Patent Description:
Conventional plastic Folding Large Containers (FLC) utilise textile dunnage separators. Because of the flexibility of textiles (versus solid rigid dividers), a <NUM>% to <NUM>% uplift in pack density can be achieved on the outward leg through better nesting of the parts delivered in the FLC. Once the parts are removed from the packaging, the FLC is folded with the textile separators inside and in its folded state is one third the size. This means for every three trucks that go out, only one is needed to return the empty FLC's.

Unfortunately, textile dunnage is not strong enough for heavy parts such as brake, suspension and engine components for vehicles and most FLC's have a limited weight capacity.

This means heavy components are usually moved in rigid steel stillages with polyurethane dunnage, but as these don't generally fold, the size reduction with the attendant decrease in transport capacity needed to return the empty FLC's cannot be realised, which increases expense and is environmentally damaging through the need to use more vehicles to return the empty FLC's.

United States Patent Publication No. <CIT> discloses dunnage for supporting elongated products arranged in layers in storage or shipping containers comprises elongated plastic strips having openings for receiving the goods and also having reinforcing members extending along their undersides which are removably received in dunnage supports attached to the sides of the container. The dunnage supports are so arranged that the reinforcing members are supported out of contact with subjacent and superjacent layers of the products and dunnage. For returnable containers or boxes whose walls are collapsed inwardly over the floor of the box, space may be provided beneath the inwardly folded walls to accommodate the dunnage for return shipment. Wall brackets for supporting opposite ends of the dunnage strips may be shallow and the dunnage provided with flanges for reception between the box walls and the brackets thereby permitting use of shallow brackets allowing the box walls to be folded in bypass relation thereto.

United States Patent Publication No. <CIT> discloses a collapsible container for holding product therein during shipment and being returned for reuse that has a body including at least two collapsible side structures with support members attached thereto. Dunnage is suspended from the support members. The dunnage comprises a plurality of flexible members, at least some of the flexible members having stabilizers attached to the flexible member for stabilizing and protecting product being shipped. In one embodiment, tracks may be attached to opposite sides of the body, and support member assemblies extend between the tracks. Dunnage is suspended from the support member assemblies. Portions of the support member assemblies move in the tracks to move products suspended by the dunnage to a more ergonomically friendly position for loading or unloading.

United States Patent Publication No. <CIT> discloses a perishables shipping box including a plurality of panels constructed of a foamed material joined with a fabric material, the panels including a cover, four side panels and a bottom panel attached to one another to form a box, wherein for two of the side panels the foamed material has at least one open window and the fabric material is porous including a multiplicity of vent holes such that air flows through the vent holes and the at least one window.

Embodiments of the invention seek to at least partially overcome or ameliorate any one or more of the abovementioned disadvantages or provide the consumer with a useful or commercial choice.

According to a first aspect of the invention there is provided a Folding Large Container (FLC) comprising.

Providing a Folding Large Container (FLC) with an internal arrangement including the elongate rigid side support ribs secured to an inner side of opposed walls and the elongate rigid component support structures which are removably located relative to the elongate support ribs allows the internal arrangement to support greater loads when compared to existing Folding Large Containers with textile separators but to still be folded into a collapsed condition for return.

Typically, the elongate rigid component support structures are removably located relative to the elongate support ribs via the tongue which is removably received within a respective notch in the respective elongate side support ribs, supporting the elongate rigid component support structures using a simple abutment, possibly a friction fit, or an interference fit where some deformation of a portion of the tongue is needed to fit the tongue within the notch.

Although the FLC may be made of any material, it will typically be formed of one or more plastic material for light weight but high strength. Different components of the FLC may be made from different plastics.

Preferably, the elongate rigid side support ribs and the elongate rigid component support structures will be made from a high strength plastic such as solid polypropylene. This allows the elongate rigid side support ribs and the elongate rigid component support structures to be CNC machined to shape for example, further reducing cost as the expense of moulds is not incurred.

The FLC will preferably be generally rectangular as this will provide for better packing of multiple FLC's together, although any suitable shape could be used.

