Patent Abstract:
A collapsible container defined by a continuous rigid structure and an integrated internal truss system. The continuous rigid structure is preferably four-sided such that it defines four continuous surfaces of a cube. The continuous rigid structure is collapsible due to at least one scoring line defined on at least one surface thereof. The internal truss system includes at least one inelastic member that is threaded through the surfaces of the continuous rigid structure to form a symmetrical and unitary support. A liner may be integrally affixed to each of the four sides and additionally provides a fifth side that forms the bottom of the container. A protective cover may be secured to the exterior of the continuous rigid structure for protecting the contained materials against the elements. The cover can be selectively sealed for rendering the container of the present invention substantially impervious to the elements.

Full Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to containers for storing and/or transporting materials. More particularly, the present invention relates to semi-rigid collapsible containers that may be employed to transport bulk materials including, but not limited to, hazardous materials. 
     2. Discussion of Background Information 
     Metal containers are generally used to store and transport bulk materials, particularly hazardous materials. These metal containers are expensive to purchase, rent and store. They are fairly large and therefore require a considerable amount of space to maintain on site. That required space could be considerable, dependent upon the amount of material that must be stored and/or transported. While the storage volume of metal containers is considerable, the volume of material that is storable within multiple containers is diminished by the fact that the metal containers are generally cylindrical in nature. Cylinders generally cannot be oriented in a space-efficient manner. As such, there is a need in the art for containers that will contain a high volume of material and be storable in a low volume storage facility. 
     To meet this need, bag containers have been employed. Such bags take up much less space when not in use. However, such bags are of insufficient physical characteristics for transport purposes. That is, they are generally not tough enough to stand up to the rigors of movement by mechanical devices such as forklifts, accidental drops into cargo holds, stacking, and the like. Moreover, bag containers are easily deformed by the materials that they contain. As such, bag containers are not reliably stackable, and hence bag containers do not provide for efficient transport or storing of voluminous materials. 
     In order to overcome the limitations associated with flexible bags and rigid metal boxes, a series of semi-rigid containers have been developed. While these containers provide storage and transport benefits, they lack the rigidity and impermeability to contain a wide range of materials, such as hazardous materials. Therefore, what is needed is a rigid container for the storage and transport of bulk materials suitable for retaining a range of materials. What is also needed is a collapsible container that minimizes the exposure of the materials to the surrounding environment. Lastly, there is a need in the art for a collapsible container that can reliably hold its shape while stacked during storage and transport. 
     SUMMARY OF THE INVENTION 
     Accordingly, the present invention includes a collapsible container having an internal truss system for use in a variety of applications. The container of the present invention includes a continuous rigid structure that defines a plurality of sides. In an effort to minimize the space occupied by the container during storage, the continuous rigid structure is collapsible via a pair of scoring lines disposed on opposing surfaces. The continuous rigid structure is buttressed by an internal truss system that includes at least one inelastic member. The inelastic member is preferably composed of a synthetic material of a fixed length and dimension. The inelastic material is then threaded through the sides of the continuous rigid structure such that it provides a symmetric and rigid supporting structure for the scored surfaces of the continuous rigid structure. 
     As further described herein, the continuous rigid structure is preferably four-sided, such that it defines four continuous surfaces of a cube. In one embodiment, a liner is integrally affixed to each of the four sides and additionally provides a fifth side that forms the bottom of the container. A protective cover is secured to the exterior of the continuous rigid structure for protecting the contained materials against the elements. 
     The container of the present invention is selectively sealable via a pair of flaps that form part of the cover. The flaps are selectively attached to the exterior of the cover through a mechanical means, such as a loop and eyelet closure. In such a manner, the container can be easily and effectively sealed for stacking and transport without worry that the materials contained therein will be unnecessarily exposed to moisture and debris. The container of the present invention is also collapsible for storage and empty transport, as noted above. 
     The container of the present invention thus provides numerous benefits over the existing art. Namely, the internal truss system of the container of the present invention combines the benefits of a metal container with the adaptability of a semi-rigid container. Moreover, the liner and cover cooperate to render the container of the present invention substantially impervious to environmental damage that otherwise might harm the materials within. 
