container

Abstract

A container having three pairs of parallel sides; wherein one pair of sides is formed by a side panel comprising a honeycomb polypropylene sheet and a sheet formed of polypropylene bonded to one side of the honeycomb polypropylene sheet; and at least one pair of sides is formed by an elongated segment formed of foamed polypropylene.

Description

Technical Field

[0001] This invention relates to containers. The invention can be particularly used to provide containers for preserving artworks during transport and storage. However, it should be understood that the containers of this invention can be used for many other purposes. Background Technology

[0002] Containers designed for reuse need to be durable. These containers are typically formed from multiple components, such as sides, connectors holding the sides together, and other fasteners. Each of these components is formed from a material chosen to perform its function well, and these components can be permanently secured to each other to form a robust container. Therefore, when the container reaches the end of its lifespan, even though the materials used to form each component are inherently relatively easy to recycle, the multiple components formed from different materials make it difficult to recycle the materials used to form the container. For example, the container must be broken down into its components, and each material must be identified and processed individually, including separating different types of plastics.

[0003] Therefore, there is a need for a high-quality container that can be more easily disposed of at the end of its service life. Summary of the Invention

[0004] The present invention relates to a container having three pairs of parallel sides; the container comprising: a pair of sides formed by side panels comprising a honeycomb polypropylene sheet and two polypropylene sheets respectively joined to the two sides of the honeycomb polypropylene; two pairs of sides formed by corner segments formed of foamed polypropylene; and a material layer adapted to form part of a hook-and-loop fastener, the material layer forming a plurality of rings, the material layer being disposed on an inner surface of one of the side panels and being formed of polypropylene; wherein the corner segments formed of foamed polypropylene are joined to each other, and the joint between the corner segments formed of foamed polypropylene is partially positioned along the sides of the container such that each corner segment forms a corner between two sides and forms a portion of the two sides.

[0005] In one embodiment, the polypropylene sheet is bonded to a honeycomb polypropylene by at least one of thermal lamination and an adhesive.

[0006] In one embodiment, the polypropylene sheet bonded to the honeycomb polypropylene is cast polypropylene.

[0007] In one embodiment, a layer of material suitable for forming part of a hook-and-loop fastener substantially covers the inner surface of one of the side panels.

[0008] In one embodiment, the container further includes at least one component formed of injection-molded polypropylene.

[0009] In one embodiment, the container includes a joint reinforcement configured to reinforce the joint between the two corner segments formed of foamed polypropylene; wherein the joint reinforcement is formed of injection-molded polypropylene.

[0010] In one embodiment, the container includes an impact protector disposed on the outer surface of at least one of the sides formed by a corner segment of foamed polypropylene; wherein the impact protector is formed of injection-molded polypropylene.

[0011] In one embodiment, the impact protector protrudes from the surface of at least one side of the corner segment formed of foamed polypropylene.

[0012] In one embodiment, a single component serves as both a corner reinforcement and an impact protector.

[0013] In one embodiment, the corner segment formed of foamed polypropylene is joined by a connector formed of injection-molded polypropylene.

[0014] In one embodiment, one of the side panels is detachably attached to the container.

[0015] In one embodiment, one or more fittings formed of injection-molded polypropylene are used to secure the detachably attached side panel to the container.

[0016] In one embodiment, the accessory includes at least one hook-shaped element disposed on the removably attached side panel and at least one hook-shaped element disposed on one side of the side panel formed of foamed polypropylene; the container also includes an elastic ring configured to extend between the two hook-shaped elements.

[0017] In one embodiment, one of the side panels is fixed to the side surface formed by a corner segment of foamed polypropylene.

[0018] In one embodiment, the side panel formed by the corner segment of foamed polypropylene includes a groove configured to receive an edge of the side panel within the groove; and the edge of the side panel is secured to the groove.

[0019] In one embodiment, an adhesive is used to attach the side panel to the side surface formed by a corner segment of foamed polypropylene.

[0020] In one embodiment, the length of the shortest edge of the side formed by the side panel is at least twice the length of the shortest edge of the other sides.

[0021] In one embodiment, the foamed polypropylene used to form the corner section constituting the side of the container is at least 90% gas by volume.

[0022] In one embodiment, the container is at least 80% polypropylene by mass.

[0023] In one embodiment, the container further includes an accessory configured to allow the artwork to be secured within the container.

[0024] In one embodiment, at least one of the fittings configured as a fixed artwork is formed of injection-molded polypropylene.

[0025] In one embodiment, the length of the shortest edge of the side formed by the side panel is at least three times the length of the shortest edge of the other sides.

