Abstract:
Collapsible containers, collapsible container systems, and storage devices are disclosed herein. An aspect of this disclosure is directed to a collapsible container having a flexible base, first and second rigid end walls each attached to a respective opposing end of the base, and first and second rigid sidewalls each attached to a respective opposing side of the flexible base. The sidewalls are permanently attached to the base and the end walls. The first and second rigid sidewalls are foldable such that the container can selectively transition between an expanded state, whereat the first and second sidewalls are generally perpendicular with the first and second end walls, and a collapsed state, whereat at least portions of the first and second sidewalls overlap one another interleaved between the first and second end walls.

Description:
FIELD OF THE INVENTION 
       [0001]    The present disclosure relates generally to containers and receptacles, and more specifically, to collapsible and expandable containers for packaging, storing, and/or transporting items. 
       BACKGROUND 
       [0002]    Virtually every product in today&#39;s industrialized society that is bought, sold, or used is physically transported at one point in time. Regardless of the type of shipping employed, whether it be by ground, air, or water, most goods are packaged in some sort of protective container prior to transport. Many containers, such as cardboard boxes, paper and plastic bags, and ornamental product packaging, are disposable and, thus, intended for a single use. Some containers are fabricated from more resilient materials, such as canvas, high-strength plastics, and metals, and are therefore reusable. Some such containers are designed to collapse such that the container, when not in use, can be more easily stored and transported. When a person so wishes, the container can be assembled or expanded, and subsequently filled with goods for transport, storage, or any other known use. 
         [0003]    In general, there are three standard types of collapsible containers. The first type of collapsible container generally consists of detachable walls that pull apart or otherwise disconnect from a rigid base. Some such containers require latches or hinges for manually fastening the walls to the base. These designs have various drawbacks. For example, the constituent parts, when separated, require individual handling and storage, which is not ergonomic and can lead to lost or misplaced parts. In addition, expanding and collapsing these containers for use and storage, respectively, requires additional time and manual labor in order to assemble and disassemble the various constituent parts. 
         [0004]    Another well-known type of collapsible container is the sack-and-skeleton type receptacle (most commonly known as the collapsible hamper). These designs typically comprise a flexible bag that is propped up and supported by a twist-and-lock frame or other rigid skeletal armature. To use these containers, numerous elongated support arms are interconnected to form the skeletal support structure, at which time the hamper bag is placed in or around the assembled skeleton. Sack-and-skeleton type receptacles suffer all of the same drawbacks as the previously described collapsible containers due to the additional assembly requirements and the separable components. 
         [0005]    A third common type of collapsible container is known as a foldable or “knockdown” container. In these designs, the walls and base are permanently attached to one another; thus, actuation of a latch or hinge is not required. Generally speaking, the walls of a knockdown container can be folded such that expanding and collapsing these containers merely requires folding and unfolding the walls. Current knockdown containers suffer various shortcomings. For instance, the expanded volume of current knockdown container configurations is severely limited by the manner in which the containers fold. Conversely, attempts to increase the storage capacity (i.e., expanded volume) of current knockdown container designs require a coextensive increase in the storage footprint (i.e., collapsed area) of the knockdown container. 
         [0006]    As such, there is a need for collapsible containers that do not require assembly and disassembly for normal use thereof, and provide sufficient stowage capacity while maintaining a minimal collapsed footprint. 
       SUMMARY 
       [0007]    Collapsible containers are set forth herein having four walls that are permanently attached to each other and to a flexible base. A unique and surprising aspect to some of these collapsible containers relates to the lengths of the walls and the size of the base. It is known to make an open cube-shaped container with square walls and a square base, wherein the side walls do not overlap one another when the cube container is collapsed. In contrast, collapsible containers presented herein can have a rectangular shape (allowing for a larger interior volume compared to a cube), which means that the side walls overlap each other slightly when collapsing the container. 
