Collapsible container

[0002] This invention relates to injection molded containers, and more particularly, to a collapsible container.

[0003] Many transport and storage containers are known. Certain collapsible containers are used to transport goods such as produce and other perishables. Collapsible containers are commonly rectangular in shape with four sidewalls hinged to the base. More recent collapsible containers are injection molded plastic having sidewalls that collapse outwardly for cleaning and inwardly for storage. The sidewalls are latched in an assembled position and unlatched in a collapsed position.

[0004] A collapsable container is taught in WO Patent Application 99/32362. This container includes a base, two sidewalls, and two end walls. A pair of opposing sidewall edges and a pair of opposing end wall flanges are integral with the base and depend therefrom. The end walls are pivotablv attached to each wall flange and include defined comers at each side that abut the corresponding sidewalls. A pair of opposing sidewalls are pivotably attached to the sidewall edges. Each sidewall has a latch member at each lateral edge and each end wall has a pair of flanges with a latch receiver for capturing the latch member in the assembled position

[0005] Each latch member comprises a rigid, substantially parallelopiped body and a raised tooth at its distal end. The latch receiver includes an aperture to receive the latch member and a resiliently deformable latch hinge with a lip complementary to the raised tooth. The latch hinge has a resting position that locks the tooth and a flexed position to allow the latch member to pass through the aperture.

[0006] During assembly of the container from the collapsed position, each latch member is inserted in the corresponding aperture. As the latch member passes through the aperture, the raised tooth flexes the latch hinge upwards from the rest position, temporarily flexing the latch hinge into the flexed position. In the assembled position, the raised tooth is locked on the outside of the latch hinge as it returns to rest position. The lip of the latch hinge abuts the tooth to retain the latch member in the aperture. Users of the container will appreciate that the assembly can be somewhat awkward as each opposing end wall must be outwardly collapsed at a given angle greater than forty-five degrees to the end wall flange when the each sidewall is moved upright into the assembled position. Furthermore, both corresponding sidewalls must be held upright to latch one end wall into place.

[0007] Returning the container to the collapsed position from the assembled position, each latch hinge is moved to the flexed position, raising the lip of the latch hinge so it no longer abuts the tooth. Each latch hinge is flexed by depressing the latch hinge, typically with the thumb and forefinger of one hand, while forceably separating the corresponding sidewall with the other hand. The latch member and tooth can then be released from the latch receiver. Because of the configuration of the container, this procedure must be repeated for each latch receiver in order to release each latch member and finally collapse the container.

[0008] A second five piece collapsible container is manufactured by the Rehrig Pacific Company, 4011 East 26^thStreet, Los Angeles Calif. 90025. The latch member and latch receiver are geometrically different from the container in WO 99/32362 but are functionally similar. As a result, it still requires the same awkward procedure to collapse the container.

[0009] An example of a five piece container that is less awkward to collapse is produced by Wavin Plastics Limited. This container has sidewall edges that are joined in the comers, but unlike the collapsible container taught in WO 99/32362, can only be collapsed inwardly. There is also a latch member with a striker and a latch release member. The latch release member extends from the latch member to an activation point on the sidewall of the container. A second latch member is attached to the same sidewall. A second latch release member extends from the second latch member to a second activation point. The first and second activation points are in close proximity to each other so that both release members can be activated with one hand thereby releasing both associated latch members. Thus the container can be easily collapsed by actuating each of two sets of latch release members. Users of the container can appreciate that this latching mechanism and the assembled container is less rigid than the aforementioned collapsible containers. Further, because the container can only collapse inwardly, it is more difficult to clean.

[0010] It is an object of the present invention to provide a novel collapsible container that obviates or mitigates at least one of the disadvantages of the prior art.

[0011] In one aspect of the invention there is provided a collapsible container comprising a base, a pair of first opposing sidewalls pivotably attached to the base, and a pair of second opposing sidewalls pivotably attached to the base. The sidewalls have an assembled position, an outwardly collapsed position, and an inwardly collapsed position. A latch bar is attached to each end of each of the first opposing sidewalls and a latch member is attached to each end of the second opposing sidewalls. The latch member is biased to releasably capture a respective latch bar when the sidewalls are in the assembled position. A latch actuator is attached to each latch member and extends along a respective second sidewall to a grip. Each second sidewall has a pair of grips proximal to each other such that each pair of grips can be actuated with one hand to urge the latch member to release the latch bar.

