Patent Publication Number: US-10315801-B2

Title: Collapsible box

Description:
PRIORITY STATEMENT 
     This US non-provisional application claims priority under 35 USC § 119 to European Patent Application No. 16168146.5, which was filed on May 3, 2016, the entire content of which is incorporated herein by reference. 
     BACKGROUND 
     1. Technical Field 
     The present invention relates to a collapsible container and more specifically to a collapsible box. 
     2. Description of Related Art 
     In the global society we live in today we are used to always getting almost every product no matter which country the product comes from all year around. This means a lot of transportation. Packaging, storing and transportation have become a huge industry which has to constantly develop in order to keep up with the changing supplies of products, quantities and storage demands. For transportation, trucks are often used and this might not be the best option from an environmental point of view. Thus, transportation with trucks has to be optimized for environmental reasons. 
     Also, in order to reduce lead time and lower costs the transportation and storage process demand easy and efficient packaging. An example is a classic loading pallet, which might be easy to pack in but which is not advantageous when it is empty. 
     The publications WO 2013/002725 and WO 2006/011093 are two examples of prior art which have developed the area of packaging but both of these known boxes have disadvantages. The first one is a rather simple box with several parts that after some time in use can start to cause problems, especially around the hinge connection between the bottom edge of the side wall and the edge of the base member. The hinge connection is also disadvantageous from a manufacturing and assembling perspective. Further, the known plastic box lacks of strength and stability when stacking many boxes on top of each other. 
     The second known box is a more complex construction with many small details, which makes the manufacturing process even more difficult. Another disadvantage with this box is that a part of it covers the space within the box which makes it difficult to pack goods into it, and even more difficult if the packing process is made by a robot. Yet another disadvantage is that the heads of the container may be difficult to find when trying to stack a second container on top of the first. 
     Thus there is room for improvements in proposing a container or box that is suitable for all types of goods and demands both in a situation when transporting goods and in a situation when it is empty. 
     SUMMARY 
     An object of the present invention is to provide an improved collapsible box. This object is achieved by a technique defined in the appended independent claims; certain embodiments being set forth in the related dependent claims. 
     In a first aspect, there is provided a collapsible box having a bottom with a plurality of side edges, a plurality of foldable walls each of which is hinged to one side edge of the bottom respectively. Each wall is foldable between a collapsed state and an erected state, in which the walls are connected by locking means. The bottom together with the walls in the erected state define a space. Further, the bottom comprises a guiding element configured to receive at least a part of an upper rim of another collapsible box stacked underneath. This improved box with its guiding element makes it very easy to stack and it is well suited for both manual work and automated processes. 
     In an embodiment, guiding element is a groove arranged along said side edges of an outer surface of said bottom. A groove is easy to find when it is hard to see every part of the boxes when stacking them together. The bottom with the groove of the box on top of another is easy to guide into the right position and the worker stacking the boxes does not have to care to make sure that every part of the boxes is in their right position when stacked. It is also easy to manufacture a groove and not run the risk of being damaged during the handling process and storage. 
     In another embodiment, the groove is configured to receive the upper rim of another collapsible box stacked underneath. It is advantageous to receive the entire upper rim of the other box to increase the stability and strength of the pile of boxes. 
     In yet another embodiment, the box substrate is made in one piece. This is advantageous from a manufacturing, an assembling and a handling point of view. With no additional parts there is no risk of losing any during handling, transportation or storing processes. Also it makes the assembling process easier which can be managed by one person or be completely automated. 
     In an embodiment, the box is stackable in said collapsed state in which the box substrate is substantially planar. This reduces the volume needed when transporting empty boxes, thus increasing the number of boxes that can be transported in for example one truck. 
     In another embodiment, each wall forms in said erected state an angle of less than 90° to said bottom. This gives the box even more stacking advantages. 
     In yet another embodiment, the box comprises a first wall of said walls and a second wall of said walls where the second wall is configured to be connected to and partly overlap the first wall in the erected state. 
     Preferably, the at least one part of a top edge of the second wall at least partly overlapping the first wall slightly protrudes above the first wall in a direction away from the bottom. This is beneficial since the load of the boxes stacked on top of the box is taken and controlled by the top edge and the part of the second wall over lapping the first wall. The load can then be controlled to preferred parts of the box and not affect weaker spots. 
