Patent Publication Number: US-2009218342-A1

Title: Folding container

Description:
FIELD OF THE INVENTION 
     The present invention relates to a container for storing and transporting articles which is capable of being deployed between a folded and an unfolded configuration. More specifically, but not exclusively, the container is provided for use in applications where there is a need for a tamper-evident or water resistant sealed container arrangement. A tamper-evident container is one in which evidence of any unauthorised access or intrusion is apparent. 
     BACKGROUND TO THE INVENTION 
     Portable plastic storage containers are well known consumer and industrial products and provide important advantages in terms of strength and light weight compared to containers made of other materials. Such containers are used for a variety of storage and transporting needs such as for document files, work tools or other household articles. 
     In many areas of application, especially where the containers are in use for only a very limited amount of time, there is a significant problem associated with their storage. The space required to store a number of containers can be a drain on resources and can result in increased property rental charges etc. These problems are particularly apparent when the containers are required to be transported (for example by air or water), whereby the volume of space occupied by containers can dramatically increase transport costs and decrease their commercial viability. The above mentioned problems are particularly acute wherein the container or box is to function as a ballot box for example, wherein there is a need for a box that can easily transported and stored in the minimum of space, making it ideal for use in diverse geographical locations. Since ballot boxes are in use for only a very limited period of time, space-saving storage mechanisms are of paramount importance. 
     Foldable/collapsible containers are known and are a popular choice in the above mentioned applications due to the considerable reduction in transport volume and therefore cost which can be achieved by use thereof. 
     Whilst use of a foldable container serves to alleviate the above mentioned problems with respect to storage and transport, the presence of a folding mechanism provided in the body of the container inevitably results in sealing problems between the different parts of the foldable container that enable the container to be folded down or disassembled. The connections between displaceable panels inevitably serve as dust and dirt-traps which severely limits the applicability of such containers in the storage and transport of food or sanitary products and aseptic applications. 
     A foldable box is, by its very nature, also vulnerable to tampering whereby the joints or folds which confer the space saving advantages act as possible sites for unauthorised access. This is of particular relevance when the container is used to hold food and beverages wherein the risk of contamination of the contents during storage and transport of the container must be eliminated. Also in the ballot box application, it is important to totally restrict access to the inside of the ballot box, except for ballots, or other means used for carrying out the voting. 
     The benefits of collapsibility also means that the water-tight properties of a collapsible/foldable container are severely compromised. This makes a foldable container unsuitable for use in wet environments such as in boating/sailing or other watersport activities. The foldable container is also unsuitable for storage and/or transport of items where there is a potential risk that the container might become exposed to water such as in areas that are prone to flooding. 
     EP1418547 discloses a foldable ballot box which addresses the problem of preventing access to the inner area by means of sealing connections with a strip of adhesive paper or the like. 
     EP0542821 discloses a collapsible ballot box comprising a flexible outer bag-like member and inner collapsible reinforcing side panels associated therewith. 
     WO 03/024815 discloses a collapsible container wherein the sealing problems thereof are overcome by using a removable liner which is placed on the inside of the erected container. 
     The present invention provides an alternative foldable container which when in use is sealed against environmental contamination and unauthorised access and which is tamper resistant. 
     STATEMENTS OF THE INVENTION 
     According to the present invention there is provided a container having a body portion and capable of being deployed between a folded configuration and an unfolded configuration, said body portion including a lower base member, an upper member and two opposing foldable or hingeable walls arranged between said base member and said upper member, wherein the container further includes a flexible member which forms a holding pouch within the body portion of the container in the unfolded configuration and which is attached to the body portion. 
     Preferably the container includes two further opposing walls, each of which is flexibly attached to one of the upper and base member. 
     Preferably the foldable walls are flexibly attached to said upper member and lower base member. 
     Preferably flexible member is attached to attachment means provided by the upper member. Alternatively the flexible member is attached to attachment means provided by a wall of the container. 
     Preferably the flexible member is attached to the body of the container by ultrasonic welding, adhesion technology or friction bonding. 
     Preferably the container, when in the folded configuration, is capable of accommodating the flexible membrane in a space defined by the folded walls and the upper member. 
