Note: Descriptions are shown in the official language in which they were submitted.
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TITLE: FOLDABLE PALLET-MOUNTED CONTAINER
FIELD OF THE INVENTION
This invention pertains to foldable pallet-mounted containers and
more particularly, the present invention pertains to foldable pallet-mounted
paperboard boxes that have shallow bases for reinforcing the lower
perimeter thereof during use and for protecting the folded boxes during
shipment and storage.
BACKGROUND OF THE INVENTION
Foldable pallet-mounted containers are used for shipping a variety
of goods such as bulk material in ag~egate, fibrous or powdery form, food
in bags or pouches, commodities packed in small boxes and loose
components used in assembly lines. Paperboard pallets and containers are
generally preferred by the environment-conscious users, because this
material is entirely recyclable. Corrugated paperboard material, however,
is not as durable as wood, composite materials or metal, and the design of
a container made with it requires additional ingenuity to ensure that the
useful life of the container will be comparable or superior to the duration
of those made with the conventional materials.
A first example of a foldable pallet-mounted container of the prior
art is illustrated and described in US Patent 4,383,609 issued on May 17,
1983 to Eugene C. Lochmiller. The container of this invention comprises
a corrugated cardboard base which is built into a wooden pallet, and a
rectangular corrugated cardboard sleeve which is adapted to slide over the
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base and to vertically interlock with the base. A cover member fits over the
rectangular sleeve to form with the sleeve and the base, a closed container
integrally mounted to a wooden pallet.
In a second example of a foldable container of the prior art, US
Patent 4,927,026 issued on May 22, 1990 to Haas K. Gossler and Charles
P. Roberts, discloses a corrugated cardboard box affixed to a wooden
pallet. The box is made of two parts. The first part comprises a floor and
four vertically extending flaps. The second part is a rectangular tubular
member that fits over the four flaps, thereby forming a double layered
container.
Another type of collapsible corrugated board container is described
in US Patent 5,318,219 issued on June 7, 1994 to Glenn M. Smith. In this
invention, an integral corrugated cardboard box is stapled to a pallet and is
foldable in a compact flat form. The bottom portion of the box is foldable
over itself to allow opposite sides of the box to lay parallel over top of one
another.
A further example of a foldable container is described in US Patent
5,441,154 issued on August 15, 1995 to Donald R. Youell, III. The
paperboard container and pallet system described therein comprises a
shallow deck portion mounted on hollow cardboard runners, a wall-forming
portion and a cover. The wall-forming portion has locking tabs on its
lower edge, and these tabs are adapted to lock into matching slots through
the deck portion and the hollow runners. Notches are provided in the
hollow runners for selectively releasing the locking tabs from the deck
portion and refolding the wall-forming portion of the container into the
deck portion.
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It is believed that a first preferred requirement by the industry
regarding foldable pallet-mounted containers is that the wall forming
portion should be an inte~al part of the base portion such that the box
portion is inseparable from the base portion throughout the life of the
container. A second preferred requirement by the industry is believed to
be that the container should be foldable without having to manipulate the
pallet, or otherwise reach under the pallet and into intricate cavities to
undo
locking tabs. Similarly, it is believed that a third preferred requirement by
the industry is that the deployed container has sufficient strength for
resisting lateral internal pressure associated with a loading thereof with
heavy granular material for example. Finally, another preferred
requirement by the industry is believed to be that the corrugated board
container is securely foldable to avoid damages during transport back to the
original filler.
The foldable containers of the prior art are believed to be deficient
at least one of the above preferred requirements, and it is this reason
basically that has contributed to the development of a market demand for
better foldable containers capable of resisting the loading of a variety of
products and in particular, that can be used for a relatively large number of
shipping-returning cycles.
SUMMARY OF THE INVENTION
In the present invention, however, there is provided a foldable
pallet-mounted container that is easy to deploy and to fold down without
instructions, that has stiffening members to provide strength against lateral
internal loading caused by ~anular or similar loose loads, and that is sturdy
enough to resist the stresses of several ship and return cycles.
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In accordance with a first aspect of the present invention, there is
provided a foldable pallet-mounted container comprising a shallow base
mounted on a pallet, a foldable box mounted inside the shallow base, and
a flanged cover having overall dimensions to fit over the shallow base, for
covering the shallow base when the foldable box is folded inside the
shallow base, and for covering the foldable box when the foldable box is
deployed.
