deployed configuration, hinges  70  may be a spring-loaded or locking type of hinge. Alternatively, upper base assembly  14  may include a groove (not shown) sized to accommodate an upper surface or edge of sidewall  28  that maintains sidewall  28  therein in the deployed configuration when upper base assembly  14  is placed in position atop the deployed container  10 . In larger configurations of container  10 , sidewalls  28  may be actuated to the deployed configuration using a mechanical device (not shown) such as an electric motor, hydraulic device, or any other mechanical device known to one skilled in the art. 
     Referring to  FIG. 11 , container  10  may include a ramp assembly  90 . To accommodate ramp assembly  90 , cross-beams  20  formed below doorway  30  may be formed to have a recessed portion  92  that is adapted to accommodate ramp assembly  90 . Recessed portion  92  may be formed between cross-beam  20  and lower frame member  18 . Moreover, ramp assembly  90  may be shaped to mate with the recess  92  formed in cross-beam  20 , Ramp assembly  90  enables a user or operator to more easily wheel merchandise or other material to be stowed within container  10 . 
       FIGS. 12 and 13  illustrate collapsible containers  10  in a stacked orientation in deployed configurations and collapsed configurations, respectively. Specifically, referring to  FIG. 12 , it may be seen that at least two (and as many as three) collapsible containers  10  in their deployed configuration may be stacked. In contrast, when collapsible container  10  is in a collapsed configuration, up to four collapsible containers may be stacked ( FIG. 13 ). By stacking collapsible containers  10  in their collapsed configuration in this manner, better use of storage space within a warehouse may be utilized. In addition, transportation of the collapsible containers  10  when they are not in use becomes more efficient, which reduces fuel costs and storage costs, respectively. 
     The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the invention, and all such modifications are intended to be included within the scope of the invention.