     Preferably the body portion, and/or the flexible member are made of plastics material. Preferably the plastics material is transparent. 
     Preferably the container further includes a lid portion. Preferably the lid is made of plastics material. Preferably the plastics material is transparent. 
     A container of the present invention provides important space saving advantages yet overcomes the concomitant sealing problems of a conventional foldable container. A container of the present invention, by virtue of the flexible member associated therewith is resistant to environmental contamination such as dust and water and also provides a tamper proof arrangement. 
     The importance of a container with such multiple functionality is particularly apparent in the field of disaster recovery. Containers which can be stored with minimum footprint in minimal amount of space and minimum of cost would be useful in protecting valuable museum artefacts in the unfortunate event of flooding. As a precautionary measure, containers of the present invention could be usefully stored in underground storage facilities ready for use if the need should ever arise. 
     A container of the present invention could be cost effectively transported to flood relief victims and used for water tight storage of possessions. In such emergency circumstances, a container of the present invention could also usefully serve as transportable sink or washing/drinking facility, wherein water for washing is placed within the membrane of an assembled container and discarded after use. 
     A container of the present invention provides a useful transporting means for food and beverages. It can also double as a useful cooling facility whereby the membrane is filled with water at a picnic/beach location and used to store drink cans and other items. After use the container can be easily emptied and folded to the compact state for transport. 
     The advantages of a container of the present invention for use as a ballot box are clearly apparent. A container of the present invention can be economically transported to areas of diverse geographical location and assembled to provide a secure, reliable and tamper proof ballot box. The container can then be easily stored in minimal space. 
     A container of the present invention also carries the advantages of odour resistance and may be conveniently used to store clothes and other materials. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The invention will now be described by way of example only and with reference to the accompanying drawings in which; 
         FIG. 1  is a diagrammatic perspective view of a container in accordance with the present invention in its unfolded, assembled state. 
         FIG. 2   a  is a diagrammatic perspective view of a container in its unfolded, assembled state and a lid in accordance with the present invention. 
         FIG. 2   b  is a section of the container viewed along line I of  FIG. 2   a.    
         FIG. 3  is a diagrammatic perspective view of a container in accordance with the present invention in its folded or collapsed state. 
     
    
    
     In the figures like reference numerals denote like parts. 
     DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT 
     Throughout the description and claims of this specification, the words “comprise” and “contain” and variations of the words, for example “comprising” and “comprises”, means “including but not limited to”, and is not intended to (and does not) exclude other moieties, additives, components, integers or steps. 
     Throughout the description and claims of this specification, the singular encompasses the plural unless the context otherwise requires. In particular, where the indefinite article is used, the specification is to be understood as contemplating plurality as well as singularity, unless the context requires otherwise. 
     Features, integers or characteristics described in conjunction with a particular aspect, embodiment or example of the invention are to be understood to be applicable to any other aspect, embodiment or example described herein unless incompatible therewith. 
     Referring to  FIGS. 1 and 2 , a container, generally denoted ( 1 ), has a rectangular lower base member ( 3 ), and an upper frame member ( 5 ). Lower base member ( 3 ) has a small peripheral lip ( 7 ) which extends upwardly from the base member ( 3 ) in a vertical elevation. Upper frame member ( 5 ) defines a peripheral rim ( 9 ) and has an outwardly extending horizontal flange ( 11 ) which constitutes end flanges ( 13 ,  15 ) and side flanges ( 17 ,  19 ) and a downwardly extending peripheral outer lap ( 21 ), said lap ( 21 ) arranged substantially co-planar with the upwardly extending peripheral lip member ( 7 ) of the base member ( 3 ). Preferably the container is made by injection moulding and made of polypropylene or polyethylene. In an alternative embodiment of the invention the container is a square and comprises side and end walls of equal dimension. 
