A folding large container and lid with lid latch

Abstract

A folding large container with a base and at least one sidewall upstanding to define an internal storage volume, the at least one sidewall having an upper edge and at least one opening formed into the upper edge, and a lid with at least one lid latch, the lid comprising an upper surface, a lower surface and at least one locating portion to removably locate the lid to close an upper opening of the folding large container, the at least one lid latch provided on the lower surface of the lid and comprising at least one extension portion positioned to be received into the at least one opening in the at least one sidewall of the folding large container to removably latch the lid relative to the at least one sidewall.

Description

[0001] A FOLDING LARGE CONTAINER AND LID WITH LID LATCH

[0002] Technical Field of the Invention

[0003] The present invention relates generally to the field of reusable returnable packaging systems. In particular, but not exclusively, the invention concerns Folding Large Containers (FLC).

[0004] Background to the Invention

[0005] Conventional Folding Large Containers (FLC), sometimes also called a foldable pallet box or a folding bulk container, are typically made of plastic. They usually have a heavy-duty molded base with suitable skids and feet formed therein to allow the container to be picked up with a forklift. The walls of the FLC are mountable onto the base in an upstanding orientation to define a storage volume within. Some FLC’s are provided with a lid.

[0006] Once any load is removed from the storage volume, the walls are then demounted (in some cases folded) to be generally parallel to the base and within the footprint of the base., In its folded state, the FLC is usually about one third of the size of the assembled FLC which is more convenient for return and reuse. This means for every three trucks that go out, only one is needed to return the empty FLC’s.

[0007] In situations where an FLC is provided with a lid, an issue can be created when the lid is removed to access the storage volume either for loading (keeping the lid with the container is desirable) or when removed to open the FLC to remove items from the storage volume. In some cases, the lid is removably attached to one of the sidewalls, via a pair of hook members with a first portion extending transversely to the plane of the lid and a second, longer portion extending parallel to the plane of the lid and spaced from the inner surface of the lid so that the lid, when removed from the container, can be hooked over the sidewall of the container. This configuration is undesirable as portions of the hook encroach on the storage volume when the lid is mounted relative to the wall when removed but also when the lid is placed onto the container to close it.

[0008] It is undesirable to have a portion of any lid latch, encroach on the storage volume as this interferes with the storage volume and / or internal dunnage which may be provided within the storage volume. Further, it is undesirable to have the lid mounted relative to a sidewall of the container in a position where the lid may obstruct the upper opening of the container.

[0009] It would therefore be an advance in the art to provide a lid latch which overcomes or at least ameliorates at least one of the abovementioned problems.

[0010] Summary of the Invention

[0011] According to a first aspect of the invention, there is provided a folding large container with a base and at least one sidewall upstanding to define an internal storage volume, the at least one sidewall having an upper edge and at least one opening formed into the upper edge, and a lid with at least one lid latch, the lid comprising an upper surface, a lower surface and at least one locating portion to removably locate the lid to close an upper opening of the folding large container, the at least one lid latch provided on the lower surface of the lid and comprising at least one extension portion positioned to be received into the at least one opening in the at least one sidewall of the folding large container to removably latch the lid relative to the at least one sidewall.

[0012] According to a second aspect of the invention, there is provided a folding large container lid with a lid latch, the lid comprising an upper surface, a lower surface and at least one locating portion to removably locate the lid to close an upper opening of the folding large container, the at least one lid latch provided on the lower surface of the lid and comprising at least one extension portion positioned to be received into at least one opening in the at least one sidewall of the folding large container to removably latch the lid relative to the at least one sidewall.

[0013] Providing a folding large container and a lid as described above will allow a user to removably latch the lid relative to the sidewall of the folding large container when removed from the folding large container so that the lid remains with the folding large container, but to minimise the obstruction of the internal volume of the folding large container when the lid is fitted to close the folding large container.

[0014] For clarity, a ‘sidewall’ is a side of the container. If the container is rectangular, then the ‘sidewall’ refers to the portion between the corners of the container, regardless of the makeup of the sidewall. For example, a sidewall may comprise a number of sidewall portions and even a part that extends from a corner stile in the plane of the sidewall.

[0015] 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.

[0016] 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.

[0017] The FLC may comprise an outer container body having a footprint area with a base and plurality of sidewall portions each moveable between an assembled condition in which each wall portion is upstanding and together the sidewall portions define a transport volume within the container body and a collapsed condition in which each of the sidewall portions lies within the footprint area of the base.

[0018] The container body will typically be formed of one or more plastic materials, but any one or more materials could be used.

