Cargo unit

Abstract

To provide a unit for transporting a cargo, and to provide a method of using the unit.SOLUTION: A unit is a collapsible and stackable cargo unit. The cargo unit includes a substantially rectangular base having a forklift slot which has a front surface, a rear surface and two side surfaces, and which is provided on the front surface, the rear surface and each side surface. The cargo unit may further include front and rear walls extending upward from the base. The cargo unit may further include first and second side walls extending upward from the base between the front and rear walls. The length of the first side wall may be longer than the length of the second side wall. The cargo unit may further include an integrated lid attached to one or a plurality of the front, rear and side walls using a hinge.SELECTED DRAWING: Figure 6

Description

[Technical field]

[0001] <CROSS REFERENCE TO RELATED APPLICATIONS> This application claims priority to U.S. Provisional Patent Application No. 62 / 813,369, filed March 4, 2019, which is incorporated herein by reference in its entirety.

[0002] The present disclosure relates generally to units for transporting cargo, and more particularly to foldable and stackable cargo units. [Background technology]

[0003] Reusable stackable containers such as those disclosed in U.S. Patent No. 8,573,427, the disclosure of which is incorporated herein by reference, may be useful for transporting various types of cargo, for example by rail, in international trade and other situations. When a fleet of containers of this type is configured to include stacks of, for example, up to four or five full containers during a transportation operation, it is desirable for each container in the fleet to be capable of supporting the weight of multiple full containers stacked above it. Other conventional stackable containers are described in CN103158924B and CN201172503Y.

[0004] A problem with some containers is that components such as lids or removable walls can become detached from other components during use. This problem can be solved by permanently connecting all components together, but removing lids and walls can sometimes be useful to facilitate loading and unloading.

[0005] Another problem associated with collapsible shipping containers is that they may break in a standing or folded position during use, for example, due to impact with other containers or forklift tines. A further problem is that cargo may exert significant outward pressure against the side walls. One particular material that may exert significant outward pressure against the side walls is rubber, which may exert outward pressure during transportation that may in some cases increase over time. Also, significant inward pressure and impact loads may be exerted on the side walls by forklift tines and by other containers during transportation operations. For example, when containers are transported by rail, stopping and starting of rail cars may cause adjacent containers to come into contact and impact and / or exert forces on each other.

[0006] To provide the necessary strength to withstand such pressures as well as stacking and other loads associated with transport operations, for example, by forklift, many commercial shipping containers have a relatively heavy steel construction, and as a result, the weight of a shipping container may be a significant percentage of its capacity. For example, a Goodpack MB5 medium capacity container capable of carrying a maximum payload of about 1,650 kg or 3,637 lbs in commercial use may have a tare weight of about 126 kg to about 136 kg, or 280 lbs to 300 lbs. There is a continuing interest in providing new and improved shipping containers that provide similar functionality to existing commercial containers, but with reduced tare weights.

[0007] Collapsible shipping containers often include a bar code label, RFID tag, or other means to facilitate tracking by providing each container with a unique machine-readable identifier. In some cases, the label or tag is placed on the top container of, for example, a five-high stack. Such labels and tags can be difficult to access, for example, due to impacts or abrasion from forklift tines or other containers. There is a need for improvement in this area as well. Summary of the Invention

[0008] Disclosed herein is a foldable, stackable cargo unit having an upright configuration in which the cargo unit may define an enclosed interior and a folded configuration in which the cargo unit may be compactly stored and transported. The cargo unit comprises a generally rectangular base having a front, a rear and two sides and having forklift slots in the front, the rear and each of the sides, front and rear walls extending upwardly from the base, first and second side walls extending upwardly from the base between the front and rear walls, and an integral lid hinged to one or more of the front, rear and side walls.

[0009] In some embodiments, all four walls are completely removable.

[0010] In some embodiments, the one-piece lid comprises a first lid member including a hinged edge hinged to a first side wall and a second lid member including a hinged edge hinged to a second side wall. In some embodiments, the first lid member and the second lid member each have a free edge opposite its hinged edge, the first lid member being larger than the second lid member, and a dimension between the hinged edge of the first lid member and the free edge of the first lid member being larger than a corresponding dimension of the second lid member. In some embodiments, each lid member has a first handle extending outwardly beyond the front wall and a second handle extending outwardly beyond the rear wall, which facilitates lifting the lid to open the cargo unit. Each handle may include a downwardly projecting end that wraps downwardly over the top of its associated front or rear wall to provide strength and rigidity to the structure and / or help maintain the lid member in a closed position.