         [0008]    The container can also include a flexible base that can be captured between the overlapping, folded side walls. This coordination of overlapping the folding side walls and capturing therebetween the flexible folds of the base is not trivial. To collapse the container into a compact package, it turns out that the dimensions of the walls and the base are important. If the length of the walls are too long, the base will not tuck between the overlapping, folded sidewalls. Moreover, if made too long, the container cannot collapse into a flattened configuration because the flexible base when tucked between the overlapping sidewalls prevents the folding sidewalls from lying flat against one another. The “trick” is to dimension the walls and the base such that the sidewalls are permitted to fold and overlap each other while capturing between the overlapping portions some of the flexible base. For example, dimensioning the base to accommodate two standard-sized brown paper grocery bags when completely unfolded is within a range of dimensions that will allow the container to collapse completely. The height of the container can be dimensioned so that it corresponds to ⅔ the height or above of a standard-sized brown paper grocery bag. 
         [0009]    According to some aspects of the present disclosure, a collapsible container is presented. The collapsible container includes a flexible base, first and second rigid end walls, each of which is attached to a respective opposing end of the flexible base, and first and second rigid sidewalls, each of which is attached to a respective opposing side of the flexible base. The sidewalls are permanently attached to the base and the end walls. The first and second rigid sidewalls are foldable such that the container can selectively transition between an expanded state, whereat the first and second sidewalls are generally perpendicular with the first and second end walls, and a collapsed state, whereat at least a portion of the first sidewall overlaps at least a portion of the second sidewall and the sidewalls are interleaved between the end walls. 
         [0010]    According to other aspects of the present disclosure, a collapsible container system is featured. The collapsible container system includes an elongated flexible base, first and second opposing rigid end walls, and first and second opposing rigid sidewalls. The base is composed of a textile material. Each of the end walls includes a rigid quadrilateral panel attached at a bottom edge thereof to a respective opposing end of the flexible base. Each of the sidewalls is permanently attached at a bottom edge thereof to a respective opposing side of the flexible base. The first and second sidewalls are each permanently attached at opposing ends thereof to the first and second end walls. The end walls have a first length, whereas the sidewalls, when unfolded, have a second length that is larger than the first length of the end walls. A removable, rigid base is configured to be removably inserted into the container. Each of the sidewalls is foldable along a center folding seam such that the container can selectively transition between an expanded state and a collapsed state. When in the expanded state, the sidewalls are generally parallel to each other and generally perpendicular with the end walls to thereby define an expanded volume therebetween. When in the collapsed state, the sidewalls at least partially overlap and lie against one another and interleaved between the end walls to thereby substantially eliminate the expanded volume. 
         [0011]    According to other aspects of the present disclosure, a storage device is presented. The storage device includes an elongated base composed of a flexible material. The length of the base is greater than the width of the base. A pair of end walls are each inseparably attached along a length thereof to a respective longitudinal end of the base. A pair of sidewalls are each inseparably attached along a length thereof to a respective lateral side of the base. Each of the sidewalls is inseparably attached at respective ends thereof to each of the end walls. Each of the sidewalls has a fold line along opposing facing surfaces of the sidewalls and extending along a height of each of the sidewalls. 
         [0012]    The above summary is not intended to represent each embodiment or every aspect of the present disclosure. Rather, the foregoing summary merely provides an exemplification of some of the novel features included herein. The above features and advantages, and other features and advantages of the present disclosure, will be readily apparent from the following detailed description of the embodiments and best modes for carrying out the present invention when taken in connection with the accompanying drawings and appended claims. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0013]      FIG. 1  is a perspective-view illustration of an exemplary collapsible container in accordance with aspects of the present disclosure, showing the container in a collapsed state or configuration. 
           [0014]      FIG. 2  is a plan-view illustration of the exemplary collapsible container of  FIG. 1  shown in a collapsed state with interleafed, partially overlapping sidewalls. 