     In another embodiment, the second wall comprises a first and a second foldable extended wall portion and an intermediate wall portion, wherein the first and the second extended wall portions are hinged to a first and a second edge of said intermediate wall portion respectively. Further, in an embodiment the first and second extended wall portion are arranged to at least partly engage an inner surface of said first wall respectively, in said erected state. The extended wall portions are easy to fold and attach when assembling the box and can easily be made by one person or be completely automated. 
     In yet another embodiment, the first and second extended wall portion comprises at least one reinforcement element and said first wall comprises at least one reinforcement element, which is shaped to fit and arranged within the reinforcement element of the first and second extended wall portion respectively, in said erected state. The reinforcement elements of both walls together increase the strength and stability of the box, especially when boxes with load are stacked on top. 
     Further, in an embodiment, the at least one reinforcement element of said extended wall portions and said at least one reinforcement element of said first wall is shaped as a wedge. This shape even more increases the strength and stability of the box. It is also advantageous when manufacturing the box substrate and when stacking the box substrate in the collapsed state. 
     In yet another embodiment, at least a part of a top edge of the first and second extended wall portion slightly protrude above said first wall in a direction away from the bottom, in said erected state. This is advantageous since the load of the boxes stacked on top of the box is taken and controlled by the top edge and the part of the second wall over lapping the first wall. The load can then be controlled to preferred parts of the box and not affect weaker spots. 
     Preferably, the first and second extended wall portion comprise at least one protruding part which is arranged to engage at least one recess of said bottom in the erected state. This is favorable since the extended wall portions are guided into the right position when assembling the box and the extended wall portions are every time placed in the same position no matter if a person or a robot does the job. The protruding parts and recesses also make it possible for the extended wall portions to stay in the same place during use. 
     In yet another embodiment, the first and second extended wall portion are connected to said first wall respectively by means of said fastening means, wherein said fastening means is a snap-lock arrangement. The snap-lock arrangement is an easy locking arrangement and can be managed by both a person and a robot. 
     Further, in an embodiment each wall further comprises a reinforcement element having a base part arranged in a direction away from said bottom. The base may act as an extra support when stacking boxes on top of each other as a box may rest thereon. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Embodiments of the invention will be described in the following, reference being made to the appended drawings which illustrate non-limiting examples of how the inventive concept can be reduced into practice. 
         FIG. 1  is a perspective view of a collapsible box according to an embodiment shown in its erected state. 
         FIG. 2  is a front view of two collapsible boxes, shown in  FIG. 1 , stacked on top of each other. 
         FIG. 3  is a bottom view of the box in  FIG. 1 . 
         FIG. 4  is a bottom view of the two boxes of  FIG. 2  stacked on top of each other. 
         FIG. 5  is a cross sectional view showing the inside of a section of the two stacked boxes in  FIG. 2 . 
         FIG. 6  is a front view of the box in  FIG. 1 . 
         FIG. 7  is a side view of the box in  FIG. 1 . 
         FIG. 8  is a perspective view of the box in  FIG. 1  shown in its collapsed state. 
         FIG. 9  is a top view of the box in  FIG. 7 . 
         FIG. 10  is a perspective view of the box in  FIG. 1  in a folding state. 
         FIG. 11  is a perspective view of the box in  FIG. 1  in a folding state. 
         FIG. 12  is a top view of the box in  FIG. 1 . 
         FIG. 13  is a detailed view of a section of one side of the box in  FIG. 1 . 
         FIG. 14  is a perspective view of two boxes before stacked on top of each other. 
     
    
    
     DESCRIPTION OF NON-LIMITING EMBODIMENTS 
     With reference to the figures a collapsible container or collapsible box  1  is shown, from now on just called the box  1 . The box  1  is preferably made of a plastic material and designed such that it is possible for it to assume different states, e.g. a collapsed state and an erected state. For example  FIGS. 1-7  show the box  1  in its erected state and  FIGS. 8 and 9  show the box substrate  1 ′ in the collapsed state, where the box substrate  1 ′ is planar. The box substrate  1 ′ is manufactured in one piece and is in no need of any additional elements when assembled into the box  1 . Its erected state is preferred when handling, storing and transporting goods and its collapsed state is preferred for storage and transportation of empty boxes. 
