Collapsible container and method for erecting or collapsing a collapsible container

Abstract

The invention relates to a collapsible container (1) having a closure system, the collapsible container (1) comprising at least two active walls (2) and at least two passive walls (3), each of which is perpendicular to the active walls. Closure leaves (4) are provided on the active walls (2), the closure leaves (4) being bendable away from the active walls (2) so as to overlap with at least one part of a passive wall (3), and a closure mechanism (5) being provided in order to secure a closure leaf (4) to a passive wall (3).

Description

[0001] Folding containers and methods for setting up or folding a folding container

[0002] The present invention relates to the technical field of foldable transport containers, in particular large-volume plastic or hybrid containers such as those used in industrial logistics for transporting components. Specifically, the invention relates to a collapsible container equipped with a novel and highly durable locking system, as well as an associated method for setting up and folding it, which combines high ergonomics with exceptional stability and process reliability.

[0003] Foldable containers have long been established in the logistics sector, as they offer significant cost advantages in return transport by reducing the volume of empty containers. In the segment of special containers, which are often used to hold sensitive or complexly shaped components in flexible support systems such as textile compartments, two fundamental design principles have prevailed in the past. However, both of these have significant disadvantages, which are overcome by the present invention.

[0004] The first, older principle is based on so-called ring systems. With these, a flexible container ring, forming the side walls, is lifted as a whole from a base pallet and folded along predefined fold lines. A significant disadvantage of this design is that the attachments for the payload, such as hooks or rail systems, are mounted directly on the ring. During the folding process, the user must therefore manually lift the entire weight of the ring, including these attachments. This not only leads to unergonomic and strenuous processes but can also conflict with occupational safety regulations if the maximum weights for manual lifting are exceeded. Furthermore, the durability of such systems is often limited, as film hinges are frequently used on the outer edges of the ring, which can fail after only a few months under the continuous load of the container's weight.

[0005] The second, more modern principle utilizes individually hinged container walls. These systems are significantly more ergonomic, as the walls can be folded down one after the other with less effort. However, their major weakness becomes apparent when flexible component holders, such as multi-layered textile compartments, are used. These holders are typically attached to opposite container walls. The weight of the compartments themselves, and especially the weight of the payload, which can reach up to 300 kg, generates enormous tensile forces that pull the walls inwards. Conventional locking mechanisms in the corners of the containers, which are often designed only for simple form-fit or force-fit connections, cannot withstand these high and continuous static loads.Known solutions on the market, where the walls are connected on the inside or where an L-profile of a passive wall is simply clipped onto an active wall, prove to be unstable. They are prone to falling apart, especially if the connection is unintentionally loosened through careless handling, such as pulling on a wall. This inherent instability renders such containers unsuitable for the safe transport of heavy goods in flexible suspensions.

[0006] These disadvantages of the prior art give rise to the central objective of the present invention: to create a collapsible container that retains the ergonomic advantages of individually folding walls while simultaneously offering exceptionally high static stability and load-bearing capacity. The container should be able to safely and permanently withstand the high tensile forces that occur when using heavy goods stored in textile compartments, without compromising the stability of the structure or impairing handling safety for the user.

[0007] This problem is solved by a hinged container and an associated method, the core of which is a novel locking system based on an intelligent interaction between "active" and "passive" walls. The container according to the invention essentially consists of four pivotable walls. The walls are preferably made of a lightweight yet highly stable honeycomb panel, for example, made of polypropylene. Two of the opposing walls are referred to as "active walls" because they are primarily intended for supporting the payload. The load-bearing systems, for example, aluminum linear rails, are attached to these walls, with multi-layered textile bags suspended from them by means of sliders. The two other walls, positioned at right angles to the active walls, are referred to as "passive walls." Their main function is to absorb the static pressure generated by the contraction of the active walls under load.

[0008] The core of the invention lies in the method by which these walls are connected. Closure flaps are molded onto the vertical edges of the active walls, extending the active wall beyond the actual corner. When the container is erected, these closure flaps are folded outwards by 90 degrees and lie flat against the outer surface of the respective passive wall. There, they are secured by means of a releasable locking mechanism.

[0009] The locking wings extending from the load-bearing "active walls" thus encircle the "passive walls" from the outside. This construction creates a self-contained and statically highly resilient quadrilateral ring. The enormous tensile forces of the active walls are not transferred to the passive wall at a single point via a small locking mechanism in the corner, but rather across the entire contact surface of the locking wing, thus minimizing material stress. This results in a structurally sound force flow and exceptional stability of the overall structure. The corners of the container are effectively made "double-walled" by this overlap, effectively doubling the material in these critical areas and significantly stiffening the entire container structure.