     The present invention is directed to a collapsible container includes a continuous rigid structure defining four sides, two of the four sides having a first scoring line and a second scoring line rendering the continuous rigid structure collapsible. Each of the four sides defining a first pair of passages and an inelastic member connecting the four sides such that the inelastic member passes through each of the first pair of passages within each of the four sides thus providing support for the continuous rigid structure. 
     The present invention is directed to a method of making a collapsible container that includes providing a four-sided continuous rigid structure wherein a first scoring line and a second scoring line are defined on opposing sides. The method includes providing an inelastic member having a first end and a second end. Collapsing the four-sided continuous rigid structure such that it is a substantially planar collapsed continuous rigid structure. Punching at least two passages through the collapsed continuous rigid structure, and threading an inelastic member through the at least two passages of the collapsed continuous rigid structure. Fastening the first end of the inelastic member to the second end of the inelastic member. 
     Further features and advantages of the present invention are described in detail below with reference to the following drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is an elevated perspective view of the collapsible container of the present invention. 
         FIG. 2  is a plan view of the collapsible container of the present invention shown in  FIG. 1 . 
         FIG. 3  is a plan view of the collapsible container of the present invention in an early step in a method of making the same. 
         FIG. 4  is a plan view of the collapsible container of the present invention in an intermediate step in a method of making the same. 
         FIG. 5  is a plan view of the collapsible container of the present invention in a later step in a method of making the same. 
         FIG. 6  is an elevated partial cut-away perspective view of a collapsible container in accordance with an alternate embodiment of the present invention. 
         FIG. 7  is an exploded perspective view of a collapsible container in accordance with an alternate embodiment of the present invention. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     The present invention provides an internal truss system for a semi-rigid container that is sturdy enough for stacking, storing and transporting a variety of materials. In its preferred embodiments, the semi-rigid container of the present invention is collapsible. Therefore, unlike the ubiquitous metal containers, the container of the present invention can be collapsed from a substantially cubic volume into a substantially flat square for easy stacking and storage. The present invention thus provides numerous benefits to the user, as described more fully below with reference to the figures. 
       FIG. 1  is an elevated perspective view of the collapsible container  10  of the present invention. The container  10  preferably includes a first side  12 , a second side  14 , a third side  16  and a fourth side  18 , all of which cooperate to define a substantially cubic volume therein. The plurality of sides  12 ,  14 ,  16 ,  18  preferably delineate a continuous rigid structure  20  that is formed from a semi-rigid material such as plastic, fiberboard or cardboard. In a preferred embodiment, the continuous rigid structure  20  is formed of cardboard such that it can be easily and economically produced while providing a substantial amount of rigidity as a containment device. 
     The continuous rigid structure  20  includes a pair of scoring lines  22  that are preferably disposed on opposing sides. For example, the scoring lines  22  may be disposed on the first side  12  and third side  16 , or alternatively on the second side  14  and the fourth side  18 . The scoring lines  22  are preferably disposed along the center of the respective sides thereby ensuring uniform and symmetrical folding attributes as described more fully below. That is, a scoring line disposed on the first side  12  will be disposed equidistant between the junction of the first side  12  and the second side  14  and the junction between the first side  12  and the fourth side  18 , as illustrated in  FIG. 1 . 
     As the continuous rigid structure  20  is preferably comprised of a semi-rigid material as noted above, the collapsible container  10  of the present invention includes at least one inelastic member  30  that interconnects each respective side of the continuous rigid structure  20 . As shown in  FIG. 1 , there are two inelastic members  30  that are interwoven between the four sides of the continuous rigid structure  20  in a symmetrical fashion so as to define a network of internal trusses between each of the four sides. In a preferred embodiment, each of the inelastic members  30  shown is formed from a single element that is connected to itself at an overlap  32 . The inelastic members  30  are shown anchored to each of the four sides of the continuous rigid structure  20  by passing through a series of passages  34  that connect an inner surface of each of the four sides to an opposing outer surface. In such a manner, the internal truss system defined by the inelastic members  30  is integrated into the continuous rigid structure  20  thus forming the collapsible container  10 . 