[0019] 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.

[0020] 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.

[0021] The base of the container body will preferably be substantially rectangular.

[0022] The sidewall 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 sidewall portions provided relative to one of the pairs of sides of the preferred rectangular base will preferably be offset vertically from the sidewall portions provided relative to the other of the pairs of sides of the preferred rectangular base. This means that the sidewall 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.

[0023] The sidewall portions may be removably mounted relative to the base. For example, the sidewall portions may be mounted relative to the base such that the sidewall 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 sidewall portion to engage with a corresponding groove on an upper part of the base, or vice versa.

[0024] The sidewall portions may be substantially permanently mounted relative to the base. For example, the sidewall portions may be hinged relative to the base. The hinge arrangement may be such that a linear movement of the sidewall portion, preferably upwardly, may be required to disengage the sidewall portion from the base before rotation of the sidewall portion is possible.

[0025] The base generally has a substantially planar upper surface to form an inner bottom wall of the transport volume.

[0026] The sidewall portions are each typically planar, at least on an inner side.

[0027] When in the collapsed condition, the sidewall portions will typically lie substantially horizontally within the footprint area of the base. The sidewall portions may be angled downwardly (past horizontal) but collapsing the sidewall portions so that the sidewall portions are at least horizontal will typically realise the size reduction of the FLC.

[0028] When collapsed, the sidewall 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 sidewalls. The sidewall portions may have one or more prepared openings on an inner side thereof provided therein for the attachment of the side support ribs. The prepared openings may have reinforced surrounds for a more secure mounting.

[0029] The internal sides of the sidewall portions are preferably planar.

[0030] Each sidewall 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.

[0031] When collapsed, two of the sidewall portions will typically overlie the other two adjacent perpendicular sidewall portions in a rectangular container. Opposed sidewall portions will normally lie in the same plane when collapsed.

[0032] The FLC may be provided with one or more corner stiles or uprights extending upwardly from the base and relative to which the sidewall portions are provided.

[0033] In an embodiment, a sidewall portion may be provided with a corner part or return at an angle to the main part of the sidewall.

[0034] The at least one sidewall preferably has an upper edge and at least one opening formed into the upper edge. The upper edge of the at least one sidewall, or at least a portion of the upper edge of the at least one sidewall may be planar. The upper edge or at least a portion of the upper edge may preferably extend transversely or perpendicularly to the plane of the at least one sidewall and / or parallel to the base of the FLC.

[0035] The upper edge or portion thereof into which the at least one opening is formed may not be the uppermost edge or portion thereof, but preferably will be.

[0036] The FLC may include more than one sidewall. At least one opening may be formed into an upper edge of one or more of the sidewalls and possible all of the sidewalls. The or each sidewall may include more than one opening. The number of openings formed into the upper edge of any one or more sidewall may be dependent on the dimensions of the container. For example, smaller containers may have a single opening on at least one sidewall and larger containers may have at least two openings on at least one sidewall. In a preferred embodiment, two openings are provided on at least one sidewall as this will allow the lid to balance on the sidewall stably when the lid latch is engaged with the at least one opening.

[0037] The at least one opening may be in the corner portion or corner stile of the sidewall.

[0038] The at least one opening may be any size. The size may be dictated or correspond to the dimensions of the lid latch. The at least one opening may be any shape. The shape of the at least one opening may have at least one planar side edge which is parallel to the outer surface of the at least one sidewall. This may assist with holding the lid against the at least one sidewall when the lid latch is engaged with the at least one opening. The at least one opening may have a pair of spaced apart planar side edges and a pair of connecting end edges. The end edges of the at least one opening may be arcuate. This may make the at least one opening stronger as there are no apices to provide nucleation points for cracks.

[0039] The at least one opening may be formed in any way. For example, the at least one opening may be machined into the sidewall or may be moulded thereinto.

[0040] The at least one opening may preferably extend into the at least one sidewall perpendicularly to the upper edge of the at least one sidewall and parallel to the plane of the at least one sidewall. The at least one opening is preferably formed the thickness of the at least one sidewall.

[0041] The at least one opening may be central across the thickness of the at least one sidewall to maximise the thickness of material between the at least one opening and the side surfaces of the at least one sidewall. Alternatively, the at least one opening may be positioned closer to the inside or outside of the at least one sidewall.

[0042] The at least one opening will preferably be of sufficient depth to receive the at least one extension portion of the lid latch, or slightly deeper. The at least one opening may only be formed into the upper edge and not through the entire sidewall or sidewall portion.