[0010] Another crucial advantage of the invention lies in the ability to use precisely tensioned pocket systems. Many commercially available systems require outward movement of the walls to unlock them before they can be folded inwards. This necessitates manufacturing textile compartments with greater tolerances, i.e., looser tension, to allow for this movement. However, during transport, this leads to a significant loss of tension, causing the pockets to sag and the payload to become unstable, potentially leading to collisions between layers and damage. The present invention completely avoids this problem. For folding, the locking flaps are simply released and folded back without the walls needing to change their position. This allows the use of precisely and tightly tensioned pockets that securely fix the payload.

[0011] Process reliability is further enhanced when the locking wings are designed to be flush with the passive walls. A cover, typically with a surrounding rim, then rests over the top edge of the walls and the locking wings. This provides additional protection against unintentional opening and creates a redundant locking mechanism that offers maximum safety even under strong vibrations during transport.

[0012] In a first embodiment of the collapsible container according to the invention, rails and / or pockets are arranged on the active walls. In this way, the function of the "active walls" is defined as the primary load-bearing elements of the system.

[0013] In a further embodiment of the collapsible container according to the invention, the rails are designed as aluminum linear rails on which payload carriers are mounted so as to be horizontally displaceable by means of sliders. The technical effect is the creation of a functional and smooth-running mechanism for handling the payload carriers (e.g., bags). The decisive advantage lies in the improved ergonomics and efficiency during loading and unloading. A user can simply slide an empty upper bag to the side to gain direct access to the layer below, instead of having to empty the entire contents from top to bottom.

[0014] In a further embodiment of the collapsible container according to the invention, a reinforcing frame is included, which, when the container is erected, is arranged between the opposing active walls and rests directly against the aluminum linear rails to push them apart and pre-tension the system. This enables the generation of permanent pre-tension in the system. This pre-tension counteracts the inward tensile forces of the textile compartments even before the payload is inserted. The advantage is maximum system stabilization. It ensures that the walls remain perfectly parallel and that the textile pockets are taut even under partial load or when empty, preventing sagging and optimally protecting the payload from collisions.

[0015] In a particularly preferred embodiment of the present invention, the fastening mechanism comprises snap fasteners and / or hook-and-loop fasteners. The use of standardized, widely available, and easy-to-install fasteners offers the advantage of reduced manufacturing costs and simplified maintenance. Should a fastening mechanism wear out, it can be replaced quickly and cost-effectively without special tools.

[0016] Additionally or alternatively, a further embodiment of the present invention provides for the locking mechanism to be designed as a two-part injection-molded component comprising a latch located on the passive wall and a head piece located on the locking wing that engages positively in the latch. This is a more technically sophisticated but also more robust solution than a snap fastener or hook-and-loop fastener. The use of a two-part injection-molded component (latch and head piece) creates a positive fit instead of a purely force- or friction-based fit (as with hook-and-loop fasteners). The advantage is significantly higher security and reliability of the locking mechanism. Such a closure is insensitive to vibrations and prevents unintentional opening due to lateral shear forces or snagging, which considerably increases transport safety.

[0017] In a further embodiment, the latch is provided with four locking points arranged in a cross shape to prevent unintentional release if the container twists. The technical benefit of these four cross-shaped locking points is that the head of the latch is secured not only against tensile forces but also against torsional or twisting forces. The advantage lies in maximum locking reliability. Even if the container twists during handling or transport, unintentional release of the lock is effectively prevented.

[0018] In a further advantageous embodiment of the invention, the locking flaps are the same height as the passive walls and are flush with the passive walls when attached to them. The technical effect is the creation of a continuous, flat top edge of the upright container. The primary advantage is that this geometry provides an additional safety function through the lid. A further advantage is the creation of a clean, smooth outer contour without protruding edges that could snag. In another preferred embodiment of the collapsible container according to the invention, a lid is provided that can be placed on the container and whose circumferential rim overlaps the top edges of the flush locking flaps, thereby additionally securing them against unintentional opening.In this way, the lid's surrounding rim physically blocks the flush-fitting locking flaps from above. The advantage is the creation of a redundant, second level of security. Even if the primary locking mechanism (e.g., Velcro) should fail, the attached lid prevents the locking flaps from opening and thus the container from falling apart. This significantly increases operational safety.

[0019] Furthermore, in another embodiment of the folding container according to the invention, a rectangular base element is provided. An active wall and a passive wall are pivotably attached to each side of the base element. In this way, a kinematic base is defined that facilitates or enables the folding of the container.