The FLC typically comprises an outer container body having a footprint area with a base and plurality of wall portions each moveable between an assembled condition in which each wall portion is upstanding and together the wall portions define a transport volume within the container body and a collapsed condition in which each of the wall portions lies within the footprint area of the base.

The container body will typically be formed of one or more plastic materials but any one or more materials could be used.

The footprint area of the FLC will preferably be defined by the external dimension of the base. This will define a maximum footprint area for the FLC which is preferably the same in the assembled condition and the collapsed condition.

The base of the container body will preferably be solid although the base may have one or more openings formed thereinto. Typically, a number of openings will be formed into the base below the floor of the container body (the upper surface of the base in the transport volume) to receive a lifting tine, for example of a forklift or similar.

The base of the container body will preferably be substantially rectangular.

The wall portion provided relative to at least one side of the base is preferably offset vertically from the wall portions provided relative to at least one other side of the base. The wall portions provided relative to one of the pairs of sides of the preferred rectangular base will preferably be offset vertically from the wall portions provided relative to the other of the pairs of sides of the preferred rectangular base. This means that the wall portions can collapse into a flattened position without obstructing the other wall portions when collapsed within the footprint area of the container. For example, a first pair of opposed sides of the base may be provided with a stub wall base extending upwardly from the base and relative to which a side wall portion on that side is mounted. Typically, the other of the pair of opposed sides of the base are not provided with a stub wall base or may be provided with a stub wall base of lesser height.

The wall portions may be removably mounted relative to the base. For example, the wall portions may be mounted relative to the base such that the wall portions can be detached from the base in order to move to the collapsed condition. Any suitable mounting method could be used for example a tongue and groove assembly in which a tongue is provided on a lower edge of the wall portion to engage with a corresponding groove on an upper part of the base, or vice versa.

The wall portions may be substantially permanently mounted relative to the base. For example, the wall portions may be hinged relative to the base. The hinge arrangement may be such that a linear movement of the wall portion may be required to disengage the wall portion from the base before rotation of the wall portion is possible.

The base generally has a substantially planar upper surface to form an inner bottom wall of the transport volume.

The wall portions are each typically planar, at least on an inner side.

When in the collapsed condition, the wall portions will typically lie substantially horizontally within the footprint area of the base. The wall portions may be angled downwardly (past horizontal) but collapsing the wall portions so that the wall portions are at least horizontal will typically realise the size reduction of the FLC.

When collapsed, the wall portions will preferably be spaced from the inner bottom wall of the container body. This will typically allow the other components (side support ribs and the component support structures) to be located in the collapsed container body between the bottom wall of the container body and the collapsed side walls.

The wall portions may have one or more prepared openings provided therein for the attachment of the side support ribs. The prepared openings may have reinforced surrounds for a more secure mounting.

The internal sides of the wall portions is preferably planar.

Each wall of the container body may be formed from more than one portion. An upper wall portion may be provided which is mounted to a lower wall portion. One or more lower wall portions may be provided, at least one of which mounts the upper wall portion and is in turn mounted relative to another lower wall portion or the base. The mounting of the wall portions will preferably be such that perpendicular wall portions are offset vertically from one another. In an embodiment in which one or more hinges are used to mount the wall portions relative to one another and/or the base, the hinges of perpendicular wall portions are preferably offset vertically from one another.

When collapsed, two of the wall portions will typically overlie the other two adjacent perpendicular wall portions in a rectangular container. Opposed wall portions will normally lie in the same plane when collapsed.

The FLC will include at least one opposed pair of elongate rigid side support ribs, one of each respective pair of elongate side support ribs secured to an inner side of respective opposed wall portions, each elongate side support rib including at least one locating notch formed thereinto.

The elongate rigid side support ribs are secured to opposed wall portions. The elongate rigid side support ribs are typically secured using a robust securing mechanism such as one or more fasteners such as screws or bolts or plugs or rivets and washers for example.

More than one pair of elongate rigid side support ribs will normally be provided in a container body.

The elongate rigid side support ribs are preferably elongate and linear.

The elongate rigid side support ribs may be horizontally oriented within the container body or vertically oriented. Typically, if the FLC is transporting a single type of component, then all of the elongate rigid side support ribs in the container body will preferably extend in the same direction, but different groups of elongate rigid side support ribs may be provided, spaced through the transport volume.