[0043] The lid of the FLC may have an upper surface, a lower surface and at least one locating portion to removably locate the lid to close an upper opening of the folding large container. The upper surface is preferably the surface on the outside of the lid when the lid is fitted to the container. The lower surface is preferably the surface on the inside of the lid when the lid is fitted to the container. The at least one locating portion may be of any type. In a simple form, the at least one locating portion may be or include a peripheral lip at the side edge of the lid and extending at least partway around the periphery of the lid to fit over the container sidewalls when placed onto the container to close the upper opening. A more complex closure system could be provided if needed or desired.

[0044] The at least one lid latch is preferably provided on the lower surface of the lid. This means that the at least one lid latch will extend into the containing volume when the lid is fitted on top of the container. The lid latch may be made of any material although will preferably be plastic or metal.

[0045] The at least one lid latch may be attached to the lid using one or more fasteners for example bolts, screws or the like. The at least one lid latch may be moulded or formed integrally with the lid.

[0046] The at least one lid latch preferably includes a mounting portion extending away from the lower surface of the lid and at least one extension portion extending laterally from the mounting portion. The mounting portion may extend substantially perpendicularly away from the lower surface of the lid. It is preferably the mounting portion which is mounted to the lid. If one or more fasteners are provided, the one or more fasteners preferably extend through the mounting portion.

[0047] The at least one lid latch may have an L-shaped or T-shaped configuration when viewed from the side. If the lid latch is provide with an extension portion extending away from the mounting portion on one side only, that will form an L-shaped configuration and if an extension portion extends away from the mounting portion on opposed sides, that will form a T-shaped configuration. In a preferred form, the or each at least one extension portion is a flat tab or similar. The or each at least one extension portion may be canted away from the lower surface of the lid. The or each at least one extension portion may curve away from the lower surface of the lid.

[0048] The or each at least one extension portion is preferably spaced from the lower surface of the lid by the mounting portion. The spacing may correspond to or at least approximate the distance between the outer edge of the at least one opening in the sidewall and the outer side of the sidewall. The preferred curved shape of the at least one extension portion may allow the tab of the at least one extension to rotate into the at least one opening in a sidewall during removal of the lid, without requiring the lid to be lifted entirely clear of the container.

[0049] Any number and configuration of lid latches may be provided on a lid. For example, one lid latch may be provided relative to one side of a lid. This will allow opening of the lid to engage the lid latch in one direction. Alternatively, one lid latch may be provided relative to each of two opposite sides of a lid. This will allow opening of the lid to engage the lid latch, in two opposite directions. Still further, one lid latch may be provided relative to each of two adjacent sides of a lid. This will allow opening of the lid to engage the lid latch in two directions which are not opposite. Still further again, one lid latch may be provided relative to each side of a lid. This will allow opening of the lid to engage the lid latch, in any direction.

[0050] Two or more lid latches may be provided in any one of the above configurations for larger lids.

[0051] The lid latch(es) are preferably provided spaced inwardly away from the side edge of the lid.

[0052] In a preferred embodiment, a pair of spaced apart lid latches is provided on one lateral side of a midline of the lid, adjacent to the midline, closer to the midline than the side edge of the lid.

[0053] Two pairs of spaced apart lid latches may be provided, one pair on either lateral side of a midline of the lid, adjacent to the midline, closer to the midline than the side edge of the lid. As the at least one extension is preferably spaced from the lower side of the lid to match the distance between the outer edge of the at least one opening and the outer side of the at least one sidewall, the lid latch is significantly lower in profile than prior art lid latches. This means that the lid latch does not encroach on the internal geometry of the container when hanging on the side wall, and internal dunnage can be used to the top level of the container and the lid latch will not interfere.

[0054] By creating the at least one opening in the container, the lid latch can be much thinner which maximises the usable space in the container when the lid is in the closed position.

[0055] It also provides a more secure method of locating a lid as the lid latch(es) are enclosed on all four sides in contrast to other solutions in the market which latch completely over the side walls of the container.

[0056] Detailed Description of the Invention

[0057] In order that the invention may be more clearly understood one or more embodiments thereof will now be described, by way of example only, with reference to the accompanying drawings, of which:

[0058] Figure 1 is an axonometric view of a folding large container and lid according to an embodiment of the invention.

[0059] Figure 2 is a detailed view of the portion illustrated in Figure 1 identified by reference letter ‘A’ with the lid latch engaged with the container.

[0060] Figure 3 is a detailed view of the configuration illustrated in Figure 2 with the lid latch separated from the container.

