Abstract:
A folding container has a base, side support tubes upstanding from the corners of the base, and side panels located between the side support tubes and arranged to bound a storage space. Pivots are arranged to pivotally mount the side panels onto the side support tubes. The pivot for each side panel is disposed in a different horizontal plane to that of any other panel, such that when the container is in a folded state the side panels lie stacked substantially parallel to the base, and when in an unfolded state the side panels are substantially orthogonal to the base.

Description:
BACKGROUND OF THE INVENTION 
   1) Field of the Invention 
   This invention relates to a folding container and in particular to but not exclusively to a packing case, a shipping crate or a freight container. 
   2) Description of the Related Art 
   Containers are required for a variety of purposes and, in many circumstances, such as moving automotive parts or possessions between houses or flats and in the case of mobile offices, it is necessary for the container to be sufficiently sturdy to protect the container contents from damage when it is moved or accidentally knocked. However, such a container is unlikely to be in constant use, and as a result it would be advantageous if it could be stored in a flat condition when it is not required. 
   Containers having opposing side walls which fold onto a base panel have been described in DE 1 144 178 and DE 2 139 147. 
   U.S. Pat. No. 3,941,271 relates to a collapsible receptacle having inwardly and outwardly directed projections on a base panel frame and sidewalls. The outwardly directed projection of the sidewall overlaps the inwardly directed projection of the base panel frame to maintain the receptacle in the assembled non-collapsed condition such that a tilting of the sidewalls is necessary to raise the sidewall. 
   U.S. Pat. No. 5,642,830 describes a container having top and bottom members, and columnar members which are received in the top and bottom members when the container is in the assembled condition. When the container is disassembled the columnar members and side members may be stored inside the top and bottom members which are jointed together so that the disassembled container forms an integral unit. 
   A collapsible container is described in EP 1 028 061 having side panels associated with a base panel and movable between a collapsed and an assembled condition. The container is releasably retained in the assembled condition by side supports engaging adjacent side panels, the side supports comprising upright members demountably secured to the base panel and received and retained by a receptacle secured at or adjacent to the corners of the base panel. 
   There remains, however, a need for a compact, economical folding container design which can be readily converted from a folded to an unfolded state and which is adaptable for industrial use e.g. in shipping and intermodal containers. 
   SUMMARY OF THE INVENTION 
   A preferred feature of the present invention is directed to a folding container comprising a base panel, side support means upstanding from the corners of the base panel, side panels located between the side support means and arranged to bound a storage space, and pivot means arranged to pivotally mount the side panels onto the side support means, 
   wherein the pivot means for each side panel is disposed in a different horizontal plane to that of any other panel, such that when the container is in a folded state the side panels lie stacked substantially parallel to the base panel, and when in an unfolded state the side panels are substantially orthogonal to the base panel. 
   In a preferred embodiment the side support means includes a two part columnar member comprising a first member adjacent to the base panel and a second member remote from the base panel, the second member being pivotally secured to the first member at a position such that when the container is in the folded state the second member can be folded onto a surface of an upper one of the stacked side panels. 
   Preferably each side panel is pivotally mounted onto each of two adjacent side support means. More preferably each side panel substantially occupies a space between adjacent support means onto which each side panel is mounted. 
   Preferably the pivot means of each side panel comprises a male means cooperating with a slot in an edge of the side panel which is adjacent to the side support means when the container is unfolded, wherein said slot is terminated. 
   The male means may be arranged to be a free sliding fit along the length of a mating slot in each of the panel edges. 
   Preferably the male means comprises a pair of circularly cross sectioned pins located on adjacent side support means, wherein each pair of pins is arranged to mount side panels each at a different distance from the base panel. 