The elongate rigid side support ribs may be planar or not. Typically, the shape of the elongate rigid side support ribs and the position of the at least one notch is dependent upon whether the elongate rigid side support ribs are oriented horizontally or vertically within the transport volume (which is turn typically dependent upon the component to be transported).

In an embodiment, horizontally oriented elongate rigid side support ribs are typically planar. Horizontally oriented elongate rigid side support ribs will normally have multiple notches. Each elongate rigid side support rib of the pair are preferably aligned to align the notches.

The notches may be in an upper side edge of each horizontally oriented elongate rigid side support rib. At least one pair of elongate rigid side support ribs may have a notch in an upper edge and a lower edge. These notches may be aligned with one another.

A notch may be in one or both lateral side faces of an elongate rigid side support rib. A notch may extend through the thickness of an elongate rigid side support rib.

A notch may be approximately half of the dimension of the elongate rigid side support rib except where a pair of aligned notches are provided in opposite edges in which case the notches may be less than one half of the dimension.

Clearance may be provided between the end(s) of the elongate rigid side support ribs and the perpendicular wall portions of the container body.

In use, the wall portions relative to which the elongate rigid side support ribs are mounted are generally collapsed before the other wall portions.

When the elongate rigid side support ribs are vertically oriented, the elongate rigid side support ribs will typically have a single elongate notch. The notch is typically U-shaped. This configuration may allow one or more component support structure(s) to be inserted into the notch one above another.

The at least one notch is typically rectangular in cross-section. A convergent entryway may be provided on the or each notch.

The FLC includes at least one pair of elongate rigid component support structures, each elongate component support structure comprising a tongue to be removably received within a respective notch in the respective elongate side support ribs to position the elongate component support structures transversely between the opposed side walls and at least one shaped component-locating opening to locate a component relative to the at least one pair of elongate component support structures.

There will typically be more than one pair of component support structures. The pairs are preferably provided spaced over the width of the transport volume. More than one pair of component support structures may be provided spaced over the height of the transport volume.

Each component support structure is preferably provided with a tongue at each end. A single structure that forms a tongue at each end may be provided or a separate and distinct tongue may be provided. The tongue may be provided at the respective end only. A member or structure may be provided extending over the length of the component support structure and which forms or provides a tongue at each end.

The tongue is provided as a part of the component support structure.

At least one dimension of the tongue may correspond to the width of the component support structure. At least one dimension of the tongue may be a part of the width of the component support structure.

The tongue is preferably received, at least partially, with a notch on an elongate side support rib. A tongue may be provided at both ends of the unitary component support structure to be received in a notch of each of a pair of elongate side support ribs.

Each component support structure may be provided with one or more tongues. Typically, a tongue is provided at each end thereof. At least one component support structure may include an upper tongue and a spaced apart lower tongue. In an embodiment, each bottom component support structure (provided lowermost in the transport volume) is provided with the upper and lower tongues at each end thereof. Other component support structures in the transport volume may have a single tongue at each end.

In an embodiment, the tongue is normally a part of the height of the component support structure only. Typically, the tongue may be approximately half of the height of the component support structure. In some embodiments, the tongue may be one third (or less) of the height of the component support structure.

The component support structure may be oriented vertically within the transport volume (the height of the component support structure being greater than the width) or horizontally (the width of the component support structure being greater than the height). The orientation will normally be dependent on the component to be transported and/or whether that component is to be transported in a vertical orientation or a horizontal orientation. The component support structure will normally be oriented perpendicularly to the component(s) and/or the side support ribs. Typically, if the component is laid horizontally in the FLC, then the component support structure is normally oriented vertically. If the component is oriented vertically in the FLC, the component support structure is normally oriented horizontally.

Each component support structure includes at least one shaped component opening. Typically, a number of shaped component openings are provided over the length of each component support structure. The shape of the shaped component opening will depend on the component to be transported. The shape of the shaped component opening will typically correspond to a portion of the external shape of the component to be transported. The shaped component opening may be formed in any way. CNC machining the shaped component opening is particularly preferred but the shaped component opening may be formed using cutting or moulding.