           [0015]      FIG. 3  is a perspective-view illustration of the exemplary collapsible container of  FIG. 1  shown in a partially expanded state. 
           [0016]      FIG. 4  is a perspective-view illustration of the exemplary collapsible container of  FIG. 1  shown in a fully expanded state or configuration with an optional rigid base insert removed from the container. 
           [0017]      FIG. 5  is a perspective-view illustration of the exemplary collapsible container of  FIG. 1  shown in a fully expanded state with the optional rigid base inserted into the container. 
           [0018]      FIG. 6  is a perspective-view illustration of the exemplary collapsible container of  FIG. 1  shown upside down in a partially expanded state with the flexible rigid base captured between the end walls and sidewalls. 
       
    
    
       [0019]    While the present disclosure is susceptible to various modifications and alternative forms, specific embodiments have been shown by way of example in the drawings and will be described in detail herein. It should be understood, however, that the disclosure is not intended to be limited to the particular forms disclosed. Rather, the disclosure is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the appended claims. 
       DETAILED DESCRIPTION 
       [0020]    Referring to the drawings, wherein like reference numerals refer to like components throughout the several views,  FIG. 1  illustrates an exemplary collapsible container, designated generally as  10 , in accordance with aspects of the present disclosure. The collapsible container  10  (which may also be referred to herein as “collapsible container system” or “storage device”) is intended for storing, supporting, and/or transporting personal effects, such as, but not limited to, groceries, laundry, shopping goods, convenience goods, etc. However, it should be recognized that the collapsible container  10  may utilized for other purposes without departing from the scope and spirit of the present disclosure. In addition, the drawings presented herein are not to scale and are provided purely for explanatory purposes. Thus, the specific and relative dimensions shown in the drawings are not to be considered limiting unless explicitly stated otherwise in the claims. 
         [0021]    With collective reference to the Figures of the drawings, the container  10  generally includes a main body, designated as  22  in  FIG. 1 , with a first rigid sidewall  12  that opposes a second rigid sidewall  14 , and a first rigid end wall  16  that opposes a second rigid end wall  18 . By referring to the sidewalls  12 ,  14  as rigid, it is meant that they are capable of standing upright on their own against the force of gravity. In this example, the sidewalls  12 ,  14  are foldable along a fold line or bias, forming two panels described more fully below, and each of the panels is composed of a rigid material, such as cardboard or plastic, and surrounded by a textile, such as canvas or fabric. The sidewalls  12 ,  14  and end walls  16 ,  18  all extend upwardly from an elongated, flexible base  20 , which is most easily seen in  FIGS. 4 and 6 . The sidewalls  12 ,  14 , end walls  16 ,  18 , and base  20  are all permanently attached to one another. In the illustrated embodiment, the main body  22  is a textile casing, fabricated, for example, from a cotton-based cloth. The main body  22  acts as an outer skin, which encases and interconnects a plurality of rigid quadrilateral panels. Specifically, each of the end walls  16 ,  18  includes a rigid rectangular-shaped panel (shown hidden in  FIGS. 5  at  13  and  15 , respectively) that is encased within the main body  22 . The end-wall panels  13 ,  15  are each inseparably attached along a bottom edge thereof to a respective opposing end of the base  20 , as seen in  FIG. 5 . 
         [0022]    As used herein, “permanently attached” or “inseparably attached” is meant to infer that the joined items are neither intended nor designed to be separated or separable under normal and ordinary use. Naturally, it is possible to separate any two items by pulling them apart with a sufficient amount of force, but these terms mean that the items are joined in such a manner as to not be separable within the normal and ordinary usage of the container  10 . For example, items can be permanently or inseparably attached by stitching or glue, even though it is still possible to separate them by cutting them or ripping them apart. By contrast, items joined by hook and loop fasteners, zippers, snaps, and the like would not be permanently or inseparably attached as contemplated by the present disclosure. 