[0011] In some embodiments, each lid member is permanently attached to the side wall and is pivotable through an arc of 270° between a generally horizontal closed position in which the free edges of the lid members are adjacent to one another and a generally vertical open position in which the lid member covers the outer surface of its associated side wall when the cargo unit is in an upright configuration.

[0012] In some embodiments, the front wall comprises a releasable locking mechanism capable of locking the cargo unit in an upright position. In some embodiments, the front wall comprises a lower front wall and an upper front wall pivotally connected to the lower front wall, the lower front wall comprising the locking mechanism, and the upper front wall comprising the locking mechanism, such that when the cargo unit is in the upright position, the upper front wall is configured to either (1) be locked in an upright position associated with a fully closed condition of the cargo unit, or (2) be unlocked and fold outwardly and downwardly in an arc of approximately 180° to cover an outer surface of the lower front wall, while the lower front wall remains locked in place, thereby partially opening the cargo unit to facilitate access to the interior. In some embodiments, the rear wall is the same or substantially the same as the front wall, as described above.

[0013] In some embodiments, the base and walls each comprise a metal frame and one or more generally flat, planar metal sheets or plates welded or otherwise attached to the frame. The metal may be, for example, galvanized steel, and the cargo units may have a tare weight of, for example, 70 kg to 100 kg, 80 kg to 90 kg, or about 84 kg. In other embodiments, instead of comprising a frame combined with sheets or plates, one or more of the base and walls comprise a unitary, one-piece stamped primary member having an integral structural profile to provide strength and rigidity, and the cargo units may have a tare weight significantly less than 80 kg.

[0014] Also disclosed herein is a double cargo unit comprising a pair of similar individual cargo units joined back to back together, each of which is similar to one of the cargo units described above, except that the individual cargo units do not include a back wall. Thus, the individual cargo units in these embodiments are joined at their respective open sides. The individual cargo units may be joined by bridge plates, splice bars, or other structures that join one or more of these base members, side walls, and lid together, and / or by other means such as fastening adjacent portions of the base to one another using fasteners such as bolts. In some embodiments, the base defines a generally flat floor, where the joint between the bases of the individual cargo units does not have any noticeable upward projection or rim projecting upward. In some embodiments, stiffness and strength are increased by long, narrow removable supports, such as steel plates, steel angles, or tubular members, e.g., of rectangular cross section, that extend across the joint at the height of the lid, joining all four corners of the upper side walls adjacent the joint, and supporting the edges of the lid members adjacent the joint. The structural member may have a slot or recess to accommodate the downward projection of the lid handle.

[0015] In some embodiments, the one-piece lid of each individual cargo unit comprises a first lid member including a hinged edge hinged to the first side wall and a second lid member including a hinged edge hinged to the second side wall.

[0016] Also disclosed herein is a method of unloading and folding a foldable, stackable cargo unit having an upright configuration in which the cargo unit defines a closed interior and a folded configuration in which the cargo unit may be compactly stored and transported, the cargo unit comprising a generally rectangular base having a front, a rear and two sides and having forklift slots on the front, rear and each side, front and rear walls extending upwardly from the base, first and second side walls extending upwardly from the base between the front and rear walls, a locking mechanism operable to maintain the cargo unit in the upright configuration, and a two-piece, one-piece lid that is in a generally horizontal position when the cargo unit is in the upright configuration.

[0017] In some embodiments, the method comprises the steps of: (a) opening the first and second lid members by pivoting each of the first and second lid members through an arc of approximately 270° about a hinge connecting each of the first and second lid members to each of the first and second side walls. (b) The process of removing cargo from a cargo unit. (c) releasing the locking mechanism on the front wall and pivoting the front wall downwardly and inwardly into the base about the pivotable connection in an arc of approximately 90 degrees so as to place the front wall onto the base. (d) releasing a locking mechanism on the rear wall and pivoting the rear wall downwardly and inwardly into the base in an arc of approximately 90° about a pivotable connection comprising an upwardly extending slot in the base configured to permit upward movement of the pivotable connection between the rear wall and the base, the pivot axis of the rear wall being fixed at a height that is vertically offset upwardly relative to the pivot axis of the front wall by a dimension equal to or approximately equal to the thickness of the front wall, and the side walls being upright and supported by corner posts of the base. (e) pivoting the first sidewall downwardly and inwardly about the pivotable connection to the base in an arc of approximately 90° onto the rear wall, with the pivot axis of the first sidewall fixed at a height permitting the first sidewall to lie flat on the rear wall in a generally horizontal orientation. (f) pivoting the second side wall downwardly and inwardly about the pivotable connection to the base in an arc of approximately 90° onto the first side wall. The pivot axis of the walls is fixed at a height that permits the second side wall to lie flat on top of the first side wall in a generally horizontal orientation. (g) pivoting the second lid member through an arc of approximately 180° about the hinge connecting it to the second side wall so that it rests on the first lid member rather than on the second side wall, thereby reducing the height of the folded cargo unit.

