Field of the invention

The invention relates to the transport of goods and cargo. In particular the invention relates to packaging to transport liquids and a mounting assembly for attaching a bag to such a packaging thereof.

Background of the invention

Fluids are usually transported in barrels or drums, which are then stacked within shipping containers. The barrels or drums are bulky and takes on a fixed shape even when they are empty. Such an arrangement is not optimal for transport as they take up huge space even when they are transported empty. These empty barrels or drums would occupy space, and would incur additional shipping costs to return to the sender. Moreover, the barrels or drums may not be compatible with all kinds of liquids, especially corrosive chemicals. Thus, the sender would need to stock up on various kinds of packaging material to contain the chemicals.

Hence, there is a need for an improved packaging to transport fluids.

Summary of the invention

According to a first aspect of the invention, there is a collapsible box for insertion into an intermodal device, said collapsible box arranged to move from an erected state to a collapsed state, the collapsible box comprising: a top panel containing an aperture; two opposed side panels connected to the top panel and a base, each side panel foldable inwards along a fold line, the side panels arranged such that folding the side panels bring the base towards the top panel; a front panel and a back panel connected to the top panel and connectable to the base, both panels foldable beneath the base in the collapsed state; and locking members arranged to secure the top and side panels in the erected state. The collapsible box may be a collapsible box with panels made of metal, wood, a resilient polymer such as polypropylene, high density polyethylene, ABS, or other suitable materials. The front panel and back panel may have hinges or fold lines that facilitate folding. Locking members may be velcro, zippers, fasteners, belts, toggle locks or other suitable means. These locking members may secure the collapsible box in the collapsed state or erected state. The collapsible box can be used to store goods safely and economically. The collapsible box is erected when in use, and collapsed when empty. Multiple collapsible boxes in the collapsed state may be stacked to reduce shipping volume, for economical transportation back to the sender. Being reusable, they reduce waste and operation cost for the sender.

In an embodiment, the collapsible box may further comprise handles mountable on the top panel. The handles enable safe and fast operation when moving the collapsible box between the collapsed state and erected state.

In another embodiment, the collapsible box further comprises poles insertable through the handles. Each handle may accommodate any number of poles, as illustrated in the drawings. The handles may be used to secure stacks of collapsible box.

In an embodiment, the collapsible box may further comprise a liner bag positioned within the collapsible box, wherein the bag includes a liner bag inlet fitting insertable into the aperture; and a liner lock attachment arranged to secure the inlet fitting to the aperture. An example is shown in Figures 3 A and 3B. The liner lock attachment may be any of the following: a spring clip, a resilient clip, a hinged clip, a snap-on clip, a threaded clamp. For example, the liner lock attachment may be a circlip. Screw threads allow even alignment of the components, and tight fit at the joints. The box may further comprise an attachment component mountable to or unitary with the top panel and engageable to the liner bag inlet fitting and liner lock attachment. Corners of the liner bag may be secured to the box by adhesive means.

In an embodiment, the collapsible box may further comprise a flange connectable with an outer bag and in contact with the liner bag inlet fitting. An outer bag may have a neck or a spout, and encloses the liner bag to further prevent leakage. The flange provides an additional seal around the aperture and enables the excess spout of the outer bag to be folded under the top panel. Corners of the liner bag may be secured to the corners of the outer bag, and the corners of the outer bag may be secured to the box by adhesive means. The box may contain alignment pins around the aperture, such as on the top panel, attachment component, liner bag inlet fitting, or other suitable component, and complementary apertures in other components, such as the flange, to engage the pins. The pins can reduce the twist of the liner bag and/or outer bag. The pins may be mounted to or unitary with the top panel or suitable component.

According to a second aspect of the present invention, there is a method of moving a collapsible box comprising a liner bag mounted to an aperture from a collapsed state to an erected state, comprising the steps of: disengaging locking members securing top panel and base in the collapsed state; attaching the liner bag inlet fitting to the aperture; securing a liner lock attachment to a liner bag inlet fitting; straightening a fold line on each of opposed side panels such that the top panel separates from a base; aligning a front panel and a back panel with the side panels and base; and securing the panels in the erected state using the locking members. This method ensures that the liner bag and/or outer bag and the panels of the collapsible box are flat and not creased, thus minimizing space consumption for transportation, and reducing transportation cost.