[0026] In one embodiment, the length of the shortest edge of the side formed by the side panel is at least four times the length of the shortest edge of the other sides.

[0027] In one embodiment, the length of the shortest edge of the side formed by the side panel is at least five times the length of the shortest edge of the other sides.

[0028] In one embodiment, the foamed polypropylene used to form the corner section constituting the side of the container is at least 95% gas by volume.

[0029] In one embodiment, the foamed polypropylene used to form the corner section constituting the side of the container is at least 98% gas by volume.

[0030] In one embodiment, the container is at least 90% polypropylene by mass.

[0031] In one embodiment, the container is at least 95% polypropylene by mass.

[0032] In one embodiment, the two pairs of sides are formed by four corner segments made of foamed polypropylene. Attached Figure Description

[0033] The invention will now be further described by way of example with reference to the accompanying drawings, in which:

[0034] Figure 1 A container with its side removed is shown;

[0035] Figure 2An exploded view of the container's components is shown;

[0036] Figure 3 Details of the optional arrangement for securing the removable side panels are shown; and

[0037] Figure 4 Details of an alternative arrangement for securing the removable side panel are shown. Detailed Implementation

[0038] Figure 1 An example of a container is shown. As shown, the container can have three pairs of parallel sides 1, 2, 3, 4, 5, 6. Each of the sides can be arranged orthogonally to the other two pairs of sides, such that the container defines an approximate cuboid shape.

[0039] In such Figure 1 In the arrangement shown, the container can have dimensions that facilitate the storage and / or transport of artwork. In such an arrangement, the depth of the container can be much smaller than the dimensions of its main faces (corresponding to the first pair of sides 1, 2). For example, the shortest edge of the first pair of sides 1, 2 can be at least twice, optionally at least three times, optionally at least four times, optionally at least five times the length of the shortest edges of the other sides 3, 4, 5, 6. It should be understood that dimensions and / or relative dimensions can be chosen such that the internal volume of the container is suitable for receiving objects, such as artwork, to be held within it.

[0040] To provide containers that can be easily disposed of at the end of their service life, the containers of this disclosure are primarily formed of a single material, polypropylene, but different forms of polypropylene are used for different components to provide the desired performance characteristics for each component. After removing some components that may be formed of other materials, the entire container can be easily recycled without extensive disassembly because it is formed from the same basic material. For example, the containers according to this disclosure may be at least 80% polypropylene by weight, optionally at least 90% polypropylene by weight, and optionally at least 95% polypropylene by weight.

[0041] The first pair of sides 1, 2 can be formed by side panels 1, 2, which can have a relatively high aspect ratio as described above, i.e., relatively long and relatively wide compared to the thickness of the side panels. Figure 2 An exploded view of one of the side panels 1 and 2 is schematically shown. As shown, side panels 1 and 2 are formed of a honeycomb polypropylene sheet 11 and a polypropylene sheet 12, the polypropylene sheet 12 being bonded to at least one side of the honeycomb polypropylene 11. Figure 2As shown, each of the side panels may have polypropylene sheets 12, 13, which are joined to both sides of a honeycomb polypropylene sheet 11, which may form the core of the panel.

[0042] like Figure 2 As shown, the honeycomb polypropylene 11 can be formed from a plurality of hollow hexagonal units 21, which are oriented such that the hexagonal segments extend through the thickness of the honeycomb polypropylene sheet 11. The honeycomb polypropylene sheet can be formed, for example, by an extrusion process.

[0043] Polypropylene sheets 12 and 13 may be woven polypropylene sheets formed by braiding strands of polypropylene fibers to form a woven sheet. Alternatively, polypropylene sheets 12 and 13 may be formed from cast polypropylene. In one arrangement, one or both side panels may have woven polypropylene sheets on one side of the honeycomb polypropylene sheet and cast polypropylene sheets on the other side.

[0044] Bonding polypropylene sheets 12 and 13 to honeycomb polypropylene 11 produces a material panel with an excellent strength-to-weight ratio, excellent puncture resistance, and significantly greater rigidity than a single honeycomb polypropylene layer. Furthermore, using woven fabric polypropylene can further improve the panel's strength-to-weight ratio and puncture resistance. Using woven fabric polypropylene also enhances the ability to secure fasteners such as screws to the panel.

[0045] In one arrangement, polypropylene sheets 12 and 13 can be thermally laminated to a honeycomb polypropylene structure, in which one or both of the components are heated and then pressed together. In an alternative arrangement, adhesives can be used to bond polypropylene sheets 12 and 13 to a honeycomb polypropylene sheet 11. However, this arrangement may be considered less desirable because it introduces additional material.