[0012] A collapsible container for storage and transport of produce or other goods is provided. In one embodiment, there is provided a five piece collapsible container with a base and four pivotable walls. Each of the four walls are outwardly collapsible to facilitate washing, and inwardly collapsible for compact storage. A latch is provided at each of the four points where two sidewalls abut each other providing a rigid assembled container. Attached to each latch is an actuating member with a grip. The grips are paired to allow the operator to disengage both latches on one side of the container with one hand. Similarly, when collapsing the container from assembled position, all four latches can be disengaged with each hand at respective pairs of grips. The latches are readily disengageable and provide a rigid assembled container.

[0013] The present invention will now be explained, by way of example only, with reference to certain embodiments and the attached Figures in which:

[0014] FIG. 1 is a perspective view of the collapsible container with the sidewalls in the assembled position;

[0015] FIG. 2 is a perspective view of the collapsible container with the sidewalls in the outwardly collapsed position;

[0016] FIG. 3 is a perspective view of the collapsible container with the sidewalls in the inwardly collapsed position;

[0017] FIG. 4 is a perspective view of the two opposing long sidewalls of the collapsible container;

[0018] FIG. 5 is a perspective view of the two opposing short sidewalls of the collapsible container;

[0019] FIG. 6 is a partial perspective view of the corner of the collapsible container with the sidewalls in assembled position;

[0020] FIG. 7 is an exploded view of the latch mechanism including a catch bar, latch member, and latch actuator;

[0021] FIG. 8 is a partial top sectional view of the collapsible container in assembled position showing the catch bar, latch member, and latch actuator;

[0022] FIG. 9 is a partial top sectional view of the collapsible container with the latch member disengaged from the latch bar;

[0023] FIG. 10 is a side view of an alternative embodiment of the collapsible container;

[0024] FIG. 11 is a partial perspective view of an alternative embodiment of the collapsible container;

[0025] FIG. 12 is a side view of the collapsible container in a first alternative embodiment of the latch member and latch actuator;

[0026] FIG. 13 is a partial perspective view of the interior of the container showing the hinged catch of the latch member engaged with the catch aperture in a first alternative embodiment of the latch member and latch actuator;

[0027] FIG. 14 is a partial perspective view of the interior of the container showing the hinged catch of the latch member engaged with the catch aperture in the first alternative embodiment of the latch member and latch actuator;

[0028] FIG. 15 is a partial perspective view of the latch actuator and latch member in the first alternative embodiment of the latch member and latch actuator;

[0029] FIG. 16 is a partial perspective view of the latch actuator and latch member in the first alternative embodiment of the latch member and latch actuator;

[0030] FIG. 17 is a partial perspective view of an alternative embodiment of the latch actuator in the first alternative embodiment of the latch member and latch actuator;

[0031] FIG. 18 is a partial perspective view of the latch actuator in the first alternative embodiment of the latch member and latch actuator;

[0032] FIG. 19 is a side view of the collapsible container in a second alternative embodiment of the latch member and latch actuator;

[0033] FIG. 20 is a perspective view of the side of the collapsible container in the second alternative embodiment of the latch member and latch actuator;

[0034] FIG. 21 is a partial sectional view of section A—A of Figure J showing the second alternative embodiment of the latch member and latch actuator;

[0035] FIG. 22 is a partial sectional view of section A—A of Figure J showing the second alternative embodiment of the latch member and latch actuator;

[0036] FIG. 23 is a side view of the collapsible container in a third alternative embodiment of the latch member and latch actuator;

[0037] FIG. 24 is a partial perspective view of the interior of the container showing the hinged catch of the latch member engaged with the catch aperture in the third alternative embodiment of the latch member and latch actuator;

[0038] FIG. 25 is a partial perspective view of the latch actuator and latch member in the third alternative embodiment of the latch member and latch actuator;

[0039] FIG. 26 is a partial perspective view of the latch actuator and latch member in the third alternative embodiment of the latch member and latch actuator;

[0040] FIG. 27 is a partial perspective view of one side of the container showing an alternative embodiment of the hinge posts;

[0041] FIG. 28 is a partial perspective view of one side of the base of the container showing an alternative embodiment of the hangers;

[0042] FIG. 29 is a partial perspective view of one side and the base of the container showing the alternative embodiment of the hinge posts and hangers, and

[0043] FIG. 30 is a perspective view of container 20 in the outwardly collapsed position in an alternative embodiment of the tab configuration.