[0018] In some embodiments, the method of erecting a folded cargo unit may include the reverse of the steps described above. In some embodiments, the method of folding or erecting a double cargo unit as described above may include the same methods as those described above, with the exception that the steps for the rear wall are not applicable and the methods for the other walls must be performed for each individual cargo unit.

[0019] In some embodiments involving loading and unloading of individual or double cargo units as described above, any number of the walls can be removed from the base prior to loading and unloading, facilitating access to the interior from one or more sides, which may be useful in some situations, such as, for example, situations involving manual loading and unloading and / or using a forklift for loading and unloading.

[0020] It is contemplated that, in various embodiments, any number of the features described herein may be included in combination with one another, to the extent practical.Furthermore, it is contemplated that, in various embodiments, any number of the features described in the above-referenced U.S. Patent No. 8,573,427 may be included in combination with one or more of the features described herein, to the extent practical. [Brief description of the drawings]

[0021] [Figure 1] FIG. 2 is a perspective view of an individual cargo unit in an upright position. [Diagram 2] FIG. 2 is a perspective view of the individual cargo unit of FIG. 1 in a folded configuration. [Diagram 3] FIG. 2 is a perspective view of a double cargo unit in an upright position. [Figure 4] FIG. 4 is a perspective view of the double cargo unit of FIG. 3 in a folded position. [Figure 5A] FIG. 2 is a perspective view of the individual cargo unit of FIG. 1 with the lid member rotated to an open position. [Figure 5B] FIG. 2 is a perspective view of the individual cargo unit of FIG. 1 with the front wall in a folded position. [Figure 5C] FIG. 2 is a perspective view of the individual cargo unit of FIG. 1 with the rear wall in a folded position. [Figure 5D] 2 is a perspective view of the individual cargo unit of FIG. 1 with the first side wall in a folded position. [Figure 5E] FIG. 2 is a perspective view of the individual cargo unit of FIG. 1 with the second side wall in a folded position. [Figure 5F] 2 is a perspective view of the individual cargo unit of FIG. 1 in a folded configuration with the second wall lid member rotated so that it extends over the first wall lid member; FIG. [Figure 6] FIG. 13 is a perspective view of another cargo unit in an upright position. [Figure 7] FIG. 7 is a bottom view of the cargo unit of FIG. [Figure 8] FIG. 8 is a side elevational partial cross-sectional view taken along line 8-8 of FIG. 7. [Figure 9]FIG. 9 is a rear elevational partial cross-sectional view taken along line 9-9 of FIG. 7. [Figure 10] FIG. 7 is a rear elevational view of the cargo unit of FIG. 6 in a folded configuration. [Figure 11] FIG. 2 is a rear elevation view of a plurality of folded cargo units in a stacked arrangement. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0022] 1 and 2, a foldable, stackable cargo unit 20 is shown having an upright configuration that may define an enclosed interior and a folded configuration that may allow the cargo unit 20 to be compactly stored and transported. 0 comprises a generally rectangular base 22 having a front 24, a rear and two side surfaces 26 and having forklift slots 28 on the front, rear and each side surface, a front wall 30 and a rear wall 32 extending upwardly from the base 22, a first side wall 34 and a second side wall 36 extending upwardly from the base 22 between the front wall 30 and the rear wall 32, and a one-piece lid hinged to one or more of the front wall, rear wall and side walls.

[0023] In some embodiments, all four walls are completely removable.

[0024] In some embodiments, the one-piece lid comprises a first lid member 38 including a hinge edge 40 hinged to the first side wall 34 and a second lid member 42 including a hinge edge 44 hinged to the second side wall 36. In some embodiments, the first and second lid members 38, 42 each include a free edge 46, 48 opposite its hinge edge, with the first lid member 38 being larger than the second lid member 42 such that a dimension between its hinge edge 40 and its free edge 46 is larger than a corresponding dimension of the second lid member 42. In some embodiments, each lid member has a first handle 50 that extends outwardly beyond the front wall 30 and a second handle 52 that extends outwardly beyond the rear wall 32 to facilitate lifting the lid to open the cargo unit 20. Each handle 50 may include a downwardly projecting end that wraps downwardly over the top of its associated front or rear wall, thereby providing strength and rigidity to the structure and / or assisting in maintaining the lid member in the closed position.

[0025] In some embodiments, each lid member is permanently attached to a side wall and is pivotable through an arc of 270° between a generally horizontal closed position in which the free ends of the lid members are adjacent to one another and a generally vertical open position in which the lid member covers the outer surface of its associated side wall when the cargo unit is in an upright position.