[0046] One or both of the other two pairs of sides 3, 4, 5, and 6 of the container may be formed from elongated segments of foamed polypropylene. Foamed polypropylene is polypropylene that has been foamed and formed into its final shape. The foamed polypropylene may be at least 90% gas by volume, optionally at least 95% gas by volume, and optionally at least 98% gas by volume. Depending on the production method, the gas may be air. The resulting material has a good strength-to-weight ratio, being both tough and capable of absorbing energy from impacts.

[0047] Two or more (optionally, all) of the sides 3, 4, 5, and 6 formed from elongated segments of foamed polypropylene can be formed as a single component, for example, produced in a single mold. Alternatively, each of the sides 3, 4, 5, and 6 can be formed as a separate component, in which case the two sides formed from the foamed polypropylene can be joined together at a corner, for example, using a miter joint, dovetail joint, or other suitable joint. Depending on the joint used, an adhesive can also be used to complete the joining.

[0048] In another arrangement, segments made of foamed polypropylene can be joined along sides 3, 4, 5, and 6 of the container. For example, the container can be formed by four corner segments made of foamed polypropylene, each corner segment forming a corner and a portion (e.g., half) of both sides between two sides 3, 4, 5, and 6 of the container. In a variation of this arrangement, one or more segments made of foamed polypropylene can be positioned between two corner segments made of foamed polypropylene and joined to these two corner segments to form the sides of the container.

[0049] In an arrangement where two segments formed of foamed polypropylene are joined together, a joint reinforcement can be used to strengthen the joint. The joint reinforcement can be disposed within the foamed polypropylene segments, and can take the form of one or more rods extending from one foamed polypropylene segment into an adjacent foamed polypropylene segment. Alternatively or additionally, the joint reinforcement can be disposed outside the foamed polypropylene segments, for example as a reinforcing plate spanning the joint. In any case, the joint reinforcement can be attached to the foamed polypropylene segments using adhesives and / or fasteners (such as screws or barbed plugs) inserted into the foamed polypropylene.

[0050] Joint reinforcements can be formed from injection-molded polypropylene, eliminating the need to remove the joint reinforcements from the container before recycling. Alternatively or additionally, any fasteners used to secure the joint reinforcements to foamed polypropylene can also be formed from injection-molded polypropylene. Although made from the same material, injection-molded polypropylene may be stronger and tougher than foamed polypropylene, making it suitable for forming joint reinforcements and / or fasteners.

[0051] like Figure 1As shown, the impact protector 20 can be disposed on the outer surface of at least one of the sides 3, 4, 5, 6 formed of foamed polypropylene. This impact protector 20 may be advantageous because, although foamed polypropylene is good at absorbing impact energy, it is relatively soft and therefore may not provide good puncture resistance and / or may wear down during use. Similar to joint reinforcements, the impact protector 20 can be attached to the foamed polypropylene using adhesives and / or fasteners such as screws or barbed plugs. Likewise, like joint reinforcements, the impact protector 20 can also be formed of injection-molded polypropylene. Injection-molded polypropylene can provide better abrasion resistance than foamed polypropylene, making it suitable for use as an impact protector. Similarly, any fasteners used to secure the impact protector to the impact polypropylene can be alternatively or additionally formed of injection-molded polypropylene.

[0052] like Figure 1 As shown, the impact protector 20 can be positioned at the corner where two foamed polypropylene sections meet. In this arrangement where two foamed polypropylene sections meet at the corner, a single component can function as both a joint reinforcement and the impact protector 20.

[0053] Alternatively or additionally, the container may include an impact protector partially disposed along the side of the container formed of foamed polypropylene. This impact protector may coincide with the joint between two segments of foamed polypropylene, in which case the single component partially along the side of the container can function as both a joint reinforcement and an impact protector.

[0054] When an impact protector is installed, the impact protector protrudes from the surface of the foamed polypropylene sides 3, 4, 5, and 6 where the impact protector is installed. This arrangement can advantageously protect the sides formed by the foamed polypropylene, for example, when the container is placed on the ground, because the impact protector protruding from the surface of the foamed polypropylene ensures that the surface of the foamed polypropylene remains separated from the ground, thereby preventing the ground from abrading the surface of the foamed polypropylene.