         [0023]    Similar to the end walls  16 ,  18  of the collapsible container  10 , each of the sidewalls  12 ,  14  includes rigid rectangular-shaped panels (shown hidden in  FIGS. 5  at  17  and  19 , respectively) that are encased within the main body  22 . The sidewall panels  17 ,  19  are each inseparably attached along a bottom edge thereof to a respective opposing lateral side of the base  20 , as seen in  FIG. 5 . Likewise, each of the sidewalls  12 ,  14  is inseparably attached along respective opposing ends thereof to each of the end walls  16 ,  18 , as best seen in  FIG. 5 . By permanently attaching the sidewalls  12 ,  14  to the end walls  16 ,  18  and the base  20 , the collapsible container  10  eliminates the need for assembling/disassembling the constituent parts of the container  10  when in use. In so doing, the collapsible container  10  reduces time and manual labor when expanding and collapsing the container  10 . Additionally, the foregoing arrangement eliminates the need for handling and storing separate parts, which in turn eliminates the possibility of losing any of the primary components of the container  10 . Finally, the collapsible container  10  can be characterized by the absence of a separate rigid skeletal structure (e.g., a twist-and-lock frame) that must be assembled to maintain the collapsible container  10  in an expanded state. 
         [0024]    The collapsible container  10  can be fabricated from any of a large variety of materials. By way of example, and not limitation, the sidewall and end wall panels  13 ,  15 ,  17 ,  19  can be fabricated from or composed of a heavy-duty paper, such as cardboard, wood-based materials, such as fiberboard, polymeric materials, such as polyethylene terephthalate (PET), or metallic materials, such as aluminum. In addition, the main body  22  can be fabricated from a variety of different textile materials, such as animal-based textiles (e.g., leather and silk), plant-based textiles (e.g., cotton, flax, and canvas), and synthetic textiles (e.g., nylon and polyester), for example. Likewise, the flexible base  20  can be fabricated from the same textile material as the main body  22  or, in alternate embodiments, a different material. It is also envisioned that the collapsible container be fabricated as a monolithic, single-piece structure. In another alternative arrangement, the sidewalls, end walls and base of the collapsible container  10  can be chemically adhered, mechanically fastened, or otherwise directly attached to one another, thus eliminating the need for an outer skin. 
         [0025]    In some embodiments, forming the container  10  includes cutting one or more pieces of flexible material, such as fabric. Rigid panels corresponding to the sidewall and end wall panels are arranged on the flexible material. The sidewalls and end walls are permanently attached together, such as by sewing stitches through the flexible material where adjacent panels meet. The flexible base is permanently attached to the sidewalls and end walls as described above, such as by stitching the flexible material where the base joins the sidewalls and end walls. 
         [0026]    With reference to  FIG. 5 , the sidewalls  12 ,  14  are, in the illustrated embodiment, geometrically identical. In comparison, the end walls  16 ,  18  are, in the illustrated embodiment, geometrically identical to one another, but geometrically distinct from the sidewalls  12 ,  14 . For example, the first and second end walls  16 ,  18  are generally rectangular, with a common length (“first length”) L 1  and a common height H 1 . Alternately, the end walls  16 ,  18  can be square such that L 1 =H 1 . The first and second sidewalls  12 ,  14  of  FIG. 5  are also generally rectangular and share the same common height H 1  as the end walls  16 ,  18 . However, when fully unfolded, the sidewalls  12 ,  14  have a common length (“second length”) L 2  that is larger than the length L 1  of the end walls  16 ,  18 . In some embodiments, the ratio of the first length L 1  to the second length L 2  is between approximately 1:1 and 1:1.35. In some embodiments, the second length L 2  is approximately 1.2-1.4 times larger than the first length L 1 . In some embodiments, the second length L 2  is approximately 1.31 times larger than the first length L 1 . In some embodiments, the comparative lengths of the sidewalls  12 ,  14  to the end walls  16 ,  18  (L 2 :L 1 ) are dimensioned to ensure that the container  10  can be fully collapsed, as described in further detail below, without compromising the storage capacity (i.e., expanded volume) of the container  10 . In some embodiments, the second length L 2  is approximately 43.18 cm (17.00 inches), and the first length L 1  is approximately 32.36 cm (12.75 inches). In some embodiments, the common height H 1  of the container walls is approximately 27.94 cm (11.00 inches). Recognizably, the individual and relative dimensions can be varied from that shown in the drawings. 