The shallow base is made of corrugated board material and
comprises a horizontal planar member having four straight edges defining
l0 four right angle corners. The shallow base also comprises a pair of single-
pleated uprising side members connected to and along a pair of opposite
edges of the planar member. Each uprising side member has a reinforcing
flap member connected thereto and overlapping the horizontal planar
member. The foldable box is also made of corrugated board material, and
comprises first and second side panels and first and second end panels and
a first liner member connected to the horizontal planar member of the
shallow base and to the first end panel. The pallet is made of a plurality of
runners and a plurality of rails affixed to the runners in a perpendicular
relation therewith, the runners and rails are made of laminated strips of
corrugated board.
A primary advantage of the above-described structure is that when
the foldable box is deployed, the side and end panels of the box are
retainable between the uprising side members of the shallow base and
inside the flanged cover for resisting horizontal shear stresses producible
by a content of the foldable box.
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Another advantage of this structure is that when the foldable box is
folded inside the shallow base and cover, the foldable box is protectable
against the shearing, tearing and crushing stresses normally associated with
the handling and storing of foldable containers, especially when the
foldable containers are handled or piled in stacks.
In accordance with another aspect of the present invention, there is
provided a foldable container comprising a shallow base made of
corrugated board and having a horizontal planar member having four
straight edges defining four right angle corners. The shallow base also has
l0 first and second pairs of single-pleated uprising side members connected
to and along corresponding pairs of opposite straight edges of the
horizontal planar member, and a template member laid over the horizontal
planar member and defining with three of the uprising side members a
recess bordering the horizontal planar member. The foldable container of
this aspect of the present invention also comprises a foldable box mounted
inside the shallow base. The foldable box is also made of corrugated
board. The foldable box has first and second side panels and first and
second end panels and a first liner member connected to the horizontal
planar member of the shallow base and to the first end panel. Each of the
first and second side panels and second end panel has a lower edge and a
nominal thickness, this nominal thickness is less than a width of the recess
such that when the foldable box is deployed, the lower edges of the
foldable box are securable in the recess for retaining the foldable box in a
deployed mode.
The foldable container of the present invention is easily operable
from a folded mode to a deployed mode by a user standing beside the
container, without having to reach under or otherwise manipulate the base
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of the container. The operation of the container of the present invention
is understandable in a glance and written instruction to a first user are
normally not required.
In accordance with yet another aspect of the present invention, the
foldable container and the foldable pallet-mounted container of the present
invention are entirely made of corrugated board material joined with
adhesive. These constructions do not contain staple or other metal or
plastic fastener. The adhesive used in the manufacture of the foldable
containers and pallets is a water-based pulpal glue. Therefore, the foldable
l0 containers and pallets of the present invention are entirely recyclable
after
their useful life.
The foldable pallet-mounted container and the foldable container of
the present invention are further more durable than the foldable pallet-
boxes of the prior art. Experience has shown that some of the pallet-boxes
of the prior art are usable only for 1-2 ship-return cycles, wherein the
foldable pallet-mounted containers of the preferred embodiments have
averaged in many instances, up to 6-7 ship-return cycles before being
replaced.