[0044] Referring to FIGS. 1-3, a collapsible container in accordance with an embodiment of the invention is indicated generally at 20. Container 20 is preferably used to transport and/or store products such as produce and other perishables. In a present embodiment, container 20 is injection-molded polymer such as polypropylene but other materials and forming processes can be used. Container 20 comprises a base 24 and four sidewalls 28, 32, 36, and 40 that are pivotally attached to base 24. The pivotal attachment will be discussed in greater detail below. Sidewalls 28, 32, 36, and 40 have three positions. In the assembled position, shown in FIG. 1, container 20 is used for transporting or storing product, whereby all four sidewalls 28, 32, 36, and 40 are substantially normal to base 24. In the outwardly collapsed position, shown in FIG. 2, sidewalls 28, 32, 36, and 40 are pivoted away from each other, and are substantially co-planar with base 24, thus exposing the interior of the container to facilitate washing. In the inwardly collapsed position shown in FIG. 3, sidewalls 8, 32, 36, and 40 are pivoted toward each other and are substantially parallel to base 24 thus facilitating the storage and transport of container 20 when it is empty.

[0045] In the present embodiment, base 24 is substantially planar with a rectangular footprint 44. Base 24 has two opposing short sides 48 and 52 and two opposing long sides 56 and 60. Each of short sides 48 and 52 include a base flange 64 and 68, respectively, projecting normally from footprint 44. Each side of base flanges 64 and 68 has comer sections 72, 76, 80 and 84. respectively, that are normal to footprint 44 and integral with base flanges 64 and 68 and long sides 56 and 60. Each of base ranges 64 and 68 have hinge posts 92 along the edge 96 for pivotal attachment to sidewalls 28 and 32, respectively. Long sides 56 and 60 have hinge posts 100 for pivotal attachment with sidewalls 36, 40 respectively.

[0046] As best seen in FIG. 4, a plurality of u-channel shaped hangers 108 on long sidewalls 36 and 40 are complementary with hinge posts 100 and pivotally attachable thereto. Long sidewalls 36, 40 are substantially rectangular and are defined by short sides 120 and long sides 124. Hangers 108 are attached to a contacting edge 132 on long sidewalls 36, 40. Each long sidewall 36, 40 has a free edge 136 opposite contacting edge 132. Nearest to free edge 136 and centred on sidewall 36, 40 is a handle 140 for grasping container 20. Each long sidewall 36, 40 has tabs 148 and a rigid latch bar 152 protruding from each short side 120. Latch bar 152 is substantially rectangular with a catch aperture 153 substantially centred therein and an outwardly bevelled free end 154.

[0047] As best seen in FIG. 5, a plurality of u-channel shaped hangers 104 on short sidewalls 28 and 32 are complementary with hinge posts 92 and pivotally attached thereto. Short sidewalls 28 and 32 are substantially rectangular and are defined by short sides 112 and long sides 116. Hangers 104 are attached to a contacting edge 134 on short sidewalls 28, 32. Each short sidewall 28, 32 has a free edge 138 opposing contacting edge 134. Nearest to free edge 138 and centred on sidewall 28, 32 is a handle 142 for grasping container 20. At each short side 112 of short sidewalls 28, 32, is a wall flange 156 protruding substantially normal to sidewall 28, 32. Integral with each wall flange 156, is a tab receiving aperture 160 and a latch member 164.