   In a preferred embodiment a first pair of pins associated with a first side panel is located at a distance T-S/2 from the base panel, where T is S+R, S is the thickness of a side panel, and R is the distance between adjacent panels, a second pair of pins associated with a second side panel is located at a second distance, which is 2T-S/2 from the base panel, a third pair of pins associated with a third side panel is located at a third distance, which is 3T-S/2 from the base panel, and a fourth pair of pins associated with a fourth side panel is located at a fourth distance, which is 4T-S/2 from the base panel. 
   Securing means may be provided on the side panels to secure each individual side panel in the unfolded state. 
   A cover panel may be pivotally mounted onto one of the side panels. 
   Preferably the side panels are formed from metal or plastic sheet material. 
   In a particularly preferred embodiment the base panel, side panels and support means form an integral unit. 
   In another embodiment the invention is directed to a folding container comprising a base panel, side support means upstanding from the corners of the base panel, side panels located between the side support means and arranged to bound a storage space, and pivot means arranged to pivotally mount the side panels onto the side support means, 
   wherein the pivot means for each side panel is disposed in a different horizontal plane to that of any other panel, such that when the container is in a folded state the side panels lie stacked substantially parallel to the base panel, and when in an unfolded state the side panels are substantially orthogonal to the base panel, 
   and the side support means includes a two part columnar member comprising a first member adjacent to the base panel and a second member remote from the base panel, the second member being pivotally secured to the first member at a position such that when the container is in the folded state the second member can be folded onto a surface of an upper one of the stacked side panels. 
   In a further embodiment the invention provides for a folding container comprising a base panel, side support means upstanding from the corners of the base panel, side panels located between the side support means and arranged to bound a storage space, and pivot means arranged to pivotally mount the side panels onto the side support means, wherein: 
   the pivot means for each side panel is disposed in a different horizontal plane to that of any other panel, such that when the container is in a folded state the side panels lie stacked substantially parallel to the base panel, and when in an unfolded state the side panels are substantially orthogonal to the base panel, 
   the pivot means of each side panel is provided by a slot in each edge of the side panel which are adjacent to the side support means when the container is unfolded, said slot being terminated, and male means located on the side support means arranged to engage with the slots, 
   the male means comprises a pair of circularly cross sectioned pins located on adjacent side support means, wherein each pair of pins is arranged to mount side panels each at a different distance from the base panel, 
   and a first pair of pins associated with a first side panel is located at a distance T-S/2 from the base panel, where T is S+R, S is the thickness of a side panel, and R is the distance between adjacent panels, 
   a second pair of pins associated with a second side panel is located at a second distance, which is 2T-S/2 from the base panel, 
   a third pair of pins associated with a third side panel is located at a third distance, which is 3T-S/2 from the base panel, and 
   a fourth pair of pins associated with a fourth side panel is located at a fourth distance, which is 4T-S/2 from the base panel. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The present invention will be further understood by reference to the accompanying drawings showing an exemplary embodiment thereof. 
       FIG. 1  is a perspective view of a preferred embodiment of a container in accordance with this invention in a folded state, 
       FIG. 2  is a top view of the container in an unfolded state, 
       FIG. 3  is a perspective view of a side panel of the container, 
       FIG. 4  is a perspective view of a base panel of the container, 
       FIGS. 5 and 6  show mutually orthogonal side views of a side support means in an unfolded state, 
       FIGS. 7   a  and  7   b  show side views of the side support means in different operational states thereof, 
       FIG. 8  is a perspective view of the container shown in  FIG. 1  with the side support means partially unfolded, 
       FIGS. 9 ,  10  and FIGS.  11 , 12  respectively show alternative constructions for moving a side panel from a folded to an unfolded state, 
       FIGS. 13  shows a side panel onto which a cover panel is to be mounted, 
       FIGS. 14   a  and  14   b  show a pivoting arm of the side panel of  FIG. 13  in different operational states, 
       FIGS. 15 and 16  show a cover panel being moved from a folded to an unfolded state, and 
       FIG. 17  shows the fully unfolded container with side panels secured. 