     The box  1  has a bottom  10  with a plurality of side edges  11   a ,  11   b ,  11   c ,  11   d . In the described embodiment two of the side edges  11   a ,  11   c  are shorter than the other two  11   b ,  11   d . Along the side edges  11   a ,  11   b ,  11   c ,  11   d , on the outer surface  12  of the bottom  10  there is a guiding element  14  provided. The guiding element is in this case a groove  14  arranged to act as a guide when stacking one box in the erected state on top of another. The groove  14  is shaped to match the top rim  3  of another collapsible box, stacked under the first box and the groove  14  helps to increase the stability of a pile when several boxes are packed on top of each other. The bottom  10  further has reinforcement sections  15   a ,  15   b  which are arranged to increase the strength and stability of the box  1 . 
     Furthermore, the box  1  has a first set of foldable walls  20 ,  30  and a second set of foldable walls  40 ,  50 , wherein each wall  20 ,  30 ,  40 ,  50  is at least partly hinged to one side edge  11   a ,  11   b ,  11   c ,  11   d  of the bottom  10  respectively. Each wall  20 ,  30  of the first set are preferably identical and will from now on be called the long-side walls  20 ,  30 . Thus, features of the long-side wall defined in the description will apply to both walls  20 ,  30 . The same goes for the walls  40 ,  50  of the second set. These are also identical and will from now one be called the short-side walls  40 ,  50 . 
     The long-side walls  20 ,  30  are preferably hinged to respective longer side edge  11   b ,  11   d  of the bottom  10  by means of a hinge arrangement  16 . The short-side walls  40 ,  50  are preferably at least partly hinged to respective shorter side edge  11   a ,  11   c  by means of the hinge arrangement  16 . The hinge arrangement  16  connects one wall  20 ,  30 ,  40 ,  50  to one side edge  11   a ,  11   b ,  11   c ,  11   d  of the bottom and allows the walls  20 ,  30 ,  40 ,  50  to be folded between the collapsed state and the erected state. Furthermore, the hinge arrangement  16  is an integrated hinge arrangement formed by an area with less material than the adjacent walls  20 ,  30 ,  40 ,  50  and bottom  10 . 
     The short-side wall  40 ,  50  has an intermediate wall portion  41 ,  51  and two extended wall portions  42 ,  43 ,  52 ,  53 . The first extended wall portion  42 ,  52  is hinged to a first edge  44 ,  54  of the intermediate wall portion  41 ,  51  and the second extended wall portion  43 ,  53  is hinged to a second edge  45 ,  55  of the intermediate wall portion  41 ,  51 . The hinge arrangement between the extended wall portions  42 ,  43 ,  52 ,  53  and the intermediate wall portion  41 ,  51  is of the same kind as the above described hinge arrangement  16 , i.e. an integrated arrangement formed by an area with less material that the adjacent portions  41 ,  42 ,  43 ,  51 ,  52 ,  53 . Both extended wall portions  42 ,  43 ,  52 ,  53  are foldable. The intermediate wall portion  41 ,  51  of the short-side wall  40 ,  50  is connected to the side edge  11   b ,  11   d  of the bottom  10  by means of the hinge arrangement  16 . 
     The first and second extended wall portions  42 ,  43 ,  52 ,  53  are arranged to at least partly engage the respective long-side wall  20 ,  30  in the erected state. For example  FIGS. 9-13  show the box  1  on its way to and in the erected state where an outside surface  46 ,  47 ,  56 ,  57  of the first and second extended wall portions  42 ,  43 ,  52 ,  53  engages a part of an inside surface  21 ,  22 ,  31 ,  32  of respective long-side wall  20 ,  30 . 
     The extended wall portion  42 ,  43 ,  52 ,  53  and the long-side wall  20 ,  30  are locked together by locking means, in this case a snap-lock arrangement  60 . There are four such locking arrangements  60  on the box holding its walls  20 ,  30 ,  40 ,  50  in their intended position of the erected state. Other locking arrangements are of course possible to use. Each snap-lock arrangement  60  is formed by a cavity  61  arranged on the long-side wall  20 ,  30  and a protruding locking element  62  arranged on the outside surface  46 ,  47 ,  56 ,  57  of the extended wall portion  42 ,  43 ,  52 ,  53 . The protruding locking element  62  has a first engaging part  63  and a second engaging part  64  which are arranged on opposite sides of the locking element  62 . The first engaging part  63  is formed to engage a first edge portion  66  of the cavity  61  which together prevent the walls  20 ,  30 ,  40 ,  50  of the box  1  to collapse. The second engaging part  64  is formed to engage a second edge portion  67  of the cavity  61  and to snap into a locked state. 