The component openings may be formed as a shaped crenelle between a pair of merlon portions.

Typically, the component will be supported relative to the component support structure by an edge of the shaped component opening. The component may rest at least partially in the shaped component opening. The component may be positively constrained against movement by one or more shaped component openings provided in one or more component support structures.

The shaped component openings on adjacent component support structures may correspond with each other to form a receiving opening for a component or a portion thereof. For example, a pair of shaped component openings on adjacent component support structures may at least partially surround a part of a component to hold the component between the component support structures.

A shaped component opening may interact with an edge of an adjacent component support structure to form a receiving opening for a component or a portion thereof. For example, a shaped component opening may interact with an edge of an adjacent component support structure to at least partially surround a part of a component to hold the component between the component support structures.

The FLC may further comprise a base support member or arrangement. The base support member or arrangement will typically be used in the FLC for components which are to be transported vertically oriented within the FLC.

The base support member or arrangement will typically include a number of openings. The openings will typically be oriented in a regular array so that the FLC can transport a number of components. Each of the openings is preferably shaped and configured to receive one end of a component to be transported therein.

The base support member or arrangement will preferably overlie the bottom wall of the transport volume. The base support member or arrangement may be attached or mounted to the bottom wall of the transport volume.

In an embodiment, the base support member or arrangement may be formed of a resiliently deformable material. The base support member or arrangement may be formed of a rigid material. The periphery of the openings provided in the base support member or arrangement will preferably be slightly deformable in order to positively locate the end of the component which is located therein.

One or more of the component support structures may be attached to one or more other component support structures and/or to wall portion of the container body. Typically, an elongate flexible attachment may be provided. The provision of such an attachment will typically connect the component support structure to another component support structure and/or to a wall portion of the container body in order to prevent loss or theft of the component support structures. The provision of an elongate flexible attachment will allow the component support structures to be relocated within the transport body as needed, particularly before the wall portions are collapsed. Prior to collapsing the wall portions, the component support structures are preferably located in a lower part of the container body and the wall portions collapsed on top of the component support structures. The length of the elongate flexible attachment may be such that partial removal of the component support structure from the transport volume is possible.

The elongate flexible attachment may be formed in one piece for example as a strap or in more than one piece such as for example a chain. The elongate flexible attachment will typically be securely attached to the component support structure(s) and/or the wall portion. Typically, the elongate flexible attachment is attached to a component support structure at a first end and either a component support structure at a second end and/or a wall portion.

In use, the internal arrangement comprising at least a pair of elongate rigid side support ribs and at least one pair of elongate rigid component support structures will be selected according to the component(s) to be transported. The elongate rigid side support ribs will then typically be attached securely to opposed wall portions of the container body (which are preferably already in the assembled condition) and the component support structures secured relative thereto. One or more components may be located relative to the component support structures in order to complete the FLC for transport. A lid may be provided for the FLC.

The FLC can be transported to the required destination. Once unpacked, the component support structures can then be released from the side support ribs and preferably located in a lower portion of the transport volume. The wall portions with the rigid side support ribs attached thereto are then preferably collapsed on top of the lower portion of the transport volume and the perpendicular wall portions are then typically collapsed on top of the lower collapsed wall portions. The wall portions may then be secured in position.

Collapsing the FLC will typically reduce the height of the FLC by at least one half and preferably towards one third of the height of the FLC in the assembled condition allowing better packing on the return leg of the trip.

The FLC can be reused in the same configuration in the assembled condition or alternatively, the internal arrangement may be changed when the FLC is next used.

With reference to the accompanying figures, a Folding Large Container (FLC) <NUM> is provided. The FLC <NUM> shown in the Figures is shown with a number of internal arrangements. In all embodiments, the FLC <NUM> comprises an outer container body having a footprint area, with a base <NUM> and plurality of wall portions <NUM>, each wall portion <NUM> moveable between an assembled condition (shown in <FIG>, <FIG>, <FIG> and <FIG> for example) in which each wall portion <NUM> is upstanding and together the wall portions <NUM> define an internal transport volume within the container body and a collapsed condition (shown in <FIG> and <FIG> for example) in which each of the wall portions <NUM> lies within the footprint area of the base <NUM>.