[0020] In a further advantageous embodiment of the invention, the hinges connecting the active and passive walls to the base element are designed such that the pair of hinges for the active walls lies in a different horizontal plane than the pair of hinges for the passive walls, thus enabling overlapping and trouble-free folding of the walls. This solves a specific problem encountered during the folding process. Arranging the hinges of the active and passive walls on different horizontal planes prevents the walls from colliding during folding. The advantage is a smooth, trouble-free folding process. It allows one pair of walls to lie completely flat before the other pair of walls is neatly folded over them, resulting in a minimal and very compact folded height.

[0021] Additionally or alternatively, in a further embodiment of the invention, the locking wing can be connected to the active wall via a W-shaped film hinge. The technical effect of the W-shaped hinge is that it allows the locking wing a folding angle of significantly more than 90° (up to approximately 270°). This advantage is crucial for compact folding: When the active wall is folded, the locking wing can be folded completely backward so that it lies flat and does not protrude laterally. This significantly minimizes the width of the folded wall package.

[0022] In a further embodiment of the hinged container according to the invention, an outer embossed line of the W-shaped film hinge is essentially aligned with the outer surface of the passive wall when the container is upright. The technical effect of aligning the outer embossed line with the outer surface of the passive wall is the precise positioning of the pivot point of the locking flap. The advantage is a perfect fit when closed. The locking flap rests against the passive wall without unwanted gaps or tension, ensuring a tight, secure seal and a tight corner.

[0023] In a further advantageous embodiment of the collapsible container according to the invention, the active walls and / or the passive walls are made of honeycomb panels, in particular of polypropylene. The advantage of choosing honeycomb panels is their extremely high stiffness-to-weight ratio. This ensures an optimal combination of two opposing requirements: the container is, on the one hand, very stable and rigid to withstand the high loads, and on the other hand, very lightweight, which allows for easy and ergonomic handling during folding and setup.

[0024] The aforementioned problem is also solved by a method for setting up or folding a collapsible container according to the invention, wherein, for setting up the collapsible container, the active walls and the passive walls are erected, the locking flaps are folded by 90° so that they overlap the passive walls and are placed against the outside of the respective passive wall, and wherein the locking flaps are attached to the respective passive wall by means of the locking mechanism. In this way, the controlled achievement of the stable, locked final state is possible. The aforementioned descriptions regarding the collapsible container according to the invention also apply accordingly to the method according to the invention.

[0025] In a first embodiment of the method according to the invention, it is provided that the locking mechanism is released to fold the collapsible container, whereby the locking wings are folded back by 90°, whereby the active walls and the passive walls are folded by 90°.

[0026] In a further advantageous embodiment of the method according to the invention, the active and passive walls are folded inwards immediately after the locking mechanism is released, without requiring any prior outward movement of the walls for unlocking. In other words, the walls can be folded directly inwards. Thus, no outward movement is necessary for unlocking. This allows for the use of tightly stretched textile compartments inside. This prevents the bags from sagging, protects the payload from damage, and represents a clear, commercially relevant difference compared to competing products that require greater tolerances in their internal construction.

[0027] Brief description of the characters

[0028] The invention is explained in more detail below with reference to an exemplary embodiment and accompanying drawings. The figures show:

[0029] Fig. 1a shows an upright collapsible container with a lid attached,

[0030] Figs. 1b-1c show the release of a locking mechanism of the hinged container and the folding back of locking wings against an active wall.

[0031] Figs. 1d-1e show the folding of the two active walls inwards,

[0032] Figs. 1f-1g show the subsequent folding of the two passive walls onto the already lying active walls,

[0033] Fig. 1 h shows the fully folded container with the lid replaced,

[0034] Fig. 2a shows the folded container from which the lid is lifted; Figs. 2b-2c show the erection of the two passive walls.

[0035] Figs. 2d-2e show the erection of the first active wall and the essential step of folding over and locking the locking wing on the outside of the passive wall,

[0036] Figures 2f-2g show the erection of the second active wall and its locking mechanism.

[0037] Fig. 2h shows the fully assembled and locked container, onto which the lid (6) is placed.

[0038] Detailed description of the invention

[0039] Figures 1a to 1h show a locking system for a collapsible container 1. The collapsible container 1 comprises two active walls 2, each of which may have rails and / or pockets (not shown). The collapsible container 1 also comprises two passive walls 3, each arranged perpendicular to the active walls 2. Locking flaps 4 are arranged on the active walls 2, and these flaps can be bent away from the active walls 2 such that they overlap at least part of a passive wall 3. A locking mechanism 5 is also provided for attaching a locking flap 4 to a passive wall 3.

