[0001] This invention relates to palletized containers.
[0002] Palletized containers of various descriptions have been widely known and used for
many years. Although corrugated board containers incorporating integral pallet components,
for example, as described in Australian Patent No. 426,164 (AU-B 23812/67), have been
widely used with success for many years, the need has developed for palletized containers
in which the pallet structure is relatively rigid and may, for example, be constructed
from timber components.
[0003] A palletized container of the above type is described in greater detail in Australian
Patent No. 505,345 (AU-B 23926/77) in which a hinged flap having the same dimensions
as the bottom of the container is attached to the pallet construction and the flap
is then engaged between two of the bottom flaps of the container and is held in position
by the container and its contents.
[0004] This type of palletized container has shortcomings in that the container, particularly
when empty, partially filled or enclosing a light load is capable of being displaced
laterally in one direction and may therefore be detached from the pallet construction.-
[0005] This problem has been overcome by the proposal of U.S. Patent No. 4,085,846 by Williams,
in which the floor of the container is attached directly to the pallet and is positively
located in use by folded base flanges of the container. However, this arrangement
suffers from the disadvantages that notches must be cut in the end base flanges to
facilitate entry of the folded floor components and the floor components must be held,
either manually or by means of a holding peg, during the assembly process. The notches
create regions of weakness in the assembled container and the requirement for a holding
means is generally inconvenient.
[0006] A similar arrangement, having an integral means for holding the folded floor components
in their folded condition, is shown in French specification 2,500,810 (82 01857).
However, the same disadvantages are apparent.
[0007] It is the object of the present invention to provide an improved palletized container
construction in which the above problems are at least reduced.
[0008] One aspect of the invention provides a palletized container comprising a pallet structure
and a container adapted to be secured to said pallet structure, said container comprising
side walls and top closing flaps for at least part of the top of the container if
required, bottom flaps which fold inwardly of the container from the side walls and
defining a generally rectangular opening in the base of the container, and at least
one base pad having a portion secured to or integral with said pallet structure and
being shaped to be disposed in use internally of the bottom flaps and adjacent at
least portions of each side wall to limit lateral movements of said container when
engaged therewith in all directions, characterised in that - the or each base pad
has fold lines about which the pad is folded to reduce its dimensions in all directions
to facilitate its insertion into the base of said container through said rectangular
opening, said base pad(s) when folded retaining the folded condition without any external
assistance or interconnection of parts of said pad(s).
[0009] It will be appreciated that the above construction not only avoids the slotting of
the end base flaps, as in the above described references, but also facilitates a simple
assembly technique not requiring specially constructed external or integral flap holders
such as shown in the French specification referred to above.
[0010] In the presently preferred form of the invention, two base pads are provided and
each is shaped to extend from a central portion of the pallet structure, each said
base pad having foldable ears which when folded reduce the dimensions of the pad,
when viewed in plan, to the size of approximately half of the said opening in the
base of the container.
[0011] Where the pallet structure is separately consruct- ed, each base pad has a portion
which is attached to the pallet structure, for example by being inserted between the
top deck of the pallet and the bearers or separating blocks and securely attached
therebetween. This arrangement avoidsanother disadvantage of the prior art arrangement
of point attachment along a central strip of the floor components. The foldable portion
of the base pad is of course capable of being folded flat against the top of the pallet
structure so as to lie flat against the inside of the base of the container when attached
thereto.
[0012] In another aspect of the invention a container, which is arranged to be secured to
a pallet structure, comprises a first container part which includes side walls and
bottom flaps, hereinafter defined as the 'primary flaps', which primary flaps fold
inwardly of the side walls and define an opening in the base of said first container
part, and at least one second container part having a first portion arranged to lie
below said first container part and to be secured to the pallet, a second portion
formed of a plurality of secondary flaps which can be folded to a first, erect, configuration
which permits insertion of the second portion directly through said opening, the secondary
flaps thereafter being capable of being unfolded to a second, configuration in which
parts of the secondary flaps overlie parts of the primary flaps and also lie adjacent
the side walls to limit relative lateral movement of said first and second container
parts.