[0061] Figure 4 is a sectional view of the configuration illustrated in Figure 2 along line B-B.

[0062] Figure 5 is a detailed axonometric view of the upper edge of the container illustrated in Figure 1.

[0063] Illustrated in the accompanying Figures is a folding large container (FLC) 10 with a base 11 and four sidewalls 12 upstanding to define an internal storage volume 13. In Figure 1, one sidewall 12 has an upper edge 14 with a pair of openings 15 formed into the upper edge 14.

[0064] A lid 16 with a pair of lid latches 17 is provided. The lid illustrated in Figure 1 comprise an upper surface (on reverse of lower side), a lower surface 18 and a peripheral lip 19 to removably locate the lid 16 to close an upper opening of the folding large container 10. The lid latches 17 are each provided on the lower surface 18 of the lid 16 and comprise a pair of extension tabs 20 positioned to be received into the respective openings 15 in the sidewall 12 of the folding large container 10 to removably latch the lid 16 relative to the sidewall 12.

[0065] As illustrated in the Figures, each sidewall 12 of the container 10 may be formed from more than one sidewall portion. The FLC 10 may be provided with one or more comer stiles or uprights 21 as shown in Figure 5 extending upwardly from the base and relative to which the sidewall portions are provided.

[0066] In some embodiments, a sidewall portion may be provided with a corner part or return at an angle to the main part of the sidewall as shown in Figures 2 and 3.

[0067] In the illustrated embodiments, the upper edge into which the opening 15 is formed is the uppermost edge which extends transversely or perpendicularly to the plane of the sidewall 12 and / or parallel to the base of the FLC 10.

[0068] The number of openings 15 formed into the upper edge 14 of any one or more sidewalls 12 may be dependent on the dimensions of the container 10. For example, smaller containers may have a single opening on at least one sidewall and larger containers may have at least two openings on at least one sidewall. In the preferred embodiment, two openings 12 are provided on one sidewall 12 as this will allow the lid 16 to balance on the sidewall 12 stably when the lid latches 17 are engaged with the respective opening 15.

[0069] As shown in Figure 5, the opening 15 may be in the corner stile 21 of the sidewall 12.

[0070] The opening 15 may be any size. The size may be dictated or correspond to the dimensions of the lid latch 27. The opening 25 may be any shape. The openings illustrated in the Figures have a pair of spaced apart planar side edges and a pair of arcuate connecting end edges.

[0071] The openings may be formed in any way. For example, the at least one opening may be machined into the sidewall or may be moulded thereinto.

[0072] The illustrated openings 15 extend into the sidewall 12 perpendicularly to the upper edge of the sidewall 12 and parallel to the plane of the sidewall 12. The at least one opening is preferably formed the thickness of the at least one sidewall.

[0073] As illustrated, the openings 15 are positioned closer to the outside of the sidewall 12 than to the inside of the sidewall 12. The openings 12 are each of sufficient depth to receive the extension tab 20 of the lid latch 17, or slightly deeper.

[0074] As shown, the lid latches 17 are provided on the lower surface 18 of the lid 16. This means that the lid latches 17 will extend into the containing volume of the container 10, when the lid 16 is fitted on top of the container 10.

[0075] In the illustrated embodiments, the lid latches 17 are attached to the lid 16 using one or more fasteners 23 for example bolts, screws or the like which are best shown in Figures 2 and 3. However, the lid latch(es) 17 may be moulded or formed integrally with the lid 16.

[0076] The illustrated lid latches 17 include a mounting portion 22 extending away from the lower surface of the lid 16 and the extension tabs 20 extending laterally from the mounting portion 22. The mounting portion 22 extends substantially perpendicularly away from the lower surface 18 of the lid 16. As shown, where one or more fasteners 23 are provided, the fasteners 23 extend through the mounting portion 22.

[0077] The illustrated lid latches 17 have a T-shaped configuration when viewed from the side, with an extension tab 20 extending away from the mounting portion 22 on opposed sides.

[0078] In the preferred form shown, the extension tabs 17are flat and curve away from the lower surface of the lid 16, best illustrated in Figure 4. Also best illustrated in Figure 4, the extension tabs are spaced from the lower surface 18 of the lid 16 by the mounting portion 22. Figure 4 shows that the spacing basically corresponds to the distance between the outer edge of the opening 15 in the sidewall 12 and the outer side of the sidewall 12. The preferred curved shape of the extension tabs 20 allows the tabs 20 to rotate into the opening 15 in a sidewall 12 during removal of the lid 16, without requiring the lid 16 to be lifted entirely clear of the container 10.