     Upper frame member ( 5 ) also has an inner lap ( 23 ) which extends downwardly towards base member ( 3 ) along a length which substantially corresponds to that of outer peripheral lap ( 21 ), from end flanges ( 13 ,  15 ) and side flanges ( 17 ,  19 ) and arranged substantially perpendicular thereto. Inner lap ( 23 ) has a ledge ( 25 ) which extends inwardly towards the centre of the box, substantially perpendicular to said lap ( 23 ) from which it depends. Ledge ( 25 ) is additionally provided with a flange ( 27 ) which extends upwardly, substantially perpendicular to ledge ( 25 ) from which it depends and to which a flexible sealing member, which in the specific example is membrane ( 29 ), is attached around the circumference thereof. Suitable methods for attaching sealing membrane ( 29 ) to flange ( 27 ) include ultrasonic welding, adhesion technology or friction bonding. 
     Sealing member ( 29 ) extends from flange ( 27 ) to which it is attached, down into the body of container ( 1 ) and when fully distended, is capable of enclosing substantially the same volume of space as that enclosed by container ( 1 ) in the fully unfolded state. In this way the carrying capacity of the sealed container is not compromised by the presence of the sealing membrane ( 29 ) which acts as the primary receptacle for the goods placed there-within and provides a protective barrier between the laminar container walls and interior space. 
     In one embodiment of the invention the membrane ( 29 ) is formed of transparent plastic. Preferably the body of the container ( 1 ) is also made of transparent material such as polypropylene, polyethylene, polycarbonate or the like. In this way the contents of the container can be easily viewed by the user without necessitating opening of a closed container/lid combination. 
     In an alternative embodiment of the invention, flexible membrane ( 29 ) is sealed at flange ( 27 ) as shown in the illustrated embodiment but the membrane additionally has a top or cover portion which extends across the opening of the container mouth and can be provided with a zip or other closure means. This embodiment provides the container with additional sealing properties. 
     That part of ledge ( 25 ) which depends from side flanges ( 17 ,  19 ) has means for attaching thereto, preferably by way of flexible connecting means such as a hinge or pivot ( 31 ), longitudinal side walls ( 33 ,  35 ). Longitudonal walls ( 33 ,  35 ) are a pair of rectangular laminar portions, a lower one ( 37 ,  39 ) and upper one ( 41 ,  43 ), for each longitudinal side ( 33 ,  35 ) of the ballot box. The width of each longitudinal wall ( 33 ,  35 ) corresponds to the length of the span defined by peripheral rim ( 9 ) formed by upper frame member ( 5 ), or peripheral lip ( 7 ) of base member ( 3 ). Lower and upper portions ( 37 , 39 ;  41 , 43 ) are swivel mounted together on their concordant longitudinal edge by swivel means ( 45 ). A stop is provided within said swivel means such that swivelling can occur in one direction only. 
     That part of ledge ( 25 ) which depends from end flanges ( 13 ,  15 ) has means for attaching thereto, preferably by way of flexible connecting means ( 31 ), end walls ( 47 ,  49 ). End walls ( 47 ,  49 ) comprise a pair of rectangular laminar portions. The mounting means ( 31 ) for end walls ( 47 ,  49 ) are arranged such that end walls ( 47 ,  49 ) are mounted above the plane of mounted the longitudinal side walls ( 33 ,  35 ). The width of each end wall corresponds to the distance between longitudinal walls ( 33 ,  35 ) in maximum unfolding. 
     It will be understood that the arrangement of the flexible or swivel mounting within the container can be varied. In an alternative embodiment for example, end walls ( 47 ,  49 ) are each comprised of two bi-part swivel mounted portions, each part joined by a, preferably central, swivel mount, and the longitudinal side walls have laminar portions that are flexibly mounted from a position above the plane of the end walls. It will be understood that the swivel mounting means is preferably provided in opposing walls. Alternatively the side and end walls can be flexibly mounted from the lower base member. 