[0040] The designation of the walls as "active" and "passive" derives from their primary function within the system. The active walls 2 are designed to support the actual payload, for example, in multi-layered textile bags. Due to the weight of the payload, which can be up to 300 kg, these walls are subjected to considerable tensile forces that pull them inwards. The passive walls 3 serve as static support elements that counteract this tension and absorb the pressure via the corner joints to ensure the rectangular shape of the container. Honeycomb polypropylene panels are the preferred material for walls 2 and 3 because they have a very high stiffness-to-weight ratio, making the container lightweight and ergonomically manageable despite its high stability.

[0041] In the present embodiment, the fastening mechanism 5 consists of hook-and-loop fasteners. However, snap fasteners or other suitable fastening means are also conceivable. The figures show that the fastening wings 4 have the same height as the passive walls 3. When attached to the passive walls 3, the fastening wings 4 are flush with the surface.

[0042] In a particularly advantageous embodiment, the locking mechanism 5 is designed as a robust, two-part injection-molded component. This consists of a "latch" mounted on the passive wall 3 and a "headpiece" attached to the locking wing 4. When closing, the headpiece is pressed into the latch and engages there in a positive-locking manner. To ensure a particularly high level of security against unintentional release, especially in the event of twisting of the container during transport or handling, the latch can have four retention points arranged in a cross shape. These secure the headpiece not only against tensile forces but also against torsional forces.

[0043] Furthermore, a lid 6 is provided, which can be placed on the folding container 1. The active walls 2 and the passive walls 3 are pivotally attached to a base element 7.

[0044] To enable smooth and as flat a folding process as possible, the hinges connecting the walls 2, 3 to the base element 7 are preferably arranged on different horizontal planes. For example, the hinges of the active walls 2 can be positioned higher than the hinges of the passive walls 3. This height difference prevents the wall edges from colliding during the folding process and allows the walls to be folded neatly and overlapping, resulting in a minimal overall height of the folded container.

[0045] Figures 1a to 1h illustrate a multi-step method for folding a collapsible container 1. To fold the collapsible container 1, the locking mechanism is released, the locking wings 4 are folded back by 90°, and the active walls 2 and the passive walls 3 are folded by 90°.

[0046] Figure 1a shows in more detail that the cover 6 is first lifted off. In Figure 1b, the locking flaps 4 are detached from the passive walls 3; that is, the connection between the walls is separated by opening the locking mechanism 5. In Figure 1c, the locking flaps 4 are folded against the active wall 2 at the rear. Figure 1d shows that the active wall 2 is folded downwards. Figure 1e shows how the same process is repeated for the opposite active wall 2. In Figure 1f, the first passive wall

[0047] 3 is placed on top of the already folded active walls 2. In Figure 1g, the second passive wall 3 is placed on top of the already folded active walls 2. Finally, in Figure 1h, the lid 6 is placed back onto the folded container 1.

[0048] A crucial detail for compact folding is the design of the connection between the active wall 2 and the locking wing 4. This is advantageously designed as a W-shaped film hinge. Such a hinge allows a folding angle of significantly more than 90° (up to approximately 270°). This allows the locking wing to

[0049] 4, as shown in Figure 1c, can be folded completely backwards so that it lies flat against the outside of the active wall 2 and does not protrude laterally. This significantly reduces the width of the folded wall package.

[0050] Figures 2a to 2h show the assembly of the folded collapsible container 1. The active walls 2 and the passive walls 3 are erected, with the locking flaps 4 being folded by 90° so that they overlap the passive walls 3 and are placed against the outside of each passive wall 3. The locking flaps 4 are then attached to the respective passive wall 3 by means of the locking mechanism 5.

[0051] Figure 2a shows in more detail how the lid 6 is lifted from the folded container 1. Figure 2b shows the first passive wall 3 being erected, and Figure 2c shows the second passive wall 3 being erected. Figure 2d shows the erection of the first active wall 2. In Figure 2e, the first active wall 2 is attached to the passive wall 3 by folding over the locking flaps 4 and engaging them with the locking mechanism 5. Figure 2f then shows the erection of the second active wall 2. Finally, Figure 2g shows the second active wall 2 being locked to the passive walls 3 by folding over and engaging the locking flaps 4.

[0052] Finally, in Figure 2h, the lid 6 is placed back onto the erected folding container 1.

[0053] The invention has the advantage that a statically clean force transmission of the entire train from the active to the passive walls along the entire contact surface is enabled.

[0054] If the locking flaps are advantageously pulled all the way to the top, i.e., made flush with the top edge of the walls, the lid placed on top and its surrounding rim provide additional protection against unintentional opening of the locking flaps.