BRIEF DESCRIPTION OF THE DRAWINGS
Other advantages of the invention will be apparent from the
following description of the preferred embodiments illustrated in the
accompanying drawings, in which:
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- FIG. 1 is a perspective view of the foldable pallet-mounted
container of the first preferred embodiment showing the container
in a partly folded position and the cover thereof in an exploded view
mode above the container;
- FIG. 2 is a perspective view of the foldable pallet-mounted
container of the first preferred embodiment showing the container
in a fully deployed and usable mode;
- FIG. 3 is a longitudinal cross-section view through the foldable
pallet-mounted container of the first preferred embodiment showing
the foldable box in a collapsed mode inside the shallow base;
- FIG. 4 is also a longitudinal cross-section view through the foldable
pallet-mounted container of the first preferred embodiment, as seen
from a same location as in FIG. 3, but with the foldable box in a
fully deployed mode and the flanged cover installed thereon, such
1 S as would be seen along line 4-4 in FIG. 2;
- FIG. 5 is a plan view of the foldable pallet-mounted container of
the first preferred embodiment without the cover;
- FIG. 6 is a transversal cross-section view through the foldable
pallet-mounted container of the first preferred embodiment in a fully
deployed mode, as seen along line 6-6 in FIG. 2;
- FIG. 7 is an enlarged view of a typical overlapping of a side panel
of the foldable box over an end panel, as seen in detail circle 7 in
FIG. 5;
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- FIG. 8 is an enlarged cross-section view of the forming of the
shallow base of the foldable pallet-mounted container of the first
preferred embodiment as seen in detail circle 8 in FIG. 6;
- FIG. 9 is an enlarged plan view of the typical double-crease fold
foamed in a side panel of the container of the first preferred
embodiment as seen in detail circle 9 in FIG. 5;
- FIG. 10 is a flat pattern of the shallow base of the foldable pallet-
mounted container of the first preferred embodiment;
- FIG. 11 is a perspective view of the foldable pallet-mounted
l0 container of the second preferred embodiment without a flanged
cover;
- FIG. 12 is a plan view of the foldable pallet-mounted container of
the second preferred embodiment;
- FIG.13 is a cross-section view through the foldable pallet-mounted
container of the second preferred embodiment as seen along line 13-
13 in FIG. 12;
- FIG. 14 is a flat pattern of the shallow base of the foldable pallet-
mounted container of the second preferred embodiment;
- FIG. 15 is a perspective view of the foldable pallet-mounted
container of the second preferred embodiment showing the foldable
box being pulled out of the shallow base, thereby illustrating a first
step in opening the container;
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- FIG. 16 is a perspective view of the foldable pallet-mounted
container of the second preferred embodiment showing the folded
wall-forming portion being extended into an open position, thereby
illustrating a second step in opening the container;
- FIG. 17 is a perspective view of the foldable pallet-mounted
container of the second preferred embodiment showing the foldable
box is a fully deployed mode;
- FIG. 18 is a perspective view of the foldable pallet-mounted
container of the second preferred embodiment in a fully deployed
l0 mode with a flanged cover mounted thereon;
- FIG. 19 is a perspective view of the foldable pallet-mounted
container of the second preferred embodiment with one end of the
foldable box being lifted up, thereby illustrating a first step in
folding the container;
- FIG. 20 is a perspective view of the foldable pallet-mounted
container of the second preferred embodiment with the foldable box
in a collapsed mode prior to folding it down into the shallow base,
thereby illustrating a second step in folding the container;
- FIG. 21 is a perspective view of the pallet used with the foldable
pallet-mounted container of the first preferred embodiment;
- FIG. 21A is an enlarged view of the interlocking of a rail and a
runner in the pallet illustrated in FIG. 21, as shown in detail circle
21A in FIG. 21.
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DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The foldable pallet-mounted container 20 of the first preferred
embodiment is illustrated in a partially folded mode in FIG. 1, and in a
deployed mode in FIG. 2. The foldable pallet-mounted container 20
comprises broadly; a pallet 22, a shallow base 24 mounted on the pallet 22,
a foldable box 26 mounted inside the shallow base 24, and a flanged cover
28 for covering the shallow base 24 when the foldable box 26 is folded
inside the shallow base, or for covering the upper side of the foldable box
26 when the foldable box is fully deployed.
1 o The pallet 22 is made of a double-ply corrugated board top planar
member 30; a plurality of transversally extending laminated multi-ply
corrugated board runners 32 equally spaced and glued to the underside of
the top planar member 30; and a plurality of laminated mufti-ply corrugated
board rails 34 glued perpendicularly to and under the runners 32.
The runners 32 are preferably aligned perpendicularly to the
corrugations in the top planar member 30, and the corrugations in the
runners 32 and rails 34 are preferably aligned vertically when the pallet is
in use. The runners 32 are aligned along a transversal orientation of the
foldable pallet-mounted container 20 of the first preferred embodiment, and
the rails 34 are aligned along a longitudinal orientation thereof. The
runners 32 and rails 34 each preferably comprises about eighteen to twenty
( 18-20) plies of corrugated board.
The shallow base 24 of the foldable pallet-mounted container 20 of
the first preferred embodiment is made of single-ply corrugated board and
is glued to the top planar member 30 of the pallet 22. The single-ply board
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of the shallow base 24 is folded to form a shallow receptacle having the
sides extending at a height 'A' of about 4-3/4 inches ( 12 cm) above the top
planar member 30.