[0055] In one arrangement, two segments formed of foamed polypropylene (such as two sides 3, 4, 5, 6) can be indirectly connected to each other, for example, at a corner, via a connector. This connector can be formed of injection-molded polypropylene and, similar to the joint reinforcements and impact protectors discussed above, can be attached to the injection-molded polypropylene via adhesives and / or fasteners (such as screws or barbed plugs), which themselves can be alternatively or additionally formed of injection-molded polypropylene. In cases where the connector is used to join two segments made of foamed polypropylene, the connector can be configured such that it protrudes from the surface of the foamed polypropylene forming sides 3, 4, 5, 6 of the container, such that when the container is placed on the floor with these sides facing outwards, the surface of the foamed polypropylene separates from the floor.

[0056] In one arrangement, for example to provide access to the interior of the container for placing or removing objects from the container, one of the side panels 1 can be detachably attached to the container. The detachably attached side panel 1 can be secured to the container using one or more fittings formed of injection-molded polypropylene, which can provide better tear resistance than, for example, foamed polypropylene.

[0057] In such Figure 3 In the illustrated arrangement, the fittings for securing the detachably attached panel 1 to the container may include at least one hook or attachment point 25 disposed on the detachably attached side panel 1, and at least one hook or attachment point 26 disposed on one of the sides 3, 4, 5, 6 formed of foamed polypropylene. One or both hooks or attachment points may be formed of injection-molded polypropylene. An elastic ring 27 may be provided, which may extend between two hooks or attachment points 25, 26, pulling one hook or attachment point toward the other to secure the detachably attached side panel 1 to the remainder of the container.

[0058] Alternatively or additionally, such as Figure 4As shown, the fitting for securing the detachably attached panel 1 to the container may include one or more bosses 30 embedded within sides 3, 4, 5, 6 formed of foamed polypropylene and configured to receive and secure a connector 31 passing through the side panel 1. The connector 31 may be, for example, a screw or bayonet-type connector that can be inserted into the boss 30 and then rotated to a position preventing removal. The boss 30 may be formed of injection-molded polypropylene. The boss may be co-molded within the foamed polypropylene side to secure the boss within the foamed polypropylene side. Alternatively, after the polypropylene side is formed, the boss 30 may be secured within the foamed polypropylene side, for example, by adhesive or press-fit connection, in which case the boss 30 may have barbs that engage with the foamed polypropylene. The connector 31 may be formed of injection-molded polypropylene, or the connector 31 may be metal. A reinforcement 32, which may be formed of injection-molded polypropylene, may be provided on the detachably attached panel 1 through which the connector 31 passes.

[0059] In one arrangement, one of the side panels 2 can be fixed to the sides 3, 4, 5, 6 of the container formed of foamed polypropylene, for example, making the side panel 2 non-removable. This fixing method can improve the rigidity of the container. In another arrangement, the sides 3, 4, 5, 6 formed of foamed polypropylene may include grooves along their length, the grooves being configured to receive the edges of the side panel 2 within the grooves. The edges of the side panel 2 can then be fixed to the grooves, for example, using an adhesive.

[0060] Within the container, one or more fittings can be installed to secure an object to be held within the container, for example, to prevent the object from moving within the container. In one arrangement, such fittings can be configured to allow the artwork to be secured within the container. When the fitting is configured to secure an object within the container, the fitting or a portion thereof can be formed from injection-molded polypropylene.

[0061] In one arrangement, the inner surface of the container may be provided with a layer of material suitable for forming part of a hook-and-loop fastener. For example, the material layer may be formed with multiple rings. For example, the inner surface of one of the side panels 2 may be substantially covered by the material layer. Providing such a material layer covered with multiple rings not only provides a suitable surface for securing objects inside the container using hook-and-loop fasteners, but also provides a relatively soft surface, thereby reducing the risk of damaging objects placed inside the container.

[0062] In one arrangement, the material layer suitable for forming part of the hook-and-loop fastener can itself be formed of polypropylene. Alternatively, the material layer can be formed of a different material suitable for forming the hook-and-loop fastener, such as nylon.

[0063] The material layer suitable for forming part of the hook-and-loop fastener can be secured to the side panel 2 with an adhesive. It has been found that, in cases where the material layer including the nylon ring has been adhered to the surface of the side panel formed of a woven polypropylene sheet with a suitably selected adhesive, the nylon material layer can subsequently be forcibly removed from the side panel 2, leaving the woven polypropylene sheet substantially intact. Therefore, even in arrangements where a material different from polypropylene is required to form the material layer suitable for forming the hook-and-loop fastener, this component can still be easily removed from the rest of the container, leaving the container, which is essentially made solely of polypropylene, thus allowing for easy container recycling.