[0013] In a further aspect of the invention a container comprises a first container part
which includes side walls and bottom flaps, hereinafter defined as the 'primary' flaps,
which primary flaps fold inwardly of the side walls and define an opening in the base
of said first container part, and two base pads, each being formed from sheet material
and including a first portion arranged to be secured to the pallet, and a second portion
formed of three 'secondary' flaps, namely a central and two lateral flaps, the secondary
flaps being so formed as to permit the second portion to be folded to an erect, configuration
which permits insertion of the second portions of the two base pads directly through
said opening, the secondary flaps of each base pad thereafter being capable of being
unfolded to a flat, configuration in which the second portions of the base pads lie
above their respective first portions and also overlie parts of the primary flaps
of the first container part. In yet another - aspect of the invention a container
comprises a first container a part which includes four side walls arranged to extend
vertically in a rectangular manner, and having bottom flaps, hereinafter defined as
the 'primary' flaps which fold inwardly of the side walls and define a rectangular
opening in the base of said first container part, and two base pads, each being formed
from sheet_material, and each including a first generally rectangular portion, the
two rectangular portions, when assembled in relation to the pallet, each being secured
to a different half of the pallet, each base pad having an intermediate portion arranged
to extend upwardly from the first portion of its base pad, when the latter is secured
to the pallet, with the two intermediate portions adjacent one another, and a second
portion formed of at least three flaps, namely a central flap connected to the respective
intermediate portion, and two lateral flaps extending one on each side of the central
flap, the central and lateral flaps being capable of being folded to a first configuration
which permits insertion of the three flaps of each base pad simultaneously through
said rectangular opening of the first container part, the said three flaps of each
base pad thereafter being capable of being unfolded to a flat, second, configuration
in which parts of the said three flaps of each base pad overlie parts of the primary
flaps, and also lie adjacent the side walls to limit relative lateral movement of
the first container part and the two base pads.
Detailed Description of the Drawings
[0014] The presently preferred form of the invention will now be described with reference
to the accompanying drawings, in which:
Fig. 1 shows the shape of one base pad;
Fig. 2 shows two base pads attached to a pallet structure;
Fig. 3 shows the base pads in the folded condition ready for assembly of the container
body;
Fig. 4 is a plan view of the arrangement shown
in Fig. 3; and
Fig. 5 is a perspective view from above of the container when assembled on the pallet
structure showing the base pads in position.
[0015] Referring firstly to Fig. 1 of the drawings, the base pad used to hold the container
body described further below is formed from corrugated board or other suitable material
and will be seen to comprise a rectangular attachment portion 1 which is adapted for
attachment to the pallet structure and a smaller shaped pad portion 2 formed with
crease or score lines 3, 4 to define a central trapezium-shaped portion T and shaped
foldable ears 5,6 extending from the sides of portion T. The ears 5, 6 are relieved
at 7 and 8 so that the pad portion 2 is connected to the attachment portion 1 by a
narrow neck. Fold lines F
1,F
2 are also provided about which the pad may be folded so as to lie flat against the
pallet structure.
[0016] As will be seen from Fig. 2 of the drawings, the rectangular attachment portions
1 of two base pads A and B are disposed in use between the timber top deck and the
bearers of a pallet structure P and is secured in position by attachment of the top
deck to the bearers. This leaves the shaped pad portions 2 extending upwardly from
a central portion of the pallet structure ready for folding and insertion into the
container body as shown in Figs. 3 and 4 of the drawings.
[0017] Consideration of Figs. 3 and 4 of the drawings will show that prior to assembly of
the container body onto the pallet and base pad assembly, the ears 5, 6 are folded
at about right angles to the portions T. Preferably the ears when folded retain their
folded condition without any external assistance or interconnection of parts of the
base pads A and B. Alternatively to overcome the tendency of the ears 5, 6 to unfold,
the engagement of the corners of the relieved portions 7, 8 with the top of the pallet
structure can be relied on to hold the pads A,B in the position shown in Fig. 3. Fig.
5 of the drawings shows that the container body has four side walls 9, 10, 11 and
12 from which four top flaps 1 3, 1 4, 15 and 1 6 and four short base flaps 17, 18,
19 and 20 extend. When the container body is erected and the base flaps folded inwardly,
an enlarged rectangular opening 21 is defined in the base of the container.
[0018] When the container body is to be attached to the pallet structure, the ears 5 and
6 of each shaped portion 2 of each base pad are folded as described above until the
corners of the ears contact the top of the pallet. Frictional contact of the ears
with the top of the pallet assists in holding the base pads in the required position
during assembly of the container body on the base pads if necessary. In the folded
condition, the dimensions of the shape portions 2 are approximately equal to the dimensions
of the opening 21. Accordingly, the container body may easily be inserted over the
folded portions 2 as shown in Fig. 3, whereupon the ears are straightened and the
portions 2 folded against the inside of the base of the container body as shown in
Fig. 5 of the drawings. When in this position it will be noted that the sides and
ends of the portions 2 of each base pad are in close proximity to the side walls of
the container body whereby lateral movement in all directions is effectively prevented.
[0019] Once the container is loaded with the product to be transported, the base pad portions
2 are held firmly against the base of the container body so that the container and
pallet structure behave effectively as an integral unit.
[0020] Although the base pad configuration described above is preferred, other configurations
achieving similar results may be used. For example, by changing the angle of each
relieved portion 7, 8, the ears may be folded so as to be adjacent the central portion
T.
[0021] This arrangement is useful for rectangular containers. Similarly, the relieved portions
7, 8 of the ears 2 may be arcuate to facilitate folding of the ears back upon each
other so that the dimensions of the folded pads are even smaller than in the preferred
embodiment.