The corrugations in the shallow base 24 are aligned transversally
relative to the foldable container 20, as indicated by label 'B' in FIG. 10.
The uprising side members 40 of the shallow base 24 as illustrated in
FIGS. 8 and 10, are folded along bend lines 42 to form a single pleat 44
having a reinforcing flap member 46 overlapping and being glued to the
bottom surface 48 of the shallow base 24. The width 'C' of the reinforcing
l0 flap member 46 is preferably about 4-3/4 inches (12 cm). The uprising end
members 50,52 of the shallow base 24 are made of a single-ply planar
member and are bent along bend lines 54 as illustrated in FIG. 10. The
end members 50,52 each has at each end thereof, a tab 56 the length of
which extends the full flat width of the single-pleated uprising side member
40 and the width of the flap member 46. Upon forming the shallow base
24, each tab 56 is tucked inside the pleat 44 in a respective end of an
uprising side member 40 for reinforcing each corner of the shallow base 24.
The structure of the flanged cover 28 is identical to the structure of
the shallow base 24 except that the inside dimensions of the cover 28 are
slightly larger than those of the base 24, such that the flanged cover 28 fits
over the shallow base 24 for covering the shallow base completely when
the foldable pallet-mounted container 20 of the first preferred embodiment
is in a collapsed form and is returned to a supplier for reuse for example.
This feature prevents possible damage to the foldable container, which
could occur during handling and transport of the folded container,
especially when several containers are stacked on top of one another.
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Referring back to FIGS. 1 and 2, the foldable box 26 of the pallet-
mounted container of the first preferred embodiment is made of two side
panels 60,62 and two end panels 64,66. The side and end panels are made
of a triple-ply corrugated board having a nominal thickness of about 0.5
inch ( 12 mm) and wherein the corrugations are aligned vertically when the
foldable box is deployed. The two side panels 60,62 each has three vertical
folds 70,72,74 and 70',72',74' in a central and end portions thereof
respectively and are foldable inside the box as illustrated in FIG. 1. Each
fold 70,72,74,70',72' or 74' in the side panels is preferably a double crease
fold having a width 'D' of about 1-1/4 inches (32 mm), as illustrated in
FIG. 9. This feature is to prevent a deterioration of the folds when the
foldable container of the first preferred embodiment is re-used many times.
With reference to FIG. 4, the first end panel 64, hereinafter referred
to as the outside end panel, has an outside liner portion 64' extending
therefrom and overlapping the inside horizontal surface 48 of the shallow
base 24, and is glued to the inside surface 48 of the base 24. The second
end panel 66, hereinafter referred to as the inside end panel has an inside
liner portion 66' which is foldable inside the foldable box about a crease 80
along a lower edge of the foldable box, and toward and away from the
inside end panel 66.
Referring now particularly to FIGS. 3 and 4, a longitudinal cross-
section view of the foldable box 26 of the first preferred embodiment is
shown therein with the box 26 in a folded mode and in a fully deployed
mode respectively. The foldable box 26 is set inside the shallow base 24
to fold and unfold along the longitudinal direction of the base 24 as
illustrated in FIG. 3. In that respect, the inside length 'L' of the shallow
base 24 is longer than the height 'H' of the foldable box, by at least a first
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gap 'E', which is equivalent to the collapsed thickness of the foldable box
26. When the foldable box 26 is made of triple-ply corrugated board
material as for the foldable box of the first preferred embodiment, the
dimension of the first gap 'E' is between about 4-1/2 inches ( 11.4 cm) and
about 5 inches ( 12.7 cm) and most preferably about 4-3/4 inches ( 12 cm).
The first gap 'E' allows for the unfolding of the foldable box 26
about a first transversal crease 76 across the outside end panel 64-64', in a
direction represented by arrow 78 in FIG. 3. After the foldable box 26 has
been fulded upwardly about crease 76 over an angular distance of 90°,
the
l0 inside end panel 66 is movable longitudinally relative to the outside end
panel 64 in order to extend the side panels 60,62 and to deploy the foldable
box 26 fully as illustrated in FIGS. 2 and 4.