[0026] In some embodiments, the front wall 30 includes a releasable locking mechanism 54 that can lock the cargo unit 20 in an upright position. In some embodiments, the front wall 30 includes a lower front wall 56 and an upper front wall 58 pivotally connected thereto, the lower front wall 56 including a locking mechanism, and the upper front wall 58 including a locking mechanism, such that when the cargo unit 20 is in its upright position, the upper front wall 58 is either (1) locked in an upright position associated with a fully closed condition of the cargo unit, or (2) unlocked and pivoted outwardly and downwardly through an arc of approximately 180° to cover the exterior surface of the lower front wall 56, which remains locked in place, thereby facilitating partial opening of the cargo unit 20 to access the interior while keeping the lower portion of the cargo unit closed. In some embodiments, the rear wall 32 is the same or substantially the same as the front wall 30 as described above.

[0027] In some embodiments, each of the base and walls comprises a metal frame and one or more substantially flat planar metal sheets or plates welded or otherwise attached to the frame. Each frame may include a generally rectangular perimeter and one or more stiffeners within the perimeter. The metal may be, for example, galvanized steel, and the cargo units may have a tare weight of, for example, 70 kg to 100 kg, 80 kg to 90 kg, or about 84 kg. In other embodiments, instead of comprising a frame combined with sheets or plates, one or more of the base and walls comprise a single one-piece stamped primary member having an integral structural profile to provide strength and rigidity, and the cargo units may have a tare weight significantly less than 80 kg.

[0028] 3 and 4 show a double cargo unit 60 comprising a pair of similar individual cargo units 62 joined back to back to each other, each of the individual cargo units being similar to one of the cargo units described above except that they do not include a rear wall. The individual cargo units in the configuration are joined at their respective open sides. The individual cargo units may be joined by bridge plates, splice bars, or other structures that join one or more of these base members, side walls, and lids together, and / or by other means such as directly fastening adjacent portions of the base and / or side walls together using fasteners 64 such as bolts. In some embodiments, the base defines a generally flat floor overall, with no noticeable upward projections or rims projecting upward at the joints between the bases of the individual cargo units. In some embodiments, increased rigidity and strength is provided by a long, narrow, removable support 66, such as a steel plate, steel angle, or tubular member of, for example, rectangular cross section, that extends across the joint at the height of the lid, joining all four corners of the upper side walls adjacent the joint, and supporting the edges of the lid members adjacent the joint. This structural member may have a slot or recess 68 to accommodate the downward projection of the lid handle.

[0029] In some embodiments, the one-piece lid of each individual cargo unit comprises a first lid member including a hinged edge hinged to the first side wall and a second lid member including a hinged edge hinged to the second side wall, the edges of the lid members covering the front wall, the side walls and the support 66.

[0030] 5A to 5F, a method for unloading and folding a foldable stackable cargo unit as described above and changing its configuration from that shown in FIG. 1 to that shown in FIG. 2 may include the following steps. (a) opening the first and second lid members 38, 42 by pivoting each lid member through an arc of approximately 270° about a hinge connecting each lid member to the first and second side walls 34, 36, respectively, as shown in FIG. 5A. (b) The process of removing cargo from a cargo unit. (c) releasing the locking mechanism 54 on the front wall 30 and pivoting the front wall 30 downwardly and inwardly into the base 22 in an arc of approximately 90° about the pivotable connection, as shown in FIG. 5B. (d) Releasing the locking mechanism of the rear wall 32 and pivoting the rear wall 32 downward and inward about the pivotable connection into the base in an arc of approximately 90° so that it rests on top of the front wall 30, with the side walls 34, 36 remaining upright and supported by the corner posts of the base, as shown in Figure 5C. (e) pivoting the first side wall 34 downwardly and inwardly into the base in an arc of approximately 90° about the pivotable connection to place the first side wall 34 onto the rear wall 32, as shown in FIG. 5D. (f) pivoting the second side wall 36 downwardly and inwardly into the base in an arc of approximately 90° about the pivotable connection and onto the first lid member 38, as shown in FIG. 5E. (g) pivoting the second lid member 42 through an arc of approximately 180° about the hinge connecting the second lid member 42 and the second side wall 36 so that it rests on the first lid member 38 rather than on the second side wall 36, thereby reducing the height of the folded cargo unit, as shown in FIG. 5F.

[0031] In some embodiments, the method of erecting and stowing a folded cargo unit may include the reverse of the steps described above. In some embodiments, the method of folding or erecting a double cargo unit as described above may include the same methods as those described above, with the exception that the steps for the rear wall are not applicable and the methods for the other walls must be performed for each individual cargo unit.