   

   In the Figures like reference numerals have the like parts. 
   DESCRIPTION OF THE PREFERRED EMBODIMENTS 
   The folded container illustrated in  FIG. 1  has a substantially rectangular base panel  1 , four side panels  2  stacked on top of the base panel, and four two-part side support tubes  3  upstanding from the corners of the base panel, each support tube having a lower member  4  adjacent to the base panel and an upper member  5  remote from the base panel. The support tubes  3  have a circular cross section but it will be understood that other suitable cross sections may be used. The upper member  5  is pivotally secured to the lower member  4  and is folded onto the surface  6  of the upper stacked side panel. The base panel  1 , side panels  2  and side support tubes  3  are formed from metal sheet material. 
   Referring to  FIG. 2 , each of the side panels  2  in the unfolded container occupies the space between two adjacent side support tubes  3  onto which the side panels are pivotally mounted, as will now be described. 
     FIG. 3  shows a side panel  2  having a terminated longitudinal slot  7  in one edge  8 . A similar slot is located in the opposing edge of the side panel. 
   Four pairs of laterally projecting cylindrical pins  9 ,  10 ,  11  and  12  are located on the lower members  4  of adjacent support tubes as shown in  FIG. 4 . Each pair of pins is located at a different distance from the base panel with respect to any of the other pairs. Preferably the first pair of pins  9  closest to the base panel are located at a distance T-S/2 from the base panel, where T is S+R, S is the thickness of a side panel, and R is the distance between adjacent side panels, the second pair of pins  10  at a distance 2T-S/2 from the base panel, the third pair of pins  11  at a distance 3T-S/2 from the base panel, and the fourth pair of pins  12  furthest from the base panel are at a distance 4T-S/2 from the base panel. 
   Each side panel  2  is mounted onto adjacent support tubes  3  by engagement of the relevant pair of slots  7  in the side panel edges  8  with a corresponding pair of cylindrical pins  12  as shown in  FIG. 11 . Each slot  7  is closed at opposing ends to retain the pin  12  associated therewith. The pins  12  engage with the slots  7  in a free sliding fashion so that the side panel  2  can undergo translational movement in the slot plane as well as pivotal movement about the pin axis. The spacing of the pairs of pins  12  from the base panel  1  ensures that in the folded state the side panels  2  stack together in different horizontal planes overlying the base panel  1  as shown in  FIG. 1 . 
   Referring to  FIGS. 5 and 7   a,  the upper member  5  of a side support tube  3  has an extension  50  formed by a pair of opposed flat surfaces  13  projecting from its lower end with a longitudinal opening  14  therein. Part of the wall of the lower member  4  of the side support tube  3  projects vertically from its upper end to form two opposing end pieces  15 , each end piece having a circular hole  16  located therein as shown in the mutually orthogonal side views of  FIGS. 5 and 6 . The opposing end pieces  15  define a recess  17 , which partially extends into the tubular lower member  4 , and which is dimensioned so as to receive the extension  50  of the upper member  5  in close fitting engagement, with the holes  16  aligning with the longitudinal opening  14  of the extension  50 . A cylindrically cross sectioned bar  18  projects laterally through opposing holes  16  and opening  14  so as to retain the upper member  5  of the side support within the lower member  4 . The bar  18  is in sliding engagement with the extension  50  so that the upper member  5  can be vertically extended with respect to the lower member  4  ( FIG. 7   a ). 
   Referring to  FIGS. 7   a  and  7   b  the side support  3  can be moved from a substantially vertical unfolded position to a folded position substantially perpendicular to the lower member  4  by extending the upper member  5  until the lower edge  19  of the extension  50  is clear of the upper edge  20  of the lower member followed by rotation of the upper member  5  about the axis of the bar  18 . 