[0048] As best seen in FIGS. 6 and 7, latch member 164 has a resiliently deformable catch 168 which is biased to capture latch bar 152 by engaging with aperture 153 when sidewalls 28, 32, 36, 40 are in the assembled position. Extending from each catch 168 is a substantially rectangular catch lever 172. The free end of catch lever 172 has a substantially rectangular aperture 176 for attachment to a latch actuator 180. In a present embodiment, latch actuator 180 has a pair of outwardly-turned feet 184 that are spring-biased to engage the edges of aperture 176 so that feet 184 are retained therein. A pair of legs 188 extend, respectively, from each foot 184 and merge at a body portion 192. A grip 196 is integrally formed into actuator 180 on the end of body 192 opposite feet 184. In the present embodiment, grip 196 is substantially arcuate with a raised lip 200 for grasping. When attached to latch member 164, actuator 180 is substantially co-planar with short sidewalls 28, 32 so that grip 196 is positioned near wall handle 142. It can thus be seen that each latch actuator 180 is proximal to a corresponding latch actuator 180 of a corresponding latch member 164 on a same one of sidewalls 28, 32. Thus latch members 164 respective to corresponding latch actuators 180 are simultaneously releasable and the respective sidewall 28, 32 is moveable to one of the collapsed positions.

[0049] While FIGS. 6 and 7 show the latch between sidewalls 32 and 40, it will now be apparent that the latch between the other sidewalls are similarly arranged. In particular, each short sidewall 28, 32 has two actuators 180 with grips 196 in close proximity to each other, resulting in a single point of actuation for the pair of latch members 180 on each short sidewall 28, 32.

[0050] Each latch member 164 has two positions: a resting position and a flexed position. Referring now to FIG. 8, container 20 is in the assembled position and latch member 164 is in the resting position. Catch lever 172 is substantially normal to actuator 180 and catch 168 is engaged with latch bar 152. In the flexed position, shown in FIG. 9, catch lever 172 is at an obtuse angle in relation to actuator 180 so that catch 168 is disengaged from catch bar 152. Latch member 164 is movable from the rest position to the flexed position by urging grip 196 towards handle 142. Upon releasing grip 196, latch member 164 is biased towards the resting position.

[0051] The assembly of container 20 will now be described with reference to the foregoing and the attached Figures. To assemble container 20 from the outwardly collapsed position shown in FIG. 2, long sidewalls 36, 40 are pivoted so that they are substantially normal to base 24. Short sidewalls 28, 32 are pivoted so that catch 168 abuts latch bar 152. Maintaining long sidewalls 36, 40 substantially normal to base 24. external force is applied on short walls 28, 32 so that they are directed inwardly and towards each other. When force is applied on short walls 28, 32, latch member 164 is urged from the resting position to the flexed position as catch 168 slides along bevelled free end 154. Latch member 164 returns to the rest position when catch 168 engages catch aperture 153. As will now be apparent, when each of the four catches 168 engage its respective aperture 153, each sidewall 28, 32, 36, 40 is substantially perpendicular to base 24 and container 20 is assembled as shown in FIG. 1.

[0052] The collapsing of container 20 will now be described with reference to the foregoing and the attached Figures. To collapse container 20 from the assembled position shown in FIG. 1 to the outwardly collapsed position shown in FIG. 2, both grips 196 on each short side 28, 32 are urged towards each other by the operator. Typically the operator will pinch each grip 196 using the thumb and forefinger of each hand. Referring now to FIG. 9, latch actuator 180 is moved in the direction of arrow A, thereby applying a force on catch lever 172 and urging latch member 164 into the flexed position. As corresponding latch actuators 180 on each sidewall 28, 32 are pinched, they are urged inwardly and towards each other. At the same time, latch members 164 are urged outwardly, into the flexed position, thereby disengaging catches 168 from their respective catch apertures 153. At this point, each sidewall 28, 32 is pivoted outwardly so that it is substantially co-planar with base 24, in the outwardly collapsed position. Finally, long sidewalls 36, 40 are then pivoted away from each other into the outwardly collapsed position.