According to a third aspect of the present invention, there is a mounting assembly for attaching a liner bag to an aperture in a collapsible box, comprising: a liner bag inlet fitting connected to the liner bag; and a liner lock attachment arranged to secure the liner bag inlet fitting to the aperture. The assembly may further comprise an attachment component mountable to the aperture and engageable to the liner bag inlet fitting.

In an embodiment, the assembly may further comprise a first flange connected to an outer bag positioned between the liner lock attachment and the attachment component, and beneath a top panel of the collapsible box. The assembly may further comprise a second flange positioned between the liner lock attachment and the first flange, and above the top panel. The flanges provide additional seal around the aperture. In an embodiment, the assembly may further comprise a cap encapsulating the assembly. The cap protects the components of the assembly from wear and tear, and accidental interference. The cap may contain an O-ring for a leak-proof seal.

Brief description of the figures

Figures 1A-1E are perspective views of a collapsible box as it is moved from a collapsed configuration (Figure 1A), through intermediate configurations (Figures IB and 1C), to an erected configuration (Figure ID and Figure IE).

Figure IF is a photograph of a toggle lock.

Figures 2A and 2B are perspective views of a liner bag and an outer bag respectively.

Figure 3A is a perspective view of a liner bag inlet fitting through a collapsible box top aperture. Figure 3B is an exploded cross-sectional view of a cap attachment assembly and liner lock attachment.

Figure 4 is an exploded perspective view of a cap attachment assembly and collapsible box top aperture.

Figures 5A and 5B are an exploded cross-sectional view and a cross-sectional view respectively, of a cap attachment assembly.

Figure 6 is a perspective view of a top plate attachment and liner bag inlet fitting.

Figure 7 is a perspective view of a liner lock attachment and a liner bag inlet fitting.

Figures 8A and 8B are a cross-sectional perspective view and a cross-sectional view respectively, of a liner lock attachment.

Figure 9 is a perspective view of a cap and attachment assembly.

Figures 10A and 10B are an exploded cross-sectional view and a cross-sectional view respectively of a cap assembly.

Figures 11 A and 1 IB are an exploded perspective view and a perspective view respectively, of a flange and a liner bag inlet fitting.

Figure 12 is a cross-sectional view of a flange and liner bag inlet fitting inside an outer bag. Figure 13 is an exploded view of a top plate wall attachment, liner bag inlet fitting and flange. Figure 14 is an exploded view of a liner lock attachment and liner bag inlet fitting.

Figure 15 is an exploded view of a cap with attachment assembly.

Figure 16 is an exploded cross-sectional view of a cap attachment assembly comprising the components of Figures 17 to 21.

Figure 17 is a perspective view of an extended flange attachment.

Figure 18 is a perspective view of a top plate wall attachment.

Figure 19 is a perspective view of a circular extended flange.

Figure 20 is a perspective view of a liner lock attachment.

Figure 21 is a perspective view of a liner bag inlet fitting.

Figures 22A and 22B are perspective and perspective cross-sectional views respectively, of the cap assembly of Figure 16 without the cap.

Figures 23A and 23B are perspective and perspective cross-sectional views respectively, of the cap assembly of Figure 16 with the cap.

Figures 24A and 24B are exploded cross-sectional and assembled cross-sectional views respectively, of a liner lock attachment and liner bag inlet fitting.

Figures 25A and 25B are exploded cross-sectional and assembled cross-sectional views respectively, of a cap assembly with flange.

Figures 26A and 26B are exploded cross-sectional and assembled cross-sectional views respectively, of a modified circular extended flange.

Figures 27A and 27B are open and closed configurations of a sliding wall lock.

Figures 28A and 28B are sliding ledges with mutually engageable locking mechanism.

Figures 29A and 29C are side views of collapsed boxes in the separated and stacked configurations respectively. Figure 29B is a partial perspective view of stacked boxes.

Figures 30A and 30B are perspective views of collapsed boxes and Poles in the exploded and stacked configurations respectively.

Figure 30C is a front view of 2 collapsed boxes and Poles in the stacked configuration. Figures 31 A and 3 IB are perspective and front views respectively, of a collapsible box top plate with hooks.