     In the unfolded state, as represented by  FIGS. 1 and 2 , opposite end walls ( 47 ,  49 ) and opposite side walls ( 33 ,  35 ), form substantially vertical walls surrounding base member ( 3 ) and arranged substantially at right angles thereto. In the unfolded/assembled state male connecting members ( 51 ) provided at intervals around the internal face of peripheral lip ( 7 ) of base member ( 3 ) cooperate with corresponding female portions or slots ( 53 ) provided in the lower peripheral edges of end walls ( 47 ,  49 ) which abut lip member ( 7 ) of base member ( 3 ). End walls ( 47 ,  49 ) are arranged such that their vertical edges adjoining side walls are held against the inner surface of longitudinal side walls ( 33 ,  35 ). Each adjoining edge of longitudonal side walls ( 33 ,  35 ) is additionally provided with a hook like or catch member ( 55 ) which is presented to each vertical edge of end walls ( 47 ,  49 ). Hook or catch member ( 55 ) is securely latched by a receiving slot ( 57 ) provided in the corresponding position on the adjoining walls of each end wall ( 47 ,  49 ). In the illustrated embodiment each side wall ( 33 ,  35 ) presents two hook like members ( 55 ) at a location that corresponds to the swivel mechanism ( 45 ) located there-between. It will be understood that any number of hooks and corresponding slot arrangements can be used. This arrangement prevents any swivel movement between the laminar portions of longitudinal walls ( 33 ,  35 ), preventing their folding and forcing them to maintain an upright vertical position, thus creating the inner operative area of the box. 
     Sealing membrane ( 29 ) sits inside the container and by virtue of its flexibility can comfortably accommodate articles to be transported/stored therein, whereby membrane ( 29 ) is capable of being distended to at least the same volume as the container. It will be apparent to the skilled artisan that the sealing member may be made of any suitable material such that confers a degree of flexibility, particularly with respect to the body portion. 
     Preferably the sealing member ( 29 ) is formed of impervious material which is preferably transparent. Preferably the sealing member is formed of polypropylene and is provided for use in a polypropylene container. Accordingly, the container assembly can be conveniently placed in a freezer without adversely affecting the integrity of the air-tight seal due to the simultaneous contraction of like materials. Conversely, a seal of non-like material e.g., rubber, would be subjected to differential contraction which carries the inherent risk of an impaired seal. 
     Container ( 1 ) is conveniently adapted to receive a removable lid ( 59 ) which is preferably moulded in one piece from a synthetic resin, for example, polycarbonate, polypropylene or polyethylene and preferably from the same material as the base member ( 3 ). Lid ( 59 ) is of rectangular shape with smoothed cornices and is of a size to close the open top of container ( 1 ). 
     Lid ( 59 ) has a body portion ( 61 ) and a peripheral edge ( 63 ). The peripheral edge ( 63 ) of lid ( 59 ) has an inverted U-shape and has an upwardly extending leg ( 65 ), ledge ( 67 ) which extends horizontally therefrom and substantially downwardly extending leg ( 69 ). Downwardly extending leg ( 69 ) terminates at end ( 71 ) to project from horizontal ledge ( 67 ) of lid ( 59 ) below the plane of the main body portion ( 61 ) of lid ( 59 ). 
     Reinforcing rectangular shaped webs ( 73 ) are provided at various intervals around the periphery of the lid ( 59 ) within the space defined by upwardly extending leg ( 65 ), horizontally extending ledge ( 67 ) and the uppermost portion of downwardly extending leg ( 69 ). 
     The peripheral edge ( 63 ) of lid ( 59 ) is adapted to fit over outwardly extending horizontal flange ( 11 ) of container ( 1 ) such that end ( 71 ) of downwardly extending leg ( 69 ) sits proud above downwardly extending peripheral outer lap ( 21 ). 
     To enable the removable lid ( 59 ) to be clamped on the container ( 1 ) a locking member ( 75 ) is optionally provided on the upper frame member ( 5 ) above each end wall ( 47 ,  49 ) of the container. As shown in  FIG. 2 , locking member ( 75 ) is pivotally attached to reinforcing ribs ( 76 ) which extend from handle portion ( 79 ) provided by upper frame member ( 5 ). Locking member ( 75 ) can be pivoted upwardly from a first unlocking position to a second position whereby the locking member engages the lid portion ( 59 ) and holds the lid in engagement with the body portion. The flexible membrane ( 29 ) provides a tamper proof indicator. Access to the contents of container ( 1 ) which might otherwise occur through the folding joints of a foldable container can only be achieved by disrupting and breaking the surface of the flexible membrane ( 29 ). The described container and lid combination therefore provides a sealed arrangement whereby the goods to be stored/transported inside a foldable container ( 1 ) are resistant to environmental elements such as dust and water. In one embodiment of the invention the locking member ( 75 ) is optionally further provided with a tamper evident sealing member which extends between the locking member and at least one of the body and lid portion when the locking member is in its locking position, by means of apertures provided in the locking member and at least one of the body and lid portion. 