[0053] It will now be apparent that both catches 168 on one sidewall 28, 32 can be disengaged from their respective catch apertures 153 with one hand by urging the respective grips 196 together with one hand. Further, both catches 168 on both sidewalls 28, 32 can be disengaged from their respective catch apertures 153 by urging each set of grips 196 on each wall 28, 32 together using one hand on each set of grips 196. Therefore, each wall 28, 32 can be collapsed with each hand and both walls 28, 32 can be collapsed substantially simultaneously.

[0054] To collapse container 20 from the assembled position shown in FIG. 1 to the inwardly collapsed position shown in FIG. 3, both grips 196 on each short side 28, 32 are urged towards each other by the operator. Referring to FIGS. 8 and 9, latch actuator 180 is moved in the direction of arrow A, thereby applying a force on catch lever 172 and urging latch member 164 into flexed position. When both latch actuators 180 on one of sidewalls 28, 32 are urged towards each other, both latch members 164 are urged into the flexed position, thereby disengaging both catches 168 from their respective catch apertures 153. When both catches 168 on sidewall 28 are disengaged from their respective catch apertures 153, sidewall 28 is pivoted so that it is at an obtuse angle with base 24. Similarly, both latch actuators 180 on opposing sidewall 32 are urged towards each other disengaging both catches 168 from their respective catch apertures 153 and sidewall 32 is pivoted so that it is at an obtuse angle with base 24. Long sidewalls 36,40 are then pivoted inwardly, toward each other, so they are substantially parallel with base 24. Short sidewalls 28, 32 are then pivoted inwardly, toward each other so they are substantially parallel with base 24.

[0055] It will be understood by those of skill in the art that the configurations of container 20 can be varied, and that such variations are within the scope of the invention. Referring now to FIGS. 10 and 11 an alternative latch actuator 180ais shown on short side 28. As best seen in FIG. 10, grips 196 from the previous embodiment can be eliminated and merged into a flexible single grip 196aproximal to handle 142. By urging single (grip 196atowards handle 142 each foot 184ais drawn inwardly, thus releasing latch members 164 respective to each foot.

[0056] Referring now to FIGS. 12-18, an alternative latch member 164band latch actuator 180bare shown. As best seen in FIG. 13, the resiliently deformable catch 168 of the first embodiment is replaced with a hinged catch 168b. Each hinged catch 168bhas a first position whereby catch 168bis engaged with its respective catch aperture 153b, best seen in FIG. 14. Each hinged catch 168bhas a second position whereby catch 168bis pivoted away from catch aperture 153b, thereby disengaging catch aperture 153b. In addition, latch actuator 180bincludes a pair of arms 185bwhich are joined to body 192band oriented towards grip 196b, best seen in FIGS. 15-18. Arms 185bare spring-biased, having resting position that urges hinged catch 168binto the first position engaging catch aperture 153b. Arms 185balso have a flexed position when grip 196bis urged towards handle 142, which urges hinged catch 168binto the second position thus disengaging catch 168bfrom its respective catch aperture 153b.

[0057] Referring now to FIGS. 19-22, a second alternative latch member 164cand latch actuator 180care shown. As best seen in FIG. 21, similar to hinged catch 168bof the previous embodiment, each hinged catch 168chas a first position whereby catch 168cis engaged with its respective catch aperture 153c. As best seen in FIG. 22, each hinged catch 168chas a second position whereby catch 168cis pivoted away from catch aperture 153c, thereby disengaging catch aperture 153c. As best seen in FIG. 19, each latch actuator includes a pair of splayed feet 184c. Splayed feet 184ceach grasp their respective latch member 164c. In addition, latch actuator 180cincludes a pair of arms 185cwhich are joined to body 192cand oriented towards feet 184c. Arms 185care spring-biased, having a resting position that urges hinged catch 168cinto the first position engaging catch aperture 153c. Arms 185calso have a flexed position when grip 196cis urged towards handle 142, which urges hinged catch 168cinto the second position thus disengaging catch 168cfrom its respective catch aperture 153c. The present embodiment also includes a single grip 197c, which interconnects each grip 196c. By urging single grip 197ctowards handle 142, feet 184care urged inwardly, and thus releasing latch members 164 respective to each foot.