Detailed description of the invention

Collapsible box

The function of a collapsible box (the term “container” is interchangeable in this description) is to safely store fluids such as, but not limited to, chemical, detergent, lubrication oil etc. Each collapsible box may contain a replaceable liner bag, which automatically deploys when the collapsible box is fully erected. The liner bag may be made from a flexible durable polymer, such as polypropylene, high density polyethylene. The polymer may contain a single layer or multiple layers. Thickness of a layer may range from 50 to 150 microns. The corners may be coved to distribute tension more evenly.

In Figure 1A, an empty collapsible box 1 is in a fully collapsed configuration which occupies the least space and thus optimizes storage capacity when empty. The top panel 11 has handles 111 for erecting the container, transporting the container, for tying several containers together, or securing the container to a fixture e.g. walls of a shipping container or shelves in a warehouse. Poles can be placed through the handles to engage with an external container (refer to Figures 30A and 30B), such as but not limited to Goodpack, metal box or metal cage, so as to provide a tough skin to the collapsible box and a liner bag, and transfer the internal pressure to the external container. The handles 111 are mounted on the top panel 11 using a mounting plate 113 and may be metal, such as steel or aluminum, or plastic, including PP, HDPE, ABS or other appropriate polymer. A cap 24 protrudes from the top panel 11. The container in a collapsed state may include a recess for stacking, such as to nest the cap. Alternatively, adjacently stacked containers may be inverted to accommodate the projecting cap (refer to Figures 29A and 29B).

Figure IB shows the container 1 in a semi-collapsed configuration. The front wall 12 and back wall 13 are lifted away 101, 102 from the bottom. The front wall 12 hinges 101 from a front wall hinge 120 to the side. There may be recesses on the front and back walls to act as handles or serve dual purpose for stacking. For instance, the back wall 13 hinges 102 from a back wall hinge 130 to the side.

In Figure 1C, the front wall (not shown) and back wall 13 have opened to the sides. The container 1 is lifted upwards 100 using the handles 111. A side wall 14 straightens along a side wall hinge 140 and fold line 141. Similarly, another side wall 15 straightens along a side wall hinge 150 and fold line 151.

In Figure ID, the container 1 is in a fully erected configuration. The side wall 14 is straight and contains a U-shaped groove around its periphery, so that the surfaces are flush when the container is erected. A fold line can act as a hinge, but it may also include a separate hinge and mounted to the container. The fold line may contain several parallel lines so as to increase the bending radius whilst reducing stress applied to the material. A sliding ledge 142 slides across the fold line 141 and locks the wall in the straightened position by acting as a brace across the hinge formed by the fold line. Similarly, the side wall 15 (not shown) has a sliding ledge 152 that slides across the fold line 151 (not shown). The walls may be aligned and fixed in position using other fixture mechanisms, e.g. Velcro 180 (Figure IE), zippers, toggle lock 29 (Figure IF), or other fasteners. The toggle lock may contain straps. These straps may be elastic to provide a pre-load to better secure the lock, or may be inelastic to prevent a pre-load which may add stress to the container. The walls may also be locked in position using locking mechanisms, e.g. side locks, snap fit. A disposable liner bag 203 arranged to hold liquid (Figure 2A) may be inserted into the container and secured to the container via a cap attachment assembly. The liner bag may be automatically deployed as the container is expanded.

The liner bag 203 may be inserted into a outer bag 204 (Figure 2B) which then secures to the container via a flange to the cap attachment assembly. This outer bag 204 will act as an additional protection against leakage of the liner bag 203. The container may be inserted into another container, such as a Goodpack, metal box or metal cage.

Alignment of outer bag and liner bag in collapsible box In addition to the liner bag, a collapsible box may contain an outer bag to further protect and enhance the leakproof function. The liner bag will be placed within the outer bag, and both outer bag and liner bag will automatically deploy when the collapsible box is fully erected. In an embodiment, the liner bag and/or the outer bag lies flat within the collapsed box in a “T” or “Z” configuration which allows for negative pressure in the collapsed configuration, reduces distortion in the liner bag material, and minimizes volume.

Figure 2A shows a liner bag. The liner bag contains a liner bag inlet fitting with a value. For example, the valve can be 2 inches in diameter. Figure 2B shows an outer bag having a neck, or a spout, as shown. The edges of both bags may be heat-sealed. The internal corners of the collapsible box base and outer corners of each bag contain adhesive means which align both bags within the collapsed box when the liner bag is placed within the outer bag, then within the collapsible box. The adhesive means may be Velcro heat-sealed directly or indirectly to the bag. In a particular embodiment, the liner bag has four velcro patches 190 on the exterior of the liner bag base, while the outer bag has eight velcro patches 190 - 4 in the interior corners and 4 in the exterior corners of the outer bag base.