     When assembling the box  1 , i.e. changing from the collapsed state to the erected state, the extended wall portions  42 ,  43 ,  52 ,  53  are folded in towards the intermediate wall portion  41 ,  51 , the walls  20 ,  30 ,  40 ,  50  raised towards each other and then locked in position by means of the snap-lock arrangement  60 . When disassembling the box  1 , i.e. changing from the erected state to the collapsed state, the protruding locking element  62  is released from the cavity  61  and the walls  20 ,  30 ,  40 ,  50  lowered. This assembling and disassembling process may well be automated by e.g. robots. 
     Each short-side wall  40 ,  50  also have a handle  48 ,  58  for making the handling of the box in the erected state easier. 
     In order to increase the strength, robustness and stability of the box  1  each wall  20 ,  30 ,  40 ,  50  is provided with at least one reinforcement element  70   a - d  of a first type and a number of reinforcement elements  71   a - d ,  72   a - f ,  73   a - d ,  74   a - f  of a second type. One reinforcement element  70   a - d  of the first type is in this embodiment located in the center of each wall  20 ,  30 ,  40 ,  50 . It is basically wedge-shaped with its base  70 ′ pointing upwards, away from the bottom  10  in the erected state. The base  70 ′ may act as an extra support when stacking boxes  1  on top of each other, as the bottom rim  4  may rest thereon. Furthermore, the reinforcement element  70   a - d  also increases the flexural rigidity of each wall  20 ,  30 ,  40 ,  50 . 
     The second type of reinforcement elements  71   a - d ,  72   a - f ,  73   a - d ,  74   a - f  also has a wedge-like or conical shape which from one side of the wall protrudes and from the opposite side of the wall is immersed. In the erected state the protrusion of the second type of reinforcement elements  71   a - d ,  72   a - f ,  73   a - d ,  74   a - f  is in the direction towards the inside of the box  1 . The tip  74 ′ of the reinforcement element  71   a - d ,  72   a - f ,  73   a - d ,  74   a - f  of the second type is pointing upwards, away from the bottom  10 , in the erected state. In the described embodiment each long-side wall  20 ,  30  has four reinforcement elements  71   a - d ,  73   a - d  of the second type of optionally varying size and each short-side wall  40 ,  50  has six reinforcement elements  72   a - f ,  74   a - f  of the second type of optionally varying sizes. The shape, size and number of all the reinforcement element  70   a - d ,  71   a - d ,  72   a - f ,  73   a - d ,  74   a - f  may vary. Each reinforcement element  70   a - d ,  71   a - d ,  72   a - f ,  73   a - d ,  74   a - f  acts as an extra support member for each wall  20 ,  30 ,  40 ,  50  and allows the walls  20 ,  30 ,  40 ,  50  of the box  1  to incline inwards, without decreasing the ability to carry loads. The inclination of the walls will later be described in more detail. 
     The intermediate wall portion  41 ,  51  of the short-side wall  40 ,  50  has two reinforcement elements  72   c - d ,  74   c - d  of the second type, one on each side of the protruding section  71 ,  73 . Further, each extended wall portion  42 ,  43 ,  52 ,  53  has two reinforcement elements  72   a - b ,  72   e - f ,  74   a - b ,  74   e - f  of the second type, one on each side of the locking element  62  of the snap-lock arrangement  60 . The long-side wall  20 ,  30  has four reinforcement elements  71   a - d ,  73   a - d  of the second type, two on each side of the protruding section  70 ,  72 , one on each side of the cavity  61  of the snap-lock arrangement  60 . The four reinforcement elements  71   a - d ,  73   a - d  of the second type of the long-side wall  20 ,  30  are formed to each match the shape of one of the reinforcement element  72   a - b ,  72   e - f ,  74   a - b ,  74   e - f  of the second type of the extended wall portions  42 ,  43 ,  52 ,  53  of the short-side wall  40 ,  50 . They are, in the erected state, arranged such that they engage each other, i.e. the protruding part of one reinforcement element  71   a - d ,  73   a - d  matches and engages the immersed part of another reinforcement element  72   a - b ,  72   e - f ,  74   a - b ,  74   e - f  such that they are in close contact with each other. 