       FIG. 2  is a plan view of the collapsible container of the present invention shown in  FIG. 1 . As shown, the inelastic member  30  forms a substantially octagonal profile by alternating periods on the inside of the continuous rigid structure  20  with periods on the outer surfaces of the respective sides. The inelastic member  30  is shown disposed on the outer surface of the fourth side  18 . Following the arrows in  FIG. 2 , the inelastic member  30  is then pressed through a pair of passages  34  on the fourth side  18 , through which the inelastic member  30  is shown angling towards both the first side  12  and the third side  16 . At the first side  12  and the third side  16 , the inelastic member is pressed through a pair of passages  34 , from which it angles towards the second side  14 . Through another pair of passages  34  on the second side  14 , the inelastic member  30  meets and is fastened to itself at the overlap  32 . 
     In a preferred embodiment, the inelastic member  30  is of a length suitable for providing a tension between the four sides of the continuous rigid structure  20  such that the continuous rigid structure  20  maintains a substantially square shaped profile as shown in  FIG. 2 . Of particular concern is that the scoring lines  22  disposed on opposing sides of the continuous rigid structure  20  must be able to withstand a substantial load as the collapsible container  10  of the present invention is filled. As such, the inelastic member  30  is preferably composed of a material that is light, inelastic and easy to deform into the necessary profile for creating the internal truss system for the collapsible container  10 . In preferred embodiments, the inelastic member  30  is polypropylene or polyester, although any other suitable synthetic, organic or inorganic polymer that can maintain its inelasticity under a load is suitable for use in the present invention. 
       FIG. 3  is a plan view of the collapsible container  10  of the present invention in an early step in a method of making the same. As shown, the collapsible container  10  is in a collapsed state in which it forms a substantially planar cross-section. By folding in along the scoring lines  22 , a user can compress the continuous rigid structure  20  in an accordion-like manner for easy storage and transport when not in use. 
     In order to form the internal truss system described above, the planar continuous rigid structure  20  is perforated to form the plurality of passages  34 , which pass continuously and symmetrically through each of the four sides of the continuous rigid structure  20 . In a preferred embodiment, the plurality of passages  34  are formed by a pressing machine adapted to thread the inelastic member  20  through the passages  34  as it creates them. Alternatively, the process of forming the plurality of passages  34  and the placement of the inelastic member  30  therein may be performed manually. As discussed further below, it is also conceived that the continuous rigid structure  20  of the present invention will be lined on its interior surfaces, in which case it is desirable to fit the liner into the continuous rigid structure  20  prior to threading the inelastic members  30  through the plurality of passages. 
       FIG. 4  is a plan view of the collapsible container of the present invention in an intermediate step in a method of making the same. In  FIG. 4 , the inelastic member  30  is shown fastened to itself at the overlap  32 . The means for fastening the inelastic member  30  to itself may include mechanical devices, adhesives and other bonding techniques. For example, the inelastic member  30  may be fasted to itself using staples, epoxies or resins. Preferably, however, the means for fastening will be an automated process such as sonic welding, which is particularly well suited to bonding materials composed of synthetic polymers such as polypropylene and polyester. As shown in  FIG. 4 , the overlap  32  of the inelastic member  30  is located near the outer surface of the second side  14 . While it is understood that the overlap  32  can be located at any point along the continuum of the inelastic member  30 , it is preferred that it be located near the outer surface of a side of the continuous rigid structure  20  that does not have a scoring line  22 . 
       FIG. 5  is a plan view of the collapsible container of the present invention in a later step in a method of making the same. As noted before, the inelastic member  30  is preferably of a single length of material that, when stretched to its limit, will maintain the substantially square profile of the continuous rigid structure  20 . In particular, when a load is placed upon the inner surfaces of the continuous rigid structure  20 , the sides of the continuous rigid structure  20  that have the scoring lines  22  therein will not bow or deform in an outward direction. However, as previously noted, the inelastic member  30  will permit the inward folding of the continuous rigid structure along the scoring lines  22 , thus allowing a user to collapse the continuous rigid structure  20  into a substantially planar form as shown in  FIG. 3 . 