The minimum dimension of a second gap 'F' in the shallow base 24
as shown in FIG. 3 is preferably about one inch (2.5 cm) to facilitate the
insertion of one's forgers therein to grasp an upper edge of the foldable box
26, and to tilt the foldable box 26 up from the shallow base 24, as
described above. It will be appreciated, however, that the width of this
second gap 'F' can be wider than one inch (2.5 cm) to accommodate
foldable oblong boxes that have a length 'L' dimension which is greater
than their height 'H'.
Common dimensions for the foldable box 26 of the preferred
embodiments and the corresponding dimensions for gap 'F' are as follows,
when making reference to FIGS. 3-6.
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Product # Length 'L' Width 'W' Height 'H' Gad 'F'
001 44.75 in. 32 in. 34 in. 6 in.
( 114 cm) (81 cm) (86 cm) ( 15 cm)
002 46.5 in. 46 in. 40 in. 1.5 in.
( 118 cm) ( 117 cm) ( 102 cm) (4 cm)
When the foldable box 26 is fully deployed as illustrated in FIG. 4,
the inside liner portion 66' is foldable downward against the outside liner
portion 64'. The folding down of the inside liner portion 66' about the
second transversal crease 80, pushes of the folds 70,70' in the side panels
outwardly and prevents the side panels 60,62 from folding back in. When
the inside liner portion 66' is overlapping the outside liner portion 64', the
foldable pallet-mounted container of the first preferred embodiment has a
bottom portion comprising, over a major area thereof, nine plies of
corrugated board. This characteristic of the container of the first preferred
I S embodiment is particularly advantageous for providing relatively large
bending strength in the base of the container when supporting heavy
fragmented loads inside the container 20.
There is also provided a string or strapping 90 connected to the
inside liner portion 66' of the end panel, and to the upper edge of the inside
end panel 66. The strapping 90 is useful for lifting the inside liner portion
66' upwardly while standing near the inside end panel 66, and for allowing
an easy folding of the foldable box 26. The lifting of the inside liner
portion '66 and the folding of the box 26 is doable by one person initially
standing near the inside end panel 66, by lifting the inside liner portion
66',
by pushing the inside end panel 66 toward the outside end panel 64, and by
folding the folded box 26 down against the bottom surface 48 of the
shallow base 24, as will be described later when making reference to FIGS.
15-20.
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The flanged cover 28 is then placed over the base 24 for protecting
the shallow base 24 and the folded box 26 therein against damage during
transpolrt of the folded container 20 to the original filler of the container
20,
or during handling and storage of the container 20.
Referring now to FIGS. 6 and 8, the deployed box 26 of the first
preferred embodiment is particularly strong to resist transversal shear
stresses therein, for being contained inside the pleats 44 and reinforcing
flap members 46 of the shallow base 24, and inside the rim member 92 of
the flanged cover 28.
l0 When looking at FIGS. 4, 5 and 7, one will appreciate that the
deployed box, and in particular the lower region thereof also has generous
strength in a longitudinal direction, for having its end panels 64,66,
connected to the inside and outside liner portions 64',66' which when the
container is being used, are laid over top of one-another against the bottom
surface 48 of the container and are covered, usually, by the material
contained inside the container. Furthermore, the end panels 64,66 are
connected to the side panels 60,62, by overlapping and gluing the side
panels to the end panels as illustrated in FIGS. 5 and 7. The preferred
overlapping distance'G' is about 6 inches (15 cm) to ensure a strong bond
between the sides and end panels and a good circumferential tensile
strength of the foldable box 26 of the first preferred embodiment. The
construction thus described is particularly advantageous for transporting
material in bulk form or loose articles where horizontal shear strength in
the container is required.
It will be appreciated that the configuration of the pallet 22 is not
intended to constitute structural limitations to the present invention. The
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foldable container 20 of the first preferred embodiment may be used
without the pallet 22, for mounting on a separate wooden pallet or plywood
board for examples, or for mounting on a corrugated board pallet differing
from the described pallet 22. The foldable container of the first preferred
embodiment may also be used without a pallet, as a stationary container or
otherwise. Such alternate embodiments are considered to be within the
scope of the present invention wherein all the above-described advantages
are nonetheless obtained.