[0032] Several shipments involving the loading and unloading of the above-mentioned individual cargo units or double cargo units. In some embodiments, any number of the walls can be removed from the base prior to loading and unloading and replaced afterwards, which facilitates access to the interior from one or more sides, which may be useful in some situations, such as, for example, situations involving manual loading and unloading and / or using a forklift for loading and unloading.

[0033] The cargo units 20 may include an identification component 70 that comprises an RFID tag, bar code label and / or other identifier within a slot in the base 22. This positioning provides protection against damage from contact between cargo units, and some protection from contact with forklift tines or other potential sources of damage.

[0034] In some embodiments, cargo unit 20 has dimensions of 1150mm x 995mm x 835mm, which is a "one dimension fits all" design. It helps provide a "all" feature.

[0035] As described in more detail below with respect to cargo unit 100, the length of first side wall 34 (i.e., the vertical length in the upright configuration) may be different from the length of second side wall 36. This allows first lid member 38 to be positioned flush (e.g., generally coplanar) with first side wall 34 when in the folded configuration, thereby reducing the height of the stacked walls.

[0036] Referring now to Figure 6, another cargo unit 100 is shown. The cargo unit 100 may be the same as the cargo unit 20 of Figures 1 to 5F. For example, the cargo unit 100 comprises a generally rectangular base 122 having a front 124, a rear and two side surfaces 126 and having forklift slots 128 disposed therein, a front wall 130 and a rear wall 132 extending upwardly from the base 122, a first side wall 134 and a second side wall 136 extending upwardly from the base 122 between the front wall 130 and the rear wall 132, and an integral lid hinged to one or more of the front wall, the rear wall and the side walls. As will be described in more detail with respect to Figure 8, the length of the first side wall 134 may be less than the length of the second side wall 136.

[0037] In some embodiments, all four walls are completely removable.

[0038] In some embodiments, the one-piece lid comprises a first lid member 138 including a hinge edge 140 hinged to the first side wall 134 and a second lid member 142 including a hinge edge 144 hinged to the second side wall 136. In some embodiments, the first and second lid members 138, 142 each include a free edge 146, 148 opposite its hinge edge, with the first lid member 138 being larger than the second lid member 142 such that a dimension between its hinge edge 140 and its free edge 146 is larger than a corresponding dimension of the second lid member 142. In some embodiments, each lid member has a first handle 150 that extends outwardly beyond the front wall 130 and a second handle 152 that extends outwardly beyond the rear wall 132 to facilitate lifting the lid to open the cargo unit 100. Each handle may include a downwardly projecting end that wraps downwardly over the top of its associated front or rear wall to provide strength and rigidity to the structure and / or assist in maintaining the lid member in the closed position.

[0039] In some embodiments, each lid member 138, 142 is permanently attached to a side wall and is pivotable through an arc of 270° between a generally horizontal closed position in which the free ends of the lid members are adjacent to one another and a generally vertical open position in which the lid member covers the outer surface of its associated side wall when the cargo unit 100 is in an upright position.

[0040] In some embodiments, the front wall 130 comprises a releasable locking mechanism 154 that can lock the cargo unit in an upright position. In some embodiments, the front wall 130 comprises a lower front wall 156 and an upper front wall 158 pivotally connected thereto, the lower front wall 156 including a locking mechanism, and the upper front wall 158 including a locking mechanism, such that when the cargo unit 100 is in its upright position, the upper front wall 158 is either (1) locked in an upright position associated with a fully closed condition of the cargo unit 100, or (2) unlocked and pivoted outwardly and downwardly through an arc of approximately 180° to cover the exterior surface of the lower front wall 156, which remains locked in place, thereby allowing the cargo unit 100 to be partially opened to facilitate access to the interior while the lower portion of the cargo unit is closed. In some embodiments, rear wall 132 is identical or substantially identical to front wall 130, except that it may have a different height to accommodate the vertically offset pivot axis, such that when in an upright position, the upper edges of the front and rear walls are flush, while their lower edges are at slightly different heights.

[0041] In some embodiments, each of the base and walls comprises a metal frame and one or more substantially flat planar metal sheets or plates welded or otherwise attached to the frame. Each frame may include a generally rectangular perimeter and one or more stiffeners inside the perimeter. The metal may be, for example, galvanized steel, and the tare weight of the cargo unit may be, for example, 70 to 100 kg, 80 to 90 kg, or about 84 kg. In other embodiments, instead of comprising a frame combined with sheets or plates, one or more of the base and walls comprise a unitary, one-piece stamped primary member incorporating integral structural profiles to provide strength and rigidity, and the tare weight of the cargo unit may be significantly less than 80 kg.