         [0027]    As seen in  FIG. 5 , the length L 1  of the end walls  16 ,  18  is also the width W of the elongated base  20 , whereas the length L 2  of the unfolded sidewalls  12 ,  14  is also the length L 3  of the elongated base  20 . As such, the ratio of the width W to the length L 3  of the base  20  can be commensurate with any of the various optional alternative embodiments described above with respect to the comparative lengths of the sidewalls  12 ,  14  and the end walls  16 ,  18  (L 2 :L 1 ). In addition, the collapsed footprint of the container  10  (e.g., the geometric area of a surface occupied by the container  10 ), when fully collapsed, is substantially the same size as the area of one or both of the end walls  16 ,  18 , as seen in  FIG. 1 . In contrast, the expanded footprint of the collapsible container  10 , when fully expanded, is substantially the same size as the area of the base  20 , as seen in  FIG. 5 . 
         [0028]    The collapsible container  10  is convertible between an expanded state (also referred to herein as “expanded configuration”) and a collapsed state (also referred to herein as “collapsed configuration”). In the illustrated embodiment, for example, the first foldable sidewall  12  comprises first and second rigid panels  12 A and  12 B, respectively, that are attached together at a centrally located folding seam or bias  24 , as seen in  FIG. 5  Likewise, the second foldable sidewall  14  comprises first and second rigid panels  14 A and  14 B, respectively, that are attached together at a centrally located folding seam or bias  26 . The centrally located folding seams  24 ,  26  (also referred to herein as “fold lines” or a “folding bias”) are located on opposing, inwardly facing surfaces of the sidewalls  12 ,  14 , extending along the height H 1  of each of the sidewalls  12 ,  14 . Each sidewall  12 ,  14  can be folded (and unfolded) along its respective folding seam  24 ,  26 , such that the collapsible container  10  selectively transitions from a collapsed state, which is exemplified in  FIG. 1 , through a partially unfolded state, which is exemplified in  FIG. 3 , to an expanded state, which is exemplified in  FIG. 4  (and back). 
         [0029]    The collapsible container  10  can be shifted back-and-forth between the collapsed and expanded states, for example, by transitioning the end walls  16 ,  18  generally rectilinearly toward and away from one another, respectively. Urging the end walls  16 ,  18  toward one another causes each of the sidewalls  12 ,  14  to fold inwardly toward one another along their respective fold lines  24 ,  26 . When in the expanded state, which is best seen in  FIGS. 4 and 5 , the first and second sidewalls  12 ,  14  are generally parallel to each other and generally perpendicular with the first and second end walls  16 ,  18 . In this configuration, the sidewalls  12 ,  14 , end walls  16 ,  18  and base  20  define an expanded volume, designated generally as  28  in  FIG. 4 , therebetween. In some embodiments, the expanded volume is approximately 39,066 cubic centimeters (2384 cubic inches) within a 10% tolerance. When in the collapsed state, which is best seen in  FIGS. 1 and 2 , the sidewalls  12 ,  14  at least partially overlap and lie against one another, interleaved between the first and second end walls  16 ,  18 . In so doing, the storage space of the container  10  is substantially eliminated (e.g., less than 15% of the expanded volume). 