[0022] In a modification of the invention not shown in the accompanying drawings, the configuration
of the base pad may be modified so as to form integral feet or joist members of the
types described in Australian Patent No. 426,164 or United States Patent No. 4,119,205.
Thus, the invention is not restricted to use with a separately constructed pallet
structure.
1. A palletised container comprising a pallet structure and a container adapted to
be secured to said pallet structure, said container comprising side walls and top
closing flaps for at least part of the top of the container if required, bottom flaps
which fold inwardly of the container from the side walls and defining a generally
rectangular opening in the base of the container, and at least one base pad having
a portion secured to or integral with said pallet structure and being shaped to be
disposed in use internally of the bottom flaps and adjacent at least portions of each
side wall to limit lateral movements of said container when engaged therewith in all
directions, characterised in that the or each base pad has fold lines about which
the pad is folded to reduce its dimensions in all directions to facilitate its insertion
into the base of said container through said rectangular opening.
2. The container of claim 1, wherein two base pads are provided, each being shaped
to extend from a central portion of the pallet structure, characterised in that each
base pad has foldable ears which when folded reduce the dimensions of the pad, when
viewed in plan, to the size of the opening in the base of the container to facilitate
insertion of the pads into said opening.
3. The container of claim 2, wherein the pallet is separately constructed and each
base pad has a rectangular portion which is attached to the pallet structure between
the top deck and the bearers of said pallet so that the pads are securely attached
to said pallet.
4. The container of claim 2, wherein each base pad has a rectangular attachment portion
for attachment to said pallet structure, a shaped portion extending for said attachment
portion by a narrow neck, a trapezium shaped central portion defined by fold or score
lines and foldable shaped ear portions extending from the sides of the central portion
and having relieved portions extending from the base of the central portion to the
sides of the ear portions.
5. The container of claim 4, wherein said relieved portions are shaped so that said
ear portions when folded define with said central portion a rectangular U-shaped structure
extending outwardly and upwardly from the pallet structure with the corners of ear
portions frictionally engaging the pallet structure to hold the base pads in their
folded condition.
6. The container of claim 4, wherein said relieved portions are shaped so that the
ear portions may be folded against said central portions, the corners of said ear
portions engaging the pallet structure to hold the pads in their folded condition.
7. The container of any preceding claim, wherein- said base pad(s) when folded retain
their folded condition without any external assistance or interconnection of parts
of said pad(s).
8. A container, which is arranged to be secured to a pallet structure, comprising
a first container part which includes side walls, and bottom flaps, hereinafter defined
as the 'primary flaps', which primary flaps fold inwardly of the side walls and define
an opening in the base of said first container part, and at least one second container
part having a first portion arranged to lie below said first container part and to
be secured to the pallet, a second portion formed of a plurality of secondary flaps
which can be folded to a first, erect, configuration which permits insertion of the
second portion directly through said opening, the secondary flaps thereafter being
capable of being unfolded to a second, configuration in which parts of the secondary
flaps overlie parts of the primary flaps and also lie adjacent the side walls to limit
relative lateral movement of said first and second container parts.
9. A container, which is arranged to be secured to a pallet structure, comprising
a first container part which includes side walls and bottom flaps, hereinafter defined
as the 'primary' flaps, which primary flaps fold inwardly of the side walls and define
an opening in the base of said first container part, and two base pads, each being
formed from sheet material and including a first portion arranged to be secured to
the pallet, and a second portion formed of three 'secondary' flaps, namely a central
and two lateral flaps, the secondary flaps being so formed as to permit the second
portion to be folded to an erect, config= uration which permits insertion of the second
portions of the two base pads directly through said opening, the secondary flaps of
each base pad thereafter being capable of being unfolded to a flat, configuration
in which the second portions of the base pads lie above their respective first portions
and also overlie parts of the primary flaps of the first container part.
10. A container, which is arranged to be secured to a pallet structure, comprising
a first container part which includes four side walls arranged to extend vertically
in a rectangular manner, and having bottom flaps, hereinafter defined as the 'primary'
flaps which fold inwardly of the side walls and define a rectangular opening in the
base of said first container part, and two base pads, each being formed from sheet
material, and each including a first generally rectangular portion, the two rectangular
portions, when assembled in relation to the pallet, each being secured to a different
half of the pallet, each base pad having an intermediate portion arranged to extend
upwardly from the first portion of its base pad, when the latter is secured to the
pallet, with the two intermediate portions adjacent one another, and a second portion
formed of at least three flaps, namely a central flap connected to the respective
intermediate portion, and two lateral flaps extending one on each side of the central
flap, the central and lateral flaps being capable of being folded to a first configuration
which permits insertion of three flaps of each base pad simultaneously through said
rectangular opening of the first container part, the said three flaps of each base
pad thereafter being capable of being unfolded to a flat, second, configuration in
which parts of the said three flaps of each base pad overlie parts of the primary
flaps, and also lie adjacent the side walls to limit relative lateral movement of
the first container part and two base pads.