[0042] 7, the base 122 of the cargo unit 100 includes a lower front frame 160, a lower rear frame 162 opposite the lower front frame 160, a first lower side frame 164, and a second lower side frame 166 opposite the first lower side frame 164. These lower frames extend between corner posts 170 of the base 122. The lower front frame 160 and the rear frame 162 have a common length that is greater than the common length of the first and second lower side frames 164, 166. For example, the length of each of the lower front frame 160 and the rear frame 162 may be approximately 15% greater than the length of the first and second lower side frames 164, 166. In this manner, the lower frames cooperate to form a rectangular base 122. The base 122 also includes a support structure 172 extending between the lower front frame 160 and the lower rear frame 162, and a lateral support structure 174 extending between the first lower side frame 164 and the second lower side frame 166. The lateral support structure 174 may extend perpendicular to the support structure 172. The support structure 172 and the lateral support structure 174 cooperate to support a floor 176 of the base 122.

[0043] 8, the base 122 includes a first upright side 180 extending vertically between the first lower side frame 164 and a hinge edge 184 of the first side wall 134, and a second upright side 182 extending vertically between the second lower side frame 166 and a hinge edge 186 of the second side wall 136. The upright sides 180, 182 may be fixed upright walls. For example, the upright sides 180, 182 may be integrally formed with the base 122.

[0044] The upright sides 180, 182 of the base 122 may have different vertical lengths. For example, as shown in Figure 8, the first upright side 180 extends to a first vertical height indicated at 190 and the second upright side 182 extends to a second vertical height indicated at 192 that is vertically above (i.e., higher above ground level) the first vertical height 190.

[0045] The first and second sidewalls 134, 136 may be hinged to the base adjacent the first and second upright sides 180, 182. More specifically, a hinge edge 184 of the first sidewall 134 is hinged to a corner post 170 of the base 122 such that the first sidewall 134 is pivotable about a first pivot axis 194. A hinge edge 186 of the second sidewall 136 is hinged to the corner post 170 of the base 122 such that the second sidewall 136 is pivotable about a second pivot axis 196 that is vertically offset from the first pivot axis 194. As shown, the second pivot axis 196 is vertically above (i.e., higher above ground level) than the first pivot axis 194.

[0046] As mentioned above, the first and second side walls 134, 136 may have different lengths. As used herein, the length of a side wall refers to the vertical dimension when the side wall is in an upright position and the horizontal dimension when the side wall is in a folded position. As shown, the length of the first side wall 134 (designated 202) may be longer than the length of the second side wall 136 (designated 200).

[0047] In this manner, the vertical height 190 of the first upright side 180 of the first sidewall 134 and the length 200 of the first sidewall 134 combine to define a total length 204 of the first side of the cargo unit 100, and the vertical height 192 of the second upright side 182 and the length 202 of the second sidewall 136 combine to define a total length 206 of the second side of the cargo unit 100, such that the first total length 204 is approximately the same as the second total length 206. In this manner, the two sides 126 of the cargo unit 100 extend to a substantially common height.

[0048] With reference to FIG. 9, the length 210 of the front wall 130 is substantially the same as the length 212 of the rear wall 132 .

[0049] The cargo unit 100 can be folded into the folded configuration shown in Figure 10 in a manner similar to that described with respect to Figures 5A-5F. For example, a user can pivot each of the first and second lid members 138, 142 through an arc of approximately 270° about the hinges connecting them to the first and second side walls 134, 136, respectively. With the first and second lid members 138, 142 leaning vertically along the first and second side walls 134, 136 (similar to the configuration shown in Figure 5A), a worker can remove cargo from the cargo unit 100.

[0050] The user can then release the locking mechanism 154 on the front wall 130 and pivot the front wall 130 downwardly and inwardly into the base 122 in an arc of approximately 90° about the pivotable connection, placing it onto the base 22 (an arrangement similar to that shown in FIG. 5B).

[0051] The user can then release the locking mechanism 154 on the rear wall 132 and pivot the rear wall 132 downwardly and inwardly about the pivotable connection in an arc of approximately 90° onto the base 122, leaving the side walls 134, 136 in an upright position supported by the corner posts of the base (similar to the arrangement shown in FIG. 5C).

[0052] The user can then pivot the first side wall 134 downwardly and inwardly to the base in an arc of approximately 90° about the pivotable connection to place it on top of the rear wall 132 (an arrangement similar to that shown in FIG. 5D ), and then pivot the second side wall 136 downwardly and inwardly to the base 122 in an arc of approximately 90° about the pivotable connection to place it on top of the first lid member 138 (an arrangement similar to that shown in FIG. 5E ).