Although different configurations are illustrated, the FLC <NUM> illustrated includes a number of opposed pairs of elongate rigid side support ribs <NUM>, one of each respective pair of elongate side support ribs <NUM> secured to an inner side of respective opposed wall portions <NUM>, each elongate side support rib <NUM> including at least one locating notch <NUM> formed thereinto. The FLC <NUM> illustrated also includes a number of pairs of elongate rigid component support structures <NUM>, each elongate component support structure <NUM> comprising a tongue <NUM> to be removably received within a respective locating notch <NUM> in the respective elongate side support ribs <NUM> to position the elongate component support structures <NUM> transversely between the opposed wall portions <NUM>. Each elongate component support structure <NUM> also includes a number of shaped, component-locating opening <NUM> to locate a component relative to the elongate component support structures <NUM>.

As shown, the elongate rigid component support structures <NUM> are removably located relative to the elongate support ribs <NUM> via the tongue <NUM>, which is removably received within a respective notch <NUM> in the respective elongate side support ribs <NUM>, supporting the elongate rigid component support structures <NUM> using a simple abutment, possibly a friction fit, or an interference fit where some deformation of a portion of the tongue <NUM> is needed to fit the tongue <NUM> within the notch <NUM>.

Although the FLC <NUM> may be made of any material, it will typically be formed of plastic for light weight but high strength. Different components of the FLC may be made from different plastics. For example, the container body may be made of one plastic and the internal components (the elongate rigid side support ribs <NUM> and the elongate rigid component support structures <NUM>) may be made from a high strength plastic such as solid polypropylene. This allows the elongate rigid side support ribs and the elongate rigid component support structures to be CNC machined to shape for example, further reducing cost as the expense of moulds is not incurred.

The FLC <NUM> illustrated is generally rectangular as this will typically provide for better packing (and stacking) of multiple FLC's together.

The footprint area of the FLC <NUM> will preferably be defined by the external dimension of the base <NUM>. This will define a maximum footprint area for the FLC <NUM> which is preferably the same in the assembled condition and the collapsed condition.

The base <NUM> of the container body will normally be solid, but have one or more openings formed thereinto. Typically, a number of openings <NUM> will be formed into the base <NUM> below the floor of the container body (the upper surface of the base in the transport volume) to receive a lifting tine, for example of a forklift or similar.

As illustrated best in the Figures showing the collapsed condition (<FIG> and <FIG> for example), the wall portions <NUM> provided relative to one of the pairs of sides of the base <NUM> are preferably offset vertically from the wall portions <NUM> provided relative to the other of the pairs of sides of the base <NUM>. This means that the wall portions <NUM> can collapse into a flattened position without obstructing the other wall portions when collapsed within the footprint area of the FLC <NUM>. As shown in <FIG> for example, a first pair of opposed sides of the base <NUM> are provided with a stub wall base <NUM> extending upwardly and relative to which a side wall portion <NUM> on that side of the FLC, is mounted. Typically, the other of the pair of opposed sides of the base <NUM> are not provided with a stub wall base <NUM> or may be provided with a stub wall base of lesser height.

The wall portions <NUM> of the illustrated embodiments are substantially permanently mounted relative to the base <NUM>. The wall portions <NUM> are hinged relative to the base <NUM> to allow folding inwardly into the collapsed condition.

The base <NUM> generally has a substantially planar upper surface to form an inner bottom wall of the transport volume. One or more base support members <NUM> or arrangements, such as that illustrated in <FIG>, <FIG> and <FIG> for example, maybe used in the FLC for components which are to be transported vertically oriented within the FLC.

The base support member or arrangement will typically include a number of openings <NUM>. The openings <NUM> will typically be provided in a regular array so that the FLC <NUM> can transport a number of components. Each of the openings <NUM> is preferably shaped and configured to receive one end of a component to be transported therein.

In the embodiment illustrated in <FIG> and <FIG>, the base support member is unitary and formed of a resiliently deformable material, such as a high-density foam. The openings <NUM> are formed directly into the base support member <NUM>.