Liner bag, liner lock attachment (Option O ^' )

Figures 3 A and 3B show how a liner bag inlet fitting 21 inserted through a collapsible box top aperture 20 and secured to the collapsible box using the liner lock attachment 28.

Cap attachment assembly (Option 1 )

Components of the cap attachment assembly 2 are shown in Figure 4. The top panel 11 has holes 110 for mounting handles (not shown) and an aperture 20 for engaging the cap attachment assembly 2. The cap attachment assembly 2 may include a liner bag inlet fitting 21, top plate wall attachment 22, liner lock attachment 23, and a cap 24. These components are shown in the exploded (Figure 5A) and assembled (Figure 5B) configurations.

Figure 6 is a perspective view of a liner bag inlet fitting 21 and a top plate wall attachment 22 with wall 220. The liner bag inlet fitting 21 may contain screw threads. A liner bag (not shown) is attached to the liner bag inlet fitting 21, which contains alignment pins 211 and 212 engageable with alignment apertures 221 and 222 in the top plate wall attachment 22. The alignment pins prevent the liner bag from twisting or moving away from its intended position during transport. The pins also ensure that the liner bag and components of the cap attachment assembly are oriented in the same way for all containers. The alignment pins may be attached or inserted into apertures in the top plate wall attachment 22. Alternatively, the alignment pins may be integrated with the top plate wall attachment 22.

Figure 7 is a perspective view of a liner lock attachment 23 aligned with a liner bag inlet fitting 21 and top plate wall attachment 22. The screw threads of the liner bag inlet fitting 21 may be engageable with the screw threads of the liner lock attachment 23. It will be appreciated that the liner lock attachment 23 acts to clamp the liner bag to the cap assembly. This has the advantage over resilient locking means, such as an O-ring in that it does not rely upon a resilient force applied to the bag which may reduce over time due to fatigue or creep.

The liner bag, in clamping is arranged to apply a uniform clamping force across the height of the liner bag, and so avoids the creep issues of the prior art.

Figure 8 A is a perspective cross sectional view of a liner lock attachment 23. Interior 233 of the liner lock attachment may contain screw threads. The attachment 23 may contain external ribs 231 to improve grip when installing or uninstalling the attachment. The attachment may contain a wall 232 that fits within the wall of the top plate wall attachment 22 and contains the contents during filling or unloading in the event of spillage. Ribs 231 on the liner lock attachment 23 improve usability by improving handling/grip when installing or uninstalling.

Figure 8B is a cross sectional view of a liner bag lock attachment 23. The liner bag lock attachment 23 may contain screw threads engageable with screw threads of the liner bag inlet fitting 21.

Figure 9 is a perspective view of an assembled liner bag inlet fitting 21, top plate wall attachment 22, and liner bag lock attachment 23. The cap 24 may contain ribs 241 for easy handling. The interior of the cap 24 may contain screw threads that are complimentary to the outer screw threads of the top plate wall attachment 22. Alternative mechanisms of engagement may be used, such as push-lock or push-twist mechanisms.

Cap assembly with outer bag and flange (Option 21

In an embodiment, the cap attachment assembly may further comprise a flange for connecting an outer bag. The flange may be attached to the liner bag inlet fitting by screw capping. The outer bag provides additional support for the liner bag and prevents accidental leakage. The outer bag may be made of a flexible and robust polymer-based material, such as tarpaulin. The outer bag may contain a protruding flexible spout at the top opening, and is secured tightly around the flange to become leak-proof. The securing may be by tying or clamping the outer spout to the flange. The flange might have a recess to prevent the tie or clamp to slip. The excess portion of the spout may be folded and compressed beneath the top plate to prevent interference with the cap assembly. The cap attachment assembly may then encapsulate the aperture 20 in the top plate as described previously.

Figures 10A and 10B show exploded sectional and assembled sectional views of a cap attachment assembly (liner bag inlet fitting 21, top plate wall attachment 22, liner bag lock attachment 23, cap 24) further comprising a flange 200. The flange 200 is sandwiched between the top plate 20 and liner bag inlet fitting 21, with the inlet penetrating through the flange.