       FIG. 6  is an elevated partial cut-away perspective view of a collapsible container in accordance with an alternate embodiment of the present invention. As noted above, the present invention may incorporate a liner  40  that is uniformly affixed to the interior surfaces of the continuous rigid structure  20 . In a preferred embodiment, the liner  40  is sufficiently large to include a top portion  42  that can be folded over and affixed to the outer surfaces of the continuous rigid structure  20 , as shown in magnified portion M 2 . As previously noted, the liner  40  will incorporate the passages  34  through which the inelastic structure  30  passes, as it is preferred to affix the liner to the continuous rigid structure  20  prior to assembling the internal truss of the present invention. 
     The liner  40  preferably includes a fifth surface that forms the bottom portion of the container  10 . The liner  40  is preferably form-fitted to the four sides  12 ,  14 ,  16 ,  18  of the continuous rigid structure  20  and uniformly affixed thereto by glue, epoxy, resin or any other adhesive that is known in the art. The liner  40  is affixed to the four sides  12 ,  14 ,  16 ,  18  in such a manner so as to render it coplanar with each of the four sides  12 ,  14 ,  16 ,  18 . That is, the liner  40  is affixed to substantially all of the interior surfaces of the respective four sides  12 ,  14 ,  16 ,  18 , as shown in magnified portion M 1 . As the liner  40  also includes the bottom portion, the liner  40  and four sides  12 ,  14 ,  16 ,  18  define five sides of a substantially symmetric cubic structure. The liner  30  is preferably composed of a water resistant or water proof synthetic material that is also resistive to degradation by temperature and corrosive compounds. 
     The continuous rigid structure  20 , inelastic member  30  and liner  40  can be utilized as an integrated unit as shown further in  FIG. 7 , which is an exploded perspective view of a covered collapsible container  100  in accordance with an alternate embodiment of the present invention. As shown, the continuous rigid structure  20 , inelastic member  30  and liner  40  form a lined semi-rigid container  50  that may be utilized on its own for the storage and transport of various types of materials. In another embodiment, the lined semi-rigid container  50  may be disposed within a cover  60  that fully encloses and encapsulates both the lined semi-rigid container  50  and its contents. 
     The cover  60  defines a substantially cubic form that is disposed over the lined semi-rigid container  50 . The cover  60  further defines a bottom (not visible), as well as two flaps  64 ,  66  that, in use, cooperate to enclose the contents of the container  100 . The cover  60  also includes a plurality of tabs  62  that may be fixed to the interior of the four sides  12 ,  14 ,  16 ,  18  of the lined semi-rigid container  50  for securing the cover  60  thereto. The plurality of tabs  62  may be so affixed by glue, epoxy, resin or any other adhesive that is known in the art. 
     The flaps  64 ,  66  include at least one end portion  68  for selectively engaging the cover  60  of the container  100 , thereby securing its contents. Any conventional and secure fastening means may be used to secure an end portion  68  of a flap  64 , 66  to a corresponding portion of the cover  60 . For example, the end portions  68  may include a plurality of eyelets  70  that are adapted for receiving a plurality of ties  72  disposed on the exterior of the cover  60 . The user may encapsulate the container  100  by folding flaps  64 ,  66  down over the cavity of the container  100  and affixing the end portions  68  to the plurality of ties  72  through the eyelets  70 . As the cover  60  is preferably composed of a water resistant or waterproof material, the user can substantially insulate the container  100  against all kinds of moisture and corrosive elements by closing the flaps  64 ,  66  in the manner described above. It should be understood that the eyelet-tie mechanism is only one means by which the container  100  may be closed, and other similar mechanisms for selectively affixing two objects are regarded as equivalent to those described herein. 
     The container  10 ,  100  of the present invention as described herein provides a number of tangible benefits over the existing rigid and semi-rigid containers known in the art. The container of the present invention is rigid enough for stacking, storing and transporting a variety of materials that other semi-rigid containers cannot handle. Through the incorporation of the inelastic members, an internal truss structure is described that provides the strength and rigidity of the less-desirable metal containers. Moreover, unlike the rigid metal containers, the container  10 ,  100  of the present invention can be collapsed from a substantially cubic volume into a substantially flat square for easy stacking and storage. 
     It should be apparent to those skilled in the art that the above-described embodiments are merely illustrative of but a few of the many possible specific embodiments of the present invention. Numerous and various other arrangements can be readily devised by those skilled in the art without departing from the spirit and scope of the invention as defined in the following claims.

Technology Classification (CPC): 1