   In erecting the container from a collapsed, folded condition, a first step is to rotate the upper members  5  of the four side support tubes  3  in turn from the folded position, where the upper members  5  are lying on the surface  6  of the uppermost side panel  2  as shown in  FIG. 1 , to the unfolded position where the upper members  5  are substantially vertical and form continuous columns with the corresponding lower members  4  as shown in  FIG. 8 . 
   In a second step each side panel  2  of the container is moved in turn from a folded to an unfolded position and preferably fastened to adjacent side support tubes  3  before the next side panel is unfolded. There are two alternative methods for performing this step as shown in  FIGS. 9 ,  10  and in  FIGS. 11 ,  12  respectively. 
   In a first method the edge  21  of the uppermost side panel  2  furthest from the side support tubes  3  onto which it is mounted is raised and rotated upwards towards the side support tubes  3  (shown in  FIG. 9 ). When the side panel  2  is in a substantially vertical position, with the opposing edges  8  parallel to the corresponding side support tubes  3 , the side panel  2  is lowered vertically towards the container base panel  1  and into the unfolded position with a bottom edge  22  of the side panel resting on the upper surface of the base panel  1  (shown in  FIG. 10 ). The side panel  2  is then fastened to adjacent side support tubes  3  by sliding engagement of bolts  34  secured to the side panel  2  within corresponding recesses  37  in the side support tubes  3 . The process is repeated for the remaining side panels in turn. 
   In a second method the uppermost side panel  2  is slid in a substantially horizontal plane outwards between the side support tubes  3  onto which it is mounted (shown in  FIG. 11 ). When the side panel  2  has been translated in this plane as far from the side support tubes  3  as the slots  7  in the edges  8  will allow, the edge  23  of the side panel  2  furthest from the side support tubes  3  is raised and rotated upwards towards the side support tubes  3  (shown in  FIG. 12 ). When the side panel  2  is in a substantially vertical position, with the opposing pivoting edges  8  parallel to the corresponding side support tubes  3 , the side panel  2  is lowered vertically towards the container base panel  1  and into the unfolded position with the bottom edge of the side panel resting on the upper surface of the base panel  1 . The side panel  2  is then fastened to adjacent side support tubes  3  as described in the first method. The process is repeated for the remaining side panels in turn. 
   A cover panel  30  is pivotally mounted onto the side panel  2  that is uppermost when the container is in the folded state by pivoted arms  24  as shown in  FIGS. 13-15 . Each arm  24  has a pin  29  arranged to co-operate with a slot  31  in opposing edges  32  of the cover panel  30 . The arm  24  also has an arcuate slot  25  cooperating with a pin  27  extending laterally through the curved slot  25  and in free sliding engagement therein. The arm  24  is secured to the edge  8  of the side panel  2  by a pin  26  ( FIG. 14   a ). The arm  24  can be partially rotated from a vertical position by pivoting about the pin  26  and sliding of the pin  27  through the slot  25  as shown in  FIG. 14   b.    
   When all four side panels  2  have been moved from the folded to the unfolded position the upper edge  33  of the cover panel  30  is moved from a position substantially parallel to the major face of the side panel onto which it is mounted to an angled position by rotation of the arm  24  about the pin  26  as described above as shown in  FIG. 15 . The cover panel  30  is then moved upwards and away from the side panel  2  as shown in  FIG. 16  by rotation about the pin  24  and sliding of the pin  24  along the slot  31  in the edge  32  of the cover panel  30  until it is resting on the upper edges of a front side panel  35  and a rear side panel  36  and substantially parallel to the container base panel  1  as shown in  FIG. 17 . 
   The container is unfolded to a collapsed condition by reversing the steps described above. 
   The person of ordinary skill in the art will appreciate that many modifications to the described embodiment are possible without departing from the spirit and scope of the invention defined in the appended claims. For instance wheels can be adapted to the base panel; the side support tubes may have any suitable transverse cross section; although the panels are preferably formed from metal, they could be formed of plastics or any other suitable material; the container can be suited for different uses and be of different sizes.