     In the erected state, at least a part of a top edge  80   a - b ,  81   a - b  of the extended wall portion  42 ,  43 ,  52 ,  53  slightly protrudes above a top rim  24 ,  34  of the long-side wall  20 ,  30  in a direction away from the bottom  10 . The protruding top edge is illustrated in e.g.  FIG. 13 , slightly exaggerated but so that the design come across. The top edge  80   a - b ,  81   a - b  can have various shapes and sizes. For example  FIG. 13  shows a protruding portion, which there is eight of in the illustrated embodiment, but it can also be a continuous rim, straight or curved. Also the thickness of the top edge  80   a - b ,  81   a - b  can vary and the height of which it protrudes above the top rim  24 ,  34  of the wall  20 ,  30 . Preferably, the height may vary between 0.5 and 3 mm. This feature may provide advantages, as described below. 
     The extended wall portion  42 ,  43 ,  52 ,  53  further has at least one protruding part, in this case two parts  82   a ,  82   b ,  83   a ,  83   b , which in the erected state is arranged in a recess  18   a ,  18   b ,  19   a ,  19   b  of the bottom  10 . Each recess  18   a ,  18   b ,  19   a ,  19   b  acts as a guide when assembling the box  1 , so that the walls and their components of the box always are in their right places in the erected state. It also serves as a support for the extended wall portion  42 ,  43 ,  52 ,  53  when loading the box and stacking boxes on each other. Due to the protruding top edge  80   a - b ,  81   a - b  of the extended wall portion  42 ,  43 ,  52 ,  53  and the protruding parts  82   a ,  82   b ,  83   a ,  83   b  most of the weight and load of the box or boxes, when stacking one box on top of another, will be distributed into the extended wall portion  42 ,  43 ,  52 ,  53  and into the bottom  10 . The weight and load will not affect the hinge arrangement  16  between the long-side walls  20 ,  30  and the bottom  10  and this will create a stronger and more stable arrangement of boxes. The protruding top edge  80   a - b ,  81   a - b  does not depend on the protruding parts  82   a ,  82   b ,  83   a ,  83   b  and recesses  18   a ,  18   b ,  19   a ,  19   b  described above. When the box  1  is in its erected state the main walls  20 ,  30 ,  40 ,  50  has an inclination with respect to the bottom  10 . The angle α between the bottom  10  and the walls  20 ,  30 ,  40 ,  50  is less than 90°. Preferably, the angle α is between 80 and 89.5°. The reinforcement element  70   a - d  of the first type partly forms outside surfaces  85 ,  86 ,  87 ,  88  of the walls  20 ,  30 ,  40 ,  50 , which does not have the same inclination. The outside surfaces  85 ,  86 ,  87 ,  88  are instead substantially perpendicular to the bottom  10 . This means that sections of each wall  20 ,  30 ,  40 ,  50  has a triangular-shaped cross section with its base  70 ′ arranged in a direction away from the bottom  10 . This gives the box  1  stacking and stability advantages. 
     In an alternative embodiment (not shown) each wall, in the erected state, is substantially perpendicular to the bottom, i.e. the angle is substantially 90°, from the bottom up to an upper part of the wall. The upper part then preferably inclines in towards to other walls in order to achieve the same stacking possibilities as the above described embodiment. 
     The box substrate is made in one piece and every part of is designed so that the box is stackable on top of each other either if it is in the erected state or the collapsed state. This is very beneficial in order to reduce empty or unnecessary transports. As it is made in one piece and no additional parts are necessary it is very easy to assemble the box substrate to a “ready to use” box. Both the assembling and disassembling process can advantageously be automated, so also the manufacturing process. 
     The plastic material used in the described embodiment is polypropylene. Other materials may be used depending on its application, for example other plastic materials, carbon fiber materials or similar. 
     Finally, although the inventive concept has been described above with reference to specific embodiments, it is not intended to be limited to the specific form set forth herein. Rather, the invention is limited only by the accompanying claims and other embodiments that the specific above are equally possible within the scope of these appended claims.