[0079] The lid latches 17 illustrated in Figure 1 are provided spaced inwardly away from the side edge of the lid 16. In that illustrated embodiment, a pair of spaced apart lid latches 17 is provided on one lateral side of a midline of the lid 16, adjacent to the midline, and closer to the midline of the lid 16 than to the side edge of the lid 16.

[0080] The one or more embodiments are described above by way of example only. Many variations are possible without departing from the scope of protection afforded by the appended claims.

Claims

CLAIMS1. A folding large container with a base and at least one sidewall upstanding to define an internal storage volume, the at least one sidewall having an upper edge and at least one opening formed into the upper edge, and a lid with at least one lid latch, the lid comprising an upper surface, a lower surface and at least one locating portion to removably locate the lid to close an upper opening of the folding large container, the at least one lid latch provided on the lower surface of the lid and comprising at least one extension portion positioned to be received into the at least one opening in the at least one sidewall of the folding large container to removably latch the lid relative to the at least one sidewall.

2. A folding large container and lid as claimed in claim 1 wherein more than one opening is provided in the at least one sidewall.

3. A folding large container and lid as claimed in claim 1 or claim 2 wherein the at least one sidewall comprises at least one comer portion or corner stile and the at least one opening is formed into an upper edge or the at least one corner portion or comer stile.

4. A folding large container and lid as claimed in any one of the preceding claims wherein the at least one opening has at least one planar side edge which is parallel to an outer surface of the at least one sidewall.

5. A folding large container and lid as claimed in any one of the preceding claims wherein the at least one opening extend into the at least one sidewall parallel to the plane of the at least one sidewall within the thickness of the at least one sidewall.

6. A folding large container lid with a lid latch, the lid comprising an upper surface, a lower surface and at least one locating portion to removably locate the lid to close an upper opening of the folding large container, the at least one lid latch provided on the lower surface of the lid and comprising at least one extension portion positioned to be received into at least one opening in the at least one sidewall of the folding large container to removably latch the lid relative to the at least one sidewall.

7. A folding large container and lid as claimed in any one of claims 1 to 5 or a folding large container lid as claimed in claim 6 wherein the at least one lid latch includes a mounting portion extending away from the lower surface of the lid and at least one extension portion extending laterally from the mounting portion.

8. A folding large container and lid or a folding large container lid as claimed in claim 7 wherein the at least one lid latch has an L-shaped or T-shaped configuration when viewed from the side, the L-shaped or T-shaped configuration provided by the extension portion extending away from the mounting portion on one side only, or on opposed sides.

9. A folding large container and lid or a folding large container lid as claimed in any one of the preceding claims wherein the or each at least one extension portion is a flat tab or similar.

10. A folding large container and lid or a folding large container lid as claimed in any one of the preceding claims wherein the or each at least one extension portion curves away from the lower surface of the lid.

11. A folding large container and lid or a folding large container lid as claimed in any one of the preceding claims wherein the or each at least one extension portion is spaced from the lower surface of the lid, the spacing corresponding to or at least approximating a distance between an outer edge of the at least one opening in the sidewall and an outer side of the sidewall.

12. A folding large container and lid or a folding large container lid as claimed in any one of the preceding claims wherein one lid latch is provided relative to one side of a lid.

13. A folding large container and lid or a folding large container lid as claimed in any one of claims 1 to 11 wherein one lid latch is provided relative to each of two opposite sides of a lid.

14. A folding large container and lid or a folding large container lid as claimed in any one of claims 1 to 11 wherein one lid latch may be provided relative to each of two adjacent sides of a lid.

15. A folding large container and lid or a folding large container lid as claimed in any one of claims 1 to 11 wherein one lid latch is provided relative to each side of a lid.

16. A folding large container and lid or a folding large container lid as claimed in any one of claims 12 to 15 wherein two or more lid latches are provided for larger lids.

17. A folding large container and lid or a folding large container lid as claimed in any one of the preceding claims wherein the or each lid latch is provided spaced inwardly away from a side edge of the lid.

18. A folding large container and lid or a folding large container lid as claimed in claim 17 wherein a pair of spaced apart lid latches is provided on one lateral side of a midline of the lid, adjacent to the midline, closer to the midline than the side edge of the lid.

19. A folding large container and lid or a folding large container lid as claimed in claim 17 wherein two pairs of spaced apart lid latches are provided, one pair on either lateral side of a midline of the lid, adjacent to the midline, closer to the midline than the side edge of the lid.

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