Claims

1. A container having three pairs of parallel sides; the container comprising: A pair of side panels formed by side panels, the side panels comprising a honeycomb polypropylene sheet and two polypropylene sheets respectively bonded to the two side panels of the honeycomb polypropylene; The two pairs of side surfaces formed by the corner section made of foamed polypropylene, and A material layer suitable for forming part of a hook-and-loop fastener, the material layer having a plurality of rings, the material layer being disposed on the inner surface of one of the side panels and being formed of polypropylene; The corner segments formed of foamed polypropylene are joined together, and the joints between the corner segments formed of foamed polypropylene are partially positioned along the side of the container, such that each corner segment forms a corner between two sides and forms a portion of the two sides.

2. The container according to claim 1, wherein, The polypropylene sheet is bonded to the honeycomb polypropylene by at least one of thermal lamination and adhesive.

3. The container according to claim 1 or 2, wherein, The polypropylene sheet bonded to the honeycomb polypropylene is cast polypropylene.

4. The container according to claim 1 or 2, wherein, A layer of material suitable for forming part of a hook-and-loop fastener substantially covers the inner surface of one of the side panels.

5. The container according to claim 1 or 2, wherein, The container also includes at least one component formed of injection-molded polypropylene.

6. The container according to claim 1, wherein, The container includes a joint reinforcement configured to reinforce the joint between the two corner segments formed of foamed polypropylene; wherein the joint reinforcement is formed of injection-molded polypropylene.

7. The container according to claim 6, wherein, The container includes an impact protector disposed on the outer surface of at least one of the sides formed by the corner section of foamed polypropylene. The impact protector is formed of injection-molded polypropylene.

8. The container according to claim 7, wherein, The impact protector protrudes from the surface of at least one side of the corner section formed of foamed polypropylene.

9. The container according to claim 7, wherein, A single component serves as a corner reinforcement and impact protector.

10. The container according to claim 1, wherein, The corner section formed by foamed polypropylene is joined by a connector formed by injection-molded polypropylene.

11. The container according to claim 1 or 2, wherein, One of the side panels is detachably attached to the container.

12. The container according to claim 11, wherein, The removable side panel is secured to the container using one or more fittings formed of injection-molded polypropylene.

13. The container according to claim 12, wherein, The accessory includes at least one hook-shaped element disposed on the removably attached side panel and at least one hook-shaped element disposed on one side of the side panel formed of foamed polypropylene; the container also includes an elastic ring configured to extend between the two hook-shaped elements.

14. The container according to claim 1, wherein, One of the side panels is fixed to the side surface formed by the corner segment of foamed polypropylene.

15. The container according to claim 14, wherein, The side panel formed by the corner segment of the foamed polypropylene includes a groove configured to receive the edge of the side panel within the groove; and The edge of the side panel is fixed to the groove.

16. The container according to claim 14 or 15, wherein, The side panel is secured to the side surface formed by the corner section of foamed polypropylene using an adhesive.

17. The container according to claim 1 or 2, wherein, The length of the shortest edge of the side formed by the side panel is at least twice the length of the shortest edge of the other sides.

18. The container according to claim 1 or 2, wherein, The foamed polypropylene used to form the corner sections constituting the sides of the container is at least 90% gas by volume.

19. The container according to claim 1 or 2, wherein, The container is at least 80% polypropylene by mass.

20. The container according to claim 1 or 2, wherein, The container also includes fittings configured to allow the artwork to be secured within the container.

21. The container according to claim 20, wherein, At least one of the fittings constructed as a fixed artwork is formed of injection-molded polypropylene.

22. The container according to claim 17, wherein, The length of the shortest edge of the side formed by the side panel is at least three times the length of the shortest edge of the other sides.

23. The container according to claim 22, wherein, The length of the shortest edge of the side formed by the side panel is at least four times the length of the shortest edge of the other sides.

24. The container according to claim 23, wherein, The length of the shortest edge of the side formed by the side panel is at least five times the length of the shortest edge of the other sides.

25. The container according to claim 18, wherein, The foamed polypropylene used to form the corner sections constituting the sides of the container is at least 95% gas by volume.

26. The container according to claim 25, wherein, The foamed polypropylene used to form the corner sections constituting the sides of the container is at least 98% gas by volume.

27. The container according to claim 19, wherein, The container is at least 90% polypropylene by mass.

28. The container according to claim 27, wherein, The container is at least 95% polypropylene by mass.

29. The container according to claim 1, wherein, The two pairs of sides are formed by four corner sections made of foamed polypropylene.

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