Refen-ing now to FIGS. 11-14, there is illustrated therein a second
preferred embodiment of the present invention. The dimensions of the
foldable pallet-mounted container of the second preferred embodiment 100
are similar to those of product no. 002 shown on a previous page. The
operation of the foldable pallet-mounted container of the second preferred
embodiment 100 does not differ substantially from the foldable pallet-
mounted container of the first preferred embodiment 20. Slight variations
in the structure of the second embodiment 100 are found in the pallet 120,
in the shallow base 130 and in the construction of both the inside and
outside end panel members 140,150.
2o The pallet 120 of the container of the second preferred embodiment
is comprised of three runners 122 secured to the bottom surface of the
shallow base 130. Here again, the pallet 120 is optional and the container
100 is usable without it. Each runner 122 is made of a plurality of
corrugated board layers stacked side by side and the corrugations in each
layer al-e ali~ed vertically. Each runner 122 has a width of about 4 inches
( 10 cm) and a height of about 3 inches (8 cm). The floor-contacting
surface of each runner is covered by a single strip 124 of corrugated board
laid against the edges of the plurality of layers described above.
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The shallow base 130 of the foldable pallet-mounted container 100
of the second preferred embodiment is made of a single ply corrugated
board. The alignment of the corrugations in the paperboard sheet of the
shallow base 130 as indicated by label 'J' in FIG. 14 is transversal to the
recommended placement of the runners as represented by labels 122' in
FIG.14. This arrangem~;nt provides greater stiffness to the bottom surface
of the base 130 when the container is lifted by a forklift truck for example.
Referring particularly to FIGS. 13 and 14, the side members
152,154 of the shallow base 130 are folded over to form a double-ply
arrangement defining a cavity 160 which has a same function as the pleat
44 as previously described, that is to receive and retain a tab 156 in each
corner of the base 130 for interlocking the corners of the shallow base. The
inside edge of each side member 152,154, has a series of tabs 157 thereon
which are spaced apart ~ nd sized to be inserted into corresponding slots
158, in the bottom surface 162 of the shallow base for retaining the side
members 152,154 in a folded mode as illustrated in FIG. 13.
The outside end member 140 of the foldable container of the second
preferred embodiment is made of two layers 164,174 or 166,176 of
corrugated board each having three plies. The outside end panel member
164 has an outside liner portion 164' extending over the bottom surface 162
of the base and is glued t~o the base 130, in a same way as the container of
the first preferred embodiment 20. Un top of the outside liner portion 164',
there is provided an additional layer 168 of triple-ply corrugated board
glued to the outside liner portion 164', hereinafter referred to as the
template member :168. Tl~e overall dimensions ofthe template member 168
are smaller than the inside dimensions of the shallow base 130, such that
there is a gap 'K' of at least about one inch (2.5 cm) defined between the
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edges of the template member 168 and the sides 152,154 of the shallow
base 130. When the foldable box portion 170 of the container of the
second preferred embodiment is deployed, the lower edges of the foldable
box portion 170 are inserted in the gap 'K' to retain the folds 172,172' of
the box in a straight alignment and to retain the foldable box 170 in an
opened configuration.
The foldable box portion 170 is made of two foldable panels
174,176 made of triple-ply corrugated board that are joined at vertical
joints 178,180 on a respective end panel 140,150. The foldable panels
174,176 overlap the outside end panel member 164 and the inside end
panel member 166 entirely. Both vertical joints 178,180 are diametrically
opposite relative to the perimeter of the foldable box 170, such that both
foldable panels 174,176 are symmetrical, easy to manufacture and easy to
assemble.
Referring now to FIGS. 15-20, there is illustrated therein a preferred
method for deploying and folding the foldable pallet-mounted container of
the second preferred embodiment. It will be appreciated that this method
also applies to a feat extent, to the foldable pallet-mounted container of
the first preferred embodiment.
Starting with FIG. 15, the foldable box 170 is tilted upwardly from
the shallow base 130, about the lower edge of the outside end panel 140,
in a direction represented by arrow 184. The angle of tilting the container
is substantially a right angle, or slightly more, one or two degrees for
example, to allow the inside end panel 150 to slide over the template
member 168 covering the bottom surface of the shallow base 130. The
inside end panel 150 is then pulled away from the outside end panel 140 in
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a direction indicated by arrow 186, to cause the folds 172,172' to stretch
and alum straight. When the box 170 is fully stretched, the lower edges of
the box drop into the gap 'K' around template member 168, such that the
box remains in an opened configuration as shown in FIG. 17. A flanged
cover 188 is then placed over the open side of the box to protect the content
of the foldable box 170.