[0053] To reduce the height of the cargo unit 100 in the folded configuration, a user can pivot the second lid member 142 in an arc of approximately 180 degrees about the hinge connecting it to the second side wall 136 so that the second lid member 42 rests on the first lid member 138 rather than on the second side wall 136.

[0054] 10, in the folded configuration, the front wall 130 is supported against the floor 176 of the base 122 and the rear wall 132 is supported against the front wall 130. The first side wall 134 is supported against the rear wall 132 with the first lid member 138 folded over and supported by the first side wall 134. The distal end 220 of the second side wall 136 is supported against the first lid member 138 with the proximal end 222 spaced from the rear wall 132. The second lid member 142 rotates to be supported against the first lid member 138. As shown, the combined length of the second side wall 136 and the second lid member 142 corresponds to or is less than an interior dimension (e.g., an interior length) of the cargo unit 100. In this manner, the second sidewall 136 and the second lid member 142 may be at least partially coplanar without interfering with opposing surfaces, such as the posts 170. In another approach, the combined length of the second sidewall 136 and the second lid member 142 may exceed an interior dimension (e.g., an interior length) of the cargo unit 100. In such an approach, the second lid member 142 may be sized to pass between the posts 170 so as not to interfere with the planar orientation of the second lid member 142.

[0055] In one embodiment, the combined length of the first sidewall 132 and the first lid member 138 may exceed an interior dimension (e.g., an interior length) of the cargo unit 100. In another embodiment, the combined length of the first sidewall 132 and the first lid member 138 may exceed an interior dimension (e.g., an interior length) of the cargo unit 100.

[0056] In this manner, folding the front wall 130, the rear wall 132, the first side wall 134, the first lid member 138 and the second side wall 136, and unfolding the second lid member 142 therefrom, provides a compact folded configuration of the cargo unit 100. More specifically, the height of the stacked walls and lid members is reduced by the thickness of the second lid member 142 (which may be, for example, approximately 26 mm). Such a compact configuration allows for compact stacking of multiple cargo units 100.

[0057] For example, referring to FIG. 11 , multiple cargo units 100, 100′ may be stacked. In the stacked configuration, the lower frame structure of the upper cargo unit 100′ is spaced (e.g., vertically spaced) from the stacked walls and lid of the lower cargo unit 100. More specifically, the lower rear frame 162′ of the base 122′ of the upper cargo unit 100′ is spaced from the second side wall 136 and second lid member 142 of the lower cargo unit 100. In the stacked configuration, the upper portion 230 of the corner post 170 of the lower cargo unit 100 may receive (or be received within) the receiving portion 232′ of the lower portion 234′ of the upper cargo unit 100′.

[0058] From the foregoing, it should be understood that there is described and illustrated herein a complete metal cargo unit that is returnable in one unit and individually uniquely identified and traceable, with four fully removable doors, an integral lid that folds down with associated walls, and a foldable half door with latch. In some embodiments, the cargo unit can provide maximum capacity utilization (e.g., one size fits all) within trucks, trailers, rail cars, and ISO 40 foot containers.

[0059] It is contemplated that, in various embodiments, any number of the features described herein may be included in combination with one another, to the extent practical.Furthermore, it is contemplated that, in various embodiments, any number of the features described in the above-referenced U.S. Patent No. 8,573,427 may be included in combination with one or more of the features described herein, to the extent practical.

[0060] In this disclosure, embodiments and examples of cargo units and associated methods of use and operation are described. Terms such as front, rear, side, vertical, horizontal, top, bottom, etc., refer to the drawings accompanying this specification.

[0061] Those skilled in the art will appreciate that various modifications, variations and combinations may be made to the above-described embodiments without departing from the scope of the claims, and such modifications, variations and combinations should be considered within the scope of the inventive concept. It should also be understood that features of one embodiment described herein may be combined with features of other embodiments described herein to provide yet other embodiments, as desired.

Claims

1. 1. A foldable, stackable cargo unit having an upright configuration in which the cargo unit may define an enclosed interior, and a folded configuration in which the cargo unit may be compactly stored and transported, comprising: a generally rectangular base having a front surface, a rear surface and two side surfaces, the front surface, the rear surface and each of the side surfaces being provided with a forklift slot; a front wall and a rear wall extending upwardly from the base; a first side wall and a second side wall extending upwardly from the base between the front wall and the rear wall; a one-piece lid hinged to one or more of the front wall, the rear wall, and the side walls; Corner posts and Equipped with the base further includes a first fixed upstanding wall adjacent the first sidewall and a second fixed upstanding wall adjacent the second sidewall; the second fixed upright wall extends higher than the first fixed upright wall; When in the folded configuration, the front wall, the rear wall, the first side wall, the second side wall and the integral lid are positioned below the corner posts, allowing the cargo unit to be stacked on another cargo unit.