[0058] Referring now to FIGS. 23-26, a third alternative latch member 164dand latch actuator 180dare shown. As best seen in FIG. 24, similar to hinged catch 168bof the previous embodiment, each hinged catch 168dhas a first position whereby catch 168dis engaged with its respective catch aperture 153d. Each hinged catch 168dhas a second position whereby catch 168dis pivoted away from catch aperture 153d, thereby disengaging catch aperture 153d. In addition, latch actuator 180dincludes a pair of arms 185dwhich are joined to body 192dat both ends. Arms 185dare spring-biased, having a resting position that urges hinged catch 168dinto the first position engaging catch aperture 153d. Arms 185dalso have a flexed position when grip 196dis urged towards handle 142, which urges hinged catch 168dinto the second position thus disengaging catch 168dfrom its respective catch aperture 153d.

[0059] Referring now to FIGS. 10, 27-29, an alternative hinge post 92e, 100eand hanger 104e, 108earrangement is shown. As best seen in FIG. 27, hinge posts 92, 100 from the first embodiment can be eliminated and replaced by L-shaped hinge posts 92e. As shown in FIG. 10, three L-shaped hinge posts 92eproject from contacting edge 134 and are centred on sidewall 32. A split-cap L-shaped hinge post 93eprojects from contacting edge 134, proximal to each short side 112 of sidewall 32. It will now be understood by those of skill in the art that each sidewall 28, 36, 40 can have L-shaped hinge posts 92eand split-cap L-shaped hinge posts 93ein similar arrangement to sidewall 132. Hangers 104, 108 from the first embodiment are replaced by hangers 104e, as shown in FIG. 28. Each L-shaped hinge post 92eis received by complementary hanger 104efor pivotal attachment of sidewalls 28, 32, 36, 40 as best shown in FIG. 29. Similarly, each split-cap L-shaped hinge post 93eis received by a complimentary hanger 105e. Split-cap L-shaped hinge posts 93einterlock with apertures 106eon hangers 105e. The removal of split-cap L-shaped hinge posts 93efrom respective hangers 105eis difficult thereby making the detachment of sidewalls 28, 32, 36, 40 from base 24 difficult.

[0060] Referring now to FIG. 30, tabs 148 from the first embodiment can be replaced by a first tab 148fand a second tab 149f. First tab 148fis tapered inwardly as shown in FIG. 30. The tapered first tab 148freduces interference between short sidewalls 28, 32 and long sidewalls 36, 40 when assembling container 20. The tapered first tab 148fallows the operator to pivot sidewalls 28, 32, 36, 40 substantially normal to base 24 in any order when assembling container 20 from the collapsed positions.

[0061] While the embodiments discussed herein are directed to particular implementations of the present invention, it will be apparent that the subsets and variations to these embodiments are within the scope of the invention. For example, the sidewalls can differ in length from above or all four sidewalls can be equal in length. Alternatively, the container can have a cover to protect the goods stored therein. Also. the container can have a plurality of apertures for ambient circulation. The hinge configuration may differ. The shape of the grips may be varied such as including an aperture for inserting one's finger or thumb for actuating. The shape of the latch actuator may be changed or the latch member configuration can differ. Also, the latch catch and aperture can have different configurations to achieve the same function.

[0062] The present invention provides a novel collapsible container for transport or storage of products such as produce or other perishables. In one embodiment, there is provided a five piece collapsible container with a base and four sides that can be collapsed outwardly to facilitate washing and inwardly for compact storage. The container has latches and actuating members with grips that allow the operator to disengage both respective latches on one side of the container with one hand from an actuation point on the side of the container. Similarly, when collapsing the container from assembled position, all four latches can be disengaged with one hand at each actuation point. The latches are readily disengageable while providing a rigid assembled container. By providing a single point of actuation, both latches on one sidewall can be substantially simultaneously disengaged and the sidewall collapsed with one hand. Similarly, with one hand on each opposing sidewall, all four latches can be simultaneously disengaged and the sidewalls moved into their collapsed positions with each hand at each respective actuation point. Also, the container is readily collapsed for washing and storage thereby allowing processing by the operator. Also, less effort can be required as the latches are easily engaged and disengaged with reduced strain on the hand.