         [0030]    As best seen in  FIG. 2 , a portion of the inner face of the first rigid panel  12 A of the first sidewall  12  lies generally flat against a portion of the inner face of the second rigid panel  14 B of the second sidewall  14  when the container  10  is in the collapsed state. Also, when in the collapsed state, an inner face of the second rigid panel  12 B of the first sidewall  12  lies generally flat against an inner face of the second end wall  18 , and an inner face of the first rigid panel  14 A of the second sidewall  14  lies generally flat against an inner face of the first end wall  16 . The orientation of the folded sidewalls  12 ,  14  with respect to each other and the end walls  16 ,  18  can be switched without changing structural characteristics of the collapsible container  10 . That is, when the container  10  is in the collapsed state, a portion of the inner face of the second rigid panel  12 B of the first sidewall  12  can lay generally flat against a portion of the inner face of the first rigid panel  14 A of the second sidewall  14 . Contemporaneously, an inner face of the first rigid panel  12 A of the first sidewall  12  can lay generally flat against an inner face of the first end wall  16 , and an inner face of the second rigid panel  14 B of the second sidewall  14  can lay generally flat against an inner face of the second end wall  18 . 
         [0031]      FIGS. 4 and 5  provide two different perspective views of an optional, rigid foldable base insert  30  that is designed to be removably inserted into the container  10 . As seen in  FIG. 5 , for example, the base insert  30  is configured to removably insert into the expanded container  10 , and lay across and cover substantially all of the flexible base  20 . When properly positioned inside the expanded container  10 , the rigid base insert  30  of  FIG. 5  provides additional structural integrity to the flexible base  20  and helps to maintain the collapsible container  10  in the expanded state. The rigid base insert  30  can also be designed to fold, as seen in  FIG. 4 , for greater compactness and, thus, ease of storage. In  FIG. 4 , for example, the rigid base insert  30  has a centrally located fold line  32 . In some embodiments, the rigid base insert  30  can be folded along the fold line  32  such that the footprint of the insert  30  is smaller than the collapsed footprint of the container  10 . According to some embodiments, when the base insert  30  is folded, it can be slid into the collapsed container  10 , interleaved with the sidewalls  12 ,  14  in between the end walls  16 ,  18  when the container  10  is in the collapsed state. 
         [0032]    Turning now to  FIG. 6 , a substantial portion of the flexible base  20  is, in some embodiments, configured to be tucked between the end walls  16 ,  18  and the sidewalls  12 ,  14  when the container  10  is in the collapsed state. That is, as the collapsible container  10  is converted from the expanded configuration (e.g.,  FIG. 4 ) to the collapsed configuration (e.g.,  FIG. 1 ), the base  20  deforms such that at least a portion of the base  20  is captured in between the folding sidewalls  12 ,  14 . In so doing, the collapsed footprint of the container  10  is kept to a minimum, not much larger than the size of one of the end walls  16 ,  18 , which is the constraining dimension. 
         [0033]    The first and second end walls  16 ,  18  can each be provided with an optional handle  34 ,  36 , respectively. In the embodiment illustrated in  FIG. 2 , for example, the handles  34 ,  36  are attached to and protrude from a respective outer surface of the end walls  16 ,  18 . Alternative arrangements are also envisioned, such as the handles  34 ,  36  being cutouts that extend through the end walls  16 ,  18 . In addition, the first and second side walls  12 ,  14  can each be provided with a pocket  38 ,  40  that protrudes from a respective outer surface thereof. In some embodiments, each of the rigid panels  12 A,  12 B,  14 A,  14 B of the side walls  12 ,  14  includes an individual pocket. 
         [0034]    While particular embodiments and applications of the present disclosure have been illustrated and described, it is to be understood that the present disclosure is not limited to the precise construction and compositions disclosed herein and that various modifications, changes, and variations can be apparent from the foregoing descriptions without departing from the spirit and scope of the invention as defined in the appended claims. To that extent, elements and limitations that are disclosed, for example, in the Abstract, Summary, and Detailed Description sections, but not explicitly set forth in the claims, should not be incorporated into the claims, singly or collectively, by implication, inference, or otherwise.