The folding of the container prior to storing it or sending it back to
the original filler for example is initiated by slightly lifting the foldable
box
170 and tilting it about the lower edge of the outside end panel 140 as
indicated by arrow 190 in FIG. 19, and pushing the inside end panel 150
against the outside end panel 140, as indicated by arrow 192. When the
inside end panel 150 is folded against the outside end panel 140, the folded
box 170 may then be tilted down into the shallow base 130 in a direction
as indicated by arrow 194 in FIG. 20, with the inside end panel 150 laying
against the template member 168. The folded box 170 and shallow base
130 are then preferably covered with the flanged cover 188 for protecting
the folded box 170 during shipment and storage, especially when two or
more foldable containers are stacked over one-another. The methods
described above for deploying or folding the container of the second
preferred embodiment are easily effected by one person while standing
near the foldable container. This person does not have to reach under the
base 130 or otherwise manipulate the pallet 120.
The method described above does not require detailed instruction or
much training to teach a new user how to deploy one of the containers of
the preferred embodiments. The resiliency of the folds 172,172' forces the
folded box 170 to open as soon as the folded box reaches an upward
position. A further pulling on the extendible end 150 of the box causes the
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lower edge of the box to fall into the gap 'K' around the template member
168, thereby keeping the box from folding back. For the foldable container
of the first preferred embodiment, the pulling on the extendible end 66 of
the box causes the inside liner portion 66' to fall down, thereby preventing
the box from folding back in. Once a person has deployed one of the
foldable containers of the preferred embodiments, it is relatively easy for
that person without having recourse to written instruction, to reverse the
above procedure and to fold the container back into a collapsed mode.
Referring now to FIGS. 21 and 21A the pallet 22 mounted under the
foldable pallet-mounted container of the first preferred embodiment is
illusri~ated therein in order to describe an important structural
characteristic
thereof. As it was mentioned earlier, this pallet 22 as well as the foldable
containers of the first and second preferred embodiments are manufactured
with a water-based pulpal glue. The preferred glue is a type known in the
industry under the tradename of SWIFT 47206 TM manufactured by or for
Reichhold Chemicals, Inc. of P.O. Box 13582, Research Triangle Park,
North Carolina, 27709, U.S.A. The glueing process is a cold process
wherein the glue is applied and the curing is done at ambient temperature.
The gluing of the runners 32 to the rails 34 is done under sufficient
pressure to interlock the runners 32 and the rails 34 together. Sufficient
pressure means a pressure that can cause a deformation 'M' in the runners
32 and a deformation 'N' in the rails 34 of about 1/8 inch (3 mm) in each
sul-face, such that the interlocking engagement is a stress-related, mutually-
induced double deformations having a total depth of at least about 1/4 inch
(6 mm). This type of interlocking engagement has been found to be
advantageous for providing superior shear and bending strength in the
pallet of the preferred embodiment, as compared to conventional
CA 02247655 1998-09-16
col-~~u~;ated board pallets. As an example, conventional corrugated board
pallets have a typical loading capacity of about 500 lbs. (227 kg) in racking
mode, that is supported on both outside rails only. The pallet of the
prefel-~~ed embodiment 22 with the described interlocking engagement and
the specified adhesive has a capacity in racking mode of 2200 lbs. ( 1000
kg). This feature is also appreciable for providing a pallet 22 with greater
lateral or diagonal compression strength, better resistance to shocks and
rough handling and a longer useable life as compared to the conventional
corrugated board pallets.
l0 While the preferred embodiments of this invention were described
as being made of corrugated board, other materials are also contemplated
by the inventor of the present invention, and are considered to be within the
scope of this invention. For examples, it is believed that the foldable
containers and pallets of the present invention and similar structures
l5 embodying the innovative features described herein can be manufactured
with materials such as paperboard, cardboard, fiberboard, wood board,
plastic sheet, plastic moulding, fiberglass, plywood, pressed wood, sheet
metal, fabric or similar flexible material mounted over a rigid frame or
similar materials or similar composite structures. It will also be appreciated
20 that various modifications, alternate construction and equivalents may also
be employed without departing from the true spirit and scope of the
invention. Therefore, the above description and accompanying illustrations
should not be construed as limiting the scope of the invention which is
defined by the appended claims.
21