[0055] Furthermore, the container's structural integrity is stabilized by "double-walled corners." By attaching the side wings of the active wall to the passive wall, the material in these areas is doubled, thus stiffening the structure.

[0056] Design of precisely tensioned pocket systems: When folding, the side panels are simply detached from the passive walls and folded back. This disconnects the walls and allows the container to be folded compactly. During the unlocking process, the walls remain in their fixed, defined position and can be folded downwards in a controlled manner after unlocking (folding the side panels away). In contrast, many systems on the market require the active walls to first be moved away from the passive walls outwards to release the lock, and only then, once unlocked, to be folded in the opposite direction. However, this necessitates larger tolerances in the compartments when using textile dividers within the container to accommodate this initial outward movement.This leads to a significant loss of tension in the pockets / compartments during transport, causing them to become unstable and sag. This sagging can lead to collisions between layers and thus damage to the payload during transport.

Claims

Patent claims 1. Folding container (1) with a locking system, wherein the folding container (1) comprises at least two active walls (2), wherein the folding container (1) comprises at least two passive walls (3), wherein the passive walls (3) are arranged perpendicular to the active walls (2), wherein locking wings (4) are arranged on the active walls (2), wherein the locking wings (4) are deflectable from the active walls (2) such that they overlap at least a part of the outside of a passive wall (3), wherein a locking mechanism (5) is provided to attach a locking wing (4) to a passive wall (3).

2. Folding container (1) according to claim 1, wherein rails and / or pockets are arranged on the active walls (2).

3. Folding container (1) according to claim 2, wherein the rails are designed as aluminium linear rails on which payload carriers are mounted horizontally displaceable by means of sliders.

4. Folding container (1) according to claim 3, further comprising a reinforcement frame which, in the erected state of the container, is arranged between the opposing active walls (2) and rests directly against the aluminium linear rails to push them apart and prestress the system.

5. Folding container according to claims 1 to 4, wherein the closure mechanism (5) comprises snap fasteners and / or hook and loop fasteners.

6. Folding container (1) according to one of claims 1 to 4, wherein the locking mechanism (5) is designed as a two-part injection-molded part comprising a latch arranged on the passive wall (3) and a head piece arranged on the locking wing (4) which engages positively in the latch.

7. Folding container (1) according to claim 6, wherein the trap has four cross-shaped arranged It has retaining points to prevent unintentional loosening when the container twists.

8. Folding container (1) according to any one of claims 1 to 7 wherein the closing wings (4) have the same height as the passive walls (3) and wherein the closing wings (4) are flush with the passive walls (3) when the closing wings (4) are attached to the passive walls (3).

9. Folding container (1) according to one of claims 1 to 8, wherein a lid (6) is provided which can be placed on the folding container (1) and whose circumferential rim overlaps the upper edges of the flush closing locking wings (4) and thereby additionally secures them against unintentional opening.

10. Folding container (1) according to one of claims 1 to 9, wherein a square base element (7) is provided and wherein an active wall (2) or a passive wall (3) is pivotably attached to each side of the base element (7).

11. Folding container (1) according to claim 10, wherein the hinges connecting the active walls (2) and the passive walls (3) to the base element (7) are designed such that the pair of hinges of the active walls (2) lies in a different horizontal plane than the pair of hinges of the passive walls (3) to allow overlapping and interference-free folding of the walls.

12. Hinged container (1) according to one of the preceding claims, wherein the closure wing (4) is connected to the active wall (2) via a W-shaped film hinge (9).

13. Folding container (1) according to claim 12, wherein an outer embossing line of the W-shaped film hinge (9) lies substantially in line with the outside of the passive wall (3) when the container is erected.

14. Collapsible container (1) according to one of the preceding claims, wherein the active walls (2) and / or the passive walls (3) are made of honeycomb panels, in particular of polypropylene.

15. Method for setting up or folding a collapsible container (1) according to any one of claims 1 to 14, wherein for setting up the collapsible container (1) the active walls (2) and the passive walls (3) are set up, wherein the locking wings (4) are folded by 90° so that they overlap the passive walls (3) and are placed on the outside of the respective passive wall (3) and wherein the locking wings (4) are attached to the respective passive wall (3) by means of the locking mechanism (5).

16. Method according to claim 15, wherein to fold the collapsible container (1) the locking mechanism (5) is released, wherein the locking wings (4) are folded back by 270°, wherein the active walls (2) and the passive walls (3) are folded by 90°.

17. Method according to claim 16, wherein the active walls (2) and the passive walls (3) are folded inwards immediately after the release of the locking mechanism (5), without requiring a prior outward movement of the walls (2, 3) for unlocking.

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