In the embodiment illustrated in <FIG>, the base support arrangement is two part, with an upper layer <NUM> and a lower layer <NUM>. The lower layer <NUM> is preferably more rigid than the upper layer <NUM>, and is provided with openings which are larger than those in the upper layer <NUM>. The openings in the upper layer <NUM> are aligned with those in the lower layer <NUM>. In this configuration, the lower layer <NUM> provides additional support for the components and the upper layer <NUM> grips the ends of the components to be transported.

The wall portions <NUM> are each typically planar, at least on an inner side as shown.

When in the collapsed condition, the wall portions <NUM> will typically lie substantially horizontally within the footprint area of the base as shown in <FIG> for example.

When collapsed, the wall portions <NUM> will preferably be spaced from the inner bottom wall of the container body. This will typically allow the other components (the component support structures <NUM>) to be located in the collapsed container body between the bottom wall of the container body and the collapsed side wall portions <NUM>.

As illustrated in <FIG> for example, the wall portions <NUM> may have one or more prepared openings <NUM> provided therein for the attachment of the side support ribs <NUM>. The prepared openings <NUM> may have reinforced surrounds for a more secure mounting.

When collapsed, two of the wall portions <NUM> will typically overlie the other two adjacent perpendicular wall portions <NUM> in a rectangular container as illustrated in <FIG> and <FIG> for example. Opposed wall portions <NUM> will normally lie in the same plane when collapsed.

Preferably, the elongate rigid side support ribs <NUM> are secured to opposed wall portions <NUM>. The elongate rigid side support ribs <NUM> are typically secured using a robust securing mechanism such as one or more threaded fasteners such as screws or bolts for example but the illustrated mechanism is a plug <NUM> inserted through the wall portion with an enlarged head and a complementary washer <NUM> or similar which is then fixed on the inside of the container. As rebate <NUM> is provided in the rib for the plug and washer.

As shown in the Figures, more than one pair of elongate rigid side support ribs <NUM> will normally be provided in a container body. The number of pairs provided will generally depend on the components to be transported and/or the orientation of the ribs <NUM>.

The elongate rigid side support ribs <NUM> are preferably elongate and linear.

The elongate rigid side support ribs may be horizontally oriented within the container body or vertically oriented (shown in <FIG>). Typically, if the FLC <NUM> is transporting a single type of component, then all of the elongate rigid side support ribs <NUM> in the container body will preferably extend in the same direction, but multiple groups of elongate rigid side support ribs <NUM> may be provided, spaced through the transport volume as shown.

Typically, the shape of the elongate rigid side support ribs <NUM> and the position of the at least one notch is dependent upon whether the elongate rigid side support ribs <NUM> are oriented horizontally or vertically within the transport volume (which is turn typically dependent upon the component to be transported).

As shown in all the embodiments except those illustrated in <FIG>, horizontally oriented elongate rigid side support ribs <NUM> are typically planar. Horizontally oriented elongate rigid side support ribs will normally have multiple notches <NUM> spaced over their length. Each elongate rigid side support rib <NUM> of the pair are preferably aligned to align the respective notches <NUM>.

The notches <NUM> of the horizontally oriented elongate rigid side support rib may be in an upper side edge of each horizontally oriented elongate rigid side support rib <NUM> as shown in <FIG> and <FIG> for example.

The lowermost pair of elongate rigid side support ribs may have an upper notch <NUM> in an upper edge and a lower notch <NUM> in a lower edge as shown in <FIG>. These notches may be aligned with one another. This allows use of a different tongue configuration on the lower component support structures <NUM>, as shown in <FIG> and <FIG> in particular.

Typically, for ribs <NUM> other than the lowermost ribs, each notch <NUM> may be approximately half of the dimension of the elongate rigid side support rib. For the lowermost ribs where a pair of aligned notches <NUM>, <NUM> are provided in upper and lower edges respectively, the notches may be less than one half of the dimension as shown in <FIG> and <FIG>.

In use, the wall portions <NUM> relative to which the elongate rigid side support ribs <NUM> are mounted are generally collapsed before the other wall portions.