     When it is desired to move the container into the folded position (i.e., for storage/transport of empty containers as shown in  FIG. 3 ), end walls ( 47 ,  49 ) can be pushed from their vertical position, as illustrated in  FIG. 1 , to a horizontal resting position that is substantially coplanar and adjacent to the lower surface of the upper frame member ( 5 ), defined by ledge ( 25 ). To effect this movement the user must push end walls ( 47 , 49 ) in towards the body of the box, thus releasing male projecting members ( 51 ) provided at the lip ( 7 ) of the base member ( 3 ) from female cooperating slots ( 53 ) and also the hook ( 55 ) and slot ( 57 ) catching mechanism provided between the adjoining walls of the side walls ( 33 ,  35 ) and end walls ( 47 ,  49 ). 
     Movement of end walls ( 47 ,  49 ) about flexible mounting means ( 31 ) pushes the flexible membrane ( 29 ) up out of the body region of the container ( 1 ) such that it is forced to occupy the space defined by the now horizontal end walls ( 47 ,  49 ) and upper peripheral rim ( 9 ) provided by upper member ( 5 ) of the container. If the container is folded in the closed state (whereby lid ( 59 ) is placed over peripheral rim ( 9 ) of container body), the flexible membrane ( 29 ) is now sandwiched between the body portion ( 61 ) of the lid ( 59 ) and the horizontal end walls ( 47 ,  49 ). Accordingly the flexible membrane ( 29 ) remains fixedly attached to the body of the container when the container is moved between the unfolded and folded state. 
     Movement of supporting end walls ( 47 ,  49 ) means that longitudinal side walls ( 33 ,  35 ) are now free to fold toward the inside of the container about the swivel mount ( 45 ) between the laminar portions ( 37 , 39 ; 41 , 43 ) provided on their concordant longitudinal edges. In the folded state, longitudinal side walls ( 33 ,  35 ) nestle between the now horizontal end walls ( 47 ,  49 ) and base member ( 3 ) such that the volume of the container ( 1 ) is reduced to approximately one quarter of that of the unfolded, operative container. The folded container can then be conveniently stored away ready for re-use, either on its own or with any number of like containers as part of a stackable system. 
     In the illustrated embodiment end wall is additionally provided with an opening member which allows for easy access to the container when the unfolded, assembled box is stored as part of a stackable system ( FIG. 3 ). End wall ( 47 ) provides a window ( 77 ) which is swivel mounted ( 78 ) to surrounding frame portion ( 81 ) of end wall ( 47 ). Window ( 77 ) within end wall ( 47 ) is firmly locked by means of a projecting member ( 83 ) which resiliently catches behind the frame portion ( 81 ) provided by end wall ( 47 ). To open the access window ( 77 ) the user compresses bi-partite opening member ( 85 ), thus releasing resilient projecting member ( 83 ) and enabling full access to the body of the container. It will be understood that additional or alternative window features can be provided in either or both or any end wall or side wall. 
     In an alternative embodiment of the invention, the sealing member ( 29 ) is fixedly attached to the body of the container ( 1 ) at an alternative position, such as around the peripheral surface of an access window, which is preferably provided on an end wall of the container. In this embodiment the membrane forms a holding pouch which encapsulates a volume that is substantially equal to the interior volume of the container and the user is able to access the interior of the space defined by the membrane seal ( 29 ) through the access window. In this embodiment the container may be provided with a separate lid or one that is integral with the body of the container. 
     As shown in the illustrated embodiment, each end wall ( 47 ,  49 ) and side wall ( 33 ,  35 ) is additionally provided with outwardly extending reinforcing ribs ( 80 ). These reinforcing ribs may optionally additionally be provided on the access window ( 77 ).