2. 2. The cargo unit of claim 1, wherein the one-piece lid comprises a first lid member including a hinged edge hinged to the first side wall and a second lid member including a hinged edge hinged to the second side wall.

3. 3. The cargo unit of claim 2, wherein when in the folded position, the first lid member is rotated against the first side wall and the second lid member is disposed substantially flush with the second side wall.

4. the first lid member and the second lid member each have a free edge opposite its hinge edge; 4. The cargo unit of claim 3, wherein the first lid member is larger than the second lid member, and a dimension between the hinge edge of the first lid member and the free edge of the first lid member is larger than a corresponding dimension in the second lid member.

5. 5. The cargo unit of claim 4, wherein each of the lid members has a first handle extending outwardly beyond the front wall and a second handle extending outwardly beyond the rear wall.

6. 6. A cargo unit as claimed in claim 5, wherein each of the lid members is permanently attached to a side wall and is pivotable through an arc of 270° between a generally horizontal closed position in which the free edges of the lid members are adjacent one another and a generally vertical open position in which the lid member covers an outer surface of its associated side wall.

7. The cargo unit of claim 6 , wherein the front wall comprises a releasable locking mechanism capable of locking the cargo unit in the upright position.

8. the front wall comprises a lower front wall and an upper front wall pivotally connected to the lower front wall; the lower front wall includes a locking mechanism; the upper front wall includes a locking mechanism; 8. The cargo unit of claim 7, wherein when the cargo unit is in the upright position, the upper front wall is configured to either (1) be locked in an upright position associated with a fully closed condition of the cargo unit, or (2) be unlocked so that the upper front wall folds outwardly and downwardly in an arc of approximately 180° to cover an outer surface of the lower front wall while the lower front wall remains locked in place, thereby partially opening the cargo unit to facilitate access to an interior.

9. 9. The cargo unit of claim 8, wherein the front wall, the rear wall and the side walls are each completely removable from the base.

10. 10. A cargo unit as claimed in claim 9, wherein the base and the walls each comprise a metal frame and one or more metal sheets welded or otherwise attached to the frame.

11. 10. The cargo unit of claim 9, wherein one or more of the base and the walls comprise a unitary, one-piece stamped primary member having an integral structural contour to provide strength and rigidity.

12. 10. The cargo unit of claim 1, wherein the cargo unit is constructed from galvanized steel and has a tare weight of about 80 kg to about 90 kg.

13. 1. A double cargo unit having an upright configuration in which the cargo unit can define an enclosed interior and a folded configuration in which the cargo unit can be compactly stored and transported, a pair of similar individual cargo units coupled together; The individual cargo units each have, in an upright configuration: a generally rectangular base having four sides, at least three of the sides having forklift slots; a first upstanding wall, a second upstanding wall and a third upstanding wall extending upwardly from the base to define a three sided enclosure, an open side; Corner posts and an integral lid hinged to one or more of said walls; Equipped with the base further includes a first fixed upstanding wall adjacent the first sidewall and a second fixed upstanding wall adjacent the second sidewall; the second fixed upright wall extends higher than the first fixed upright wall; the individual cargo units are joined at the open sides thereof; When in the folded position, the first, second and third upright walls and the integral lid are positioned below the corner posts, allowing the cargo unit to be stacked on another cargo unit.

14. 14. The cargo unit of claim 13, wherein the one-piece lid of each of the cargo units comprises a first lid member including a hinge edge hinged to the first side wall and a second lid member including a hinge edge hinged to the second side wall.

15. the first upright wall of one of the individual cargo units comprises a lower front wall and an upper front wall pivotally connected to the lower front wall; the lower front wall includes a locking mechanism; the upper front wall includes a locking mechanism; 15. The double cargo unit of claim 14, wherein when the double cargo unit is in the upright position, the upper front wall is configured to either (1) be locked in an upright position associated with a fully closed state of the cargo unit, or (2) be unlocked and fold outward and downward in an arc of approximately 180 degrees to cover an outer surface of the lower front wall, while the lower front wall remains locked in place, thereby allowing the cargo unit to be partially opened to facilitate access to the interior.

16. 16. A double cargo unit as claimed in claim 15, wherein each of said upright walls is completely removable from said base.

17. 17. A double cargo unit as claimed in claim 16, wherein the base and the upright walls each comprise a metal frame and one or more metal sheets welded or otherwise attached to the frame.

18. 20. A double cargo unit as claimed in claim 17, wherein said base and said wall each comprise a unitary, one-piece stamped primary member having an integral structural contour to provide strength and rigidity.

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