When the elongate rigid side support ribs <NUM> are vertically oriented as shown in the embodiment of <FIG>, the elongate rigid side support ribs <NUM> will typically have a single elongate notch <NUM>. The notch <NUM> is typically U-shaped. This configuration may allow the component support structures <NUM> to be inserted into the notch one above another as shown in <FIG> for example.

Each notch is typically rectangular in cross-section. An arcuate or convergent entryway <NUM> may be provided on each notch <NUM>.

As shown, there will typically be more than one pair of component support structures <NUM> located relative to each pair of elongate support ribs <NUM>. The pairs are preferably provided spaced over the width of the transport volume. More than one pair of component support structures may be provided spaced over the height of the transport volume as shown in <FIG>. Although a pair of component support structures <NUM> can support a component, one or more intermediate of component support structures <NUM> may be provided relative to each pair to provide additional support.

Each component support structure <NUM> is preferably provided with a tongue <NUM> at each end. A single structure that forms a tongue at each end may be provided such as that shown in <FIG> as an example. The tongue may be provided at the respective end only as shown in <FIG>.

An elongate member <NUM>, such as that shown in <FIG>, may be provided extending over the length of the component support structure <NUM> and which forms or provides a tongue at each end to be received in the notch <NUM> as shown in <FIG>.

The tongue may be provided as a part of the component support structure as shown in <FIG> or as a separate component <NUM> mounted or attached to the component support structure <NUM> as shown in <FIG>.

The tongue <NUM> is preferably received, at least partially, with a notch <NUM> on an elongate side support rib <NUM>. In an embodiment where the component support structure <NUM> is a unitary member such as that shown in <FIG>, a tongue <NUM> may be provided at both ends of the unitary component support structure <NUM> to be received in a notch <NUM> of each of a pair of elongate side support ribs <NUM>.

Each component support structure <NUM> may be provided with one or more tongues. Typically, a tongue is provided at each end thereof. In the embodiment shown in <FIG> and <FIG>, a component support structure <NUM> may include an upper tongue and a spaced apart lower tongue. This may be preferred for the bottom or lowermost component support structures <NUM> (provided lowermost in the transport volume). Other component support structures in the transport volume may have a single tongue at each end.

The component support structure may be oriented vertically within the transport volume (the height of the component support structure being greater than the width) which is illustrated in <FIG> <NUM> <FIG> and <FIG> or horizontally (the width of the component support structure being greater than the height), illustrated in <FIG> and <FIG>. The orientation will normally be dependent on the component to be transported and/or whether that component is to be transported in a vertical orientation or a horizontal orientation.

The component support structures <NUM> will normally be oriented perpendicularly to the component(s) and/or the side support ribs <NUM>. Typically, if the component is laid horizontally in the FLC <NUM>, then the component support structures <NUM> are normally oriented vertically. If the component is oriented vertically in the FLC <NUM>, the component support structures <NUM> are normally oriented horizontally. This presents a longer axis of the component support structure perpendicularly to the length of the component (edge on) which is likely to increase the security of the abutment with the component.

Each component support structure <NUM> illustrated includes a number of shaped component openings <NUM> over the length of each component support structure <NUM>. The shape of the shaped component opening <NUM> will depend on the component to be transported. The shape of the shaped component opening <NUM> will typically correspond to a portion of the external shape of the component to be transported. The shaped component opening may be formed in any way. CNC machining the shaped component opening <NUM> is particularly preferred but the shaped component opening may be formed using cutting or moulding.

Typically, the component will be supported relative to the component support structure <NUM> by an edge of the shaped component opening <NUM>. The component may rest at least partially in the shaped component opening <NUM>. The component may be positively constrained against movement by one or more shaped component openings <NUM> provided in one or more component support structures <NUM>.

The shaped component openings <NUM> on adjacent component support structures <NUM> may correspond with each other to form a receiving opening for a component or a portion thereof such as is illustrated in <FIG>. In this embodiment, a pair of shaped component openings <NUM> on adjacent component support structures <NUM> at least partially surround a part of a component to hold the component between the component support structures <NUM>.

A shaped component opening <NUM> may interact with an edge of an adjacent component support structure <NUM> to form a receiving opening for a component or a portion thereof such as is illustrated in <FIG>. In this embodiment, a shaped component opening <NUM> interacts with an edge of an adjacent component support structure <NUM> to at least partially surround a part of a component to hold the component between the component support structures <NUM>.

For horizontally extending component support structures <NUM>, such as those illustrated in <FIG>, the component openings may be formed as a shaped crenelle between a pair of merlon portions <NUM>.

As show in some of the illustrated embodiments, one or more of the component support structures <NUM> may be attached to one or more other component support structures <NUM> and/or to wall portion 12of the container body. Typically, an elongate flexible attachment such as a strap <NUM> may be provided. The provision of such an attachment will typically connect the component support structure <NUM> to another component support structure <NUM> and/or to a wall portion <NUM> of the container body in order to prevent loss or theft of the component support structures <NUM>. The provision of an elongate flexible attachment such as the strap <NUM> illustrated, will allow the component support structures <NUM> to be relocated within the transport body as needed, particularly before the wall portions <NUM> are collapsed. Prior to collapsing the wall portions, the component support structures <NUM> are preferably located in a lower part of the container body as shown in <FIG> for example, and the wall portions collapsed on top of the component support structures <NUM> as shown in <FIG>. The length of the elongate flexible attachment may be such that partial removal of the component support structure <NUM> from the transport volume is possible.

The elongate flexible strap <NUM> is securely attached to the component support structure(s) <NUM> and/or the wall portion <NUM>. Typically, the elongate flexible attachment is attached to a component support structure at a first end and either a component support structure at a second end and/or a wall portion. Intermediate attachments of the strap <NUM> to other component support structure(s) <NUM> may be provided as shown in <FIG>.

In use, the internal arrangement comprising at least a pair of elongate rigid side support ribs <NUM> and at least one pair of elongate rigid component support structures <NUM> will be selected according to the component(s) to be transported. The elongate rigid side support ribs <NUM> will then typically be attached securely to opposed wall portions <NUM> of the container body (which are preferably already in the assembled condition) and the component support structures <NUM> secured relative thereto. One or more components may be located relative to the component support structures <NUM> in order to complete the FLC <NUM> for transport. A lid may be provided for the FLC <NUM>. The FLC <NUM> can be transported to the required destination.

Once unpacked, the component support structures <NUM> can then be released from the side support ribs <NUM> and preferably located in a lower portion of the transport volume. The wall portions <NUM> with the rigid side support ribs <NUM> attached thereto are then preferably collapsed on top of the lower portion of the transport volume and the perpendicular wall portions are then typically collapsed on top of the lower collapsed wall portions <NUM>. The wall portions <NUM> may then be secured in position.

Collapsing the FLC <NUM> will typically reduce the height of the FLC <NUM> by at least one half and preferably towards one third of the height of the FLC in the assembled condition allowing better packing on the return leg of the trip. The FLC <NUM> can be reused in the same configuration in the assembled condition or alternatively, the internal arrangement may be changed when the FLC <NUM> is next used.

Claim 1:
A Folding Large Container (FLC) (<NUM>) comprising:
an outer container body having a footprint area with a base (<NUM>) and plurality of wall portions (<NUM>) each moveable between an assembled condition in which each wall portion (<NUM>) is upstanding and together the wall portions (<NUM>) define a transport volume within the container body and a collapsed condition in which each of the wall portions (<NUM>) lies within the footprint area of the base (<NUM>);
at least one pair of elongate rigid component support structures (<NUM>);
characterised in that the folding large container further comprises at least one opposed pair of elongate rigid side support ribs (<NUM>), one of each respective pair of elongate side support ribs (<NUM>) secured to an inner side of respective opposed wall portions (<NUM>), each elongate side support rib (<NUM>) including at least one locating notch (<NUM>) formed thereinto; and in that each elongate component support structure (<NUM>) is unitary and comprises a tongue (<NUM>) to be removably received within a respective at least one locating notch (<NUM>) in the respective elongate side support ribs (<NUM>) to position the elongate component support structures (<NUM>) transversely between the opposed wall portions (<NUM>) and at least one shaped component-locating opening (<NUM>) to locate a component relative to the at least one pair of elongate component support structures (<NUM>).