Figures 11A is an exploded view of the flange 200 and the liner bag inlet fitting 21. The flange 200 may engage the liner bag inlet fitting 21 through a threaded connection. The flange can be aligned to a single position with respect to the orientation of the liner bag by limiting the screw thread length and position. The alignment of the flange will assist to align the liner bag to the collapsible box. Alternatively, the flange 200 and inlet 21 may engage through a press fit or other resilient engagement.

Figure 1 IB is a perspective view of the flange 200 in engagement with the liner bag inlet fitting 21. Figure 12 is a sectional view of the flange 200 within a outer bag 201 before the outer bag is fixed to the collapsible container. The outer bag 201 contains a flexible spout 202 and is secured to the flange 200 at the base of the flexible spout 202.

Figure 13 is a perspective view of the top plate wall attachment 22, flange 200, liner bag inlet fitting 21. The top plate wall attachment 22 will be affixed to the collapsible box top plate (not shown) as a permanent structure. The liner bag inlet fitting 21 with flange 200 might have alignment pins on the flange to guide users to accurately align outer bag and liner bag in the correct position. The 2 or more alignment pins will have asymmetric design so that there could only be one position to fit into. Alignment pins help to prevent liner bags from twisting or moving away from their position during transport, and thus prevent excess strain on the liner bag and outer bag. The flange 200 may have apertures 205 engageable with alignment pins 206 in the liner bag inlet fitting. The alignment pins 206 prevent relative twisting of the liner bag and outer bag during transport, and ensures the correct alignment of the liner bag and outer bag. The alignment pins 206 will engage with the apertures 221 and 222 on the top plate wall attachment 22.

Figure 14 is a perspective view of the liner lock attachment 25 that secures the liner bag inlet fitting 21 and flange (not shown) to the top plate by screw lock mechanism. The liner lock keeps the liner bag inlet fitting on the box top plate. A cap 24 then covers the components to complete the cap attachment assembly (Figure 15).

Cap assembly and extended flange attachment (Option 3)

An embodiment is created to further enhance the leak-proof ability of the liner bag, and is shown in Figures 16 to 25B. Figure 16 shows individual components of the cap assembly 3 around a top plate aperture 30: liner bag inlet fitting 31, liner lock attachment 32, circular extended flange 33, top plate wall attachment 34, extended flange attachment 35, cap 36. The exterior of the circular extended flange 33 and the interior of the extended flange attachment 35 may contain complimentary screw threading. The exterior of the top plate wall attachment and the interior of the cap 36 may contain complimentary screw threading. The liner is placed within the outer bag as previously mentioned. The outer bag has a protruding spout at the top opening. The outer bag spout will go around the circular extended flange, and be secured by tying or clamping it to the circular extended flange. The flange may have a recess to prevent the tie or clamp to slip. A liner bag inlet fitting is attached to the circular extended flange by locking using a liner lock attachment. Excess spout can be folded down so prevent interference with the cap assembly.

First, the liner bag inlet fitting 31 is pulled up through the circular extended flange 33, then attached to the circular extended flange 33 using the liner lock attachment 32 (Figures 24A and 24B). This liner lock attachment 32 is clamped around the liner bag inlet fitting 31, then rested on the circular extended flange 33 so that it acts as a support to prevent the liner bag inlet fitting 31 from falling down through the aperture of the circular extended flange 33. The circular extended flange 33 is arranged to allow space to house the liner lock attachment 32 and enable easy clamping and unclamping.

Next, the extended flange attachment 35 is attached to the circular extended flange 33 by screw threads. The circular extended flange 33 can be aligned to a single position with respect to the orientation of the outer bag and liner bag by limiting the screw thread length and position. The alignment of the circular extended flange 33 assists to align both the outer bag and liner bag to the collapsible box. The top plate wall attachment 34 may be mounted to, or is unitary with, the top plate of the collapsible box.

Instead of locking the circular extended flange using screw thread, the circular extended flange 37 can be coupling device with flexually flexible tabs 370 that snap locked to protruding tabs 380 of the top plate wall attachment 38 (Figures 26A and 26B).

Sliding ledges

In an embodiment, side walls 14 and 15 may contain sliding ledges that maintain them in the straightened position.

Figures 27A and 27B are perspective views of a sliding ledge in an open configuration and a closed configuration respectively. In the open configuration, a sliding ledge 81 is positioned flush along the edge of a side wall and does not obstruct the fold line 82. In the closed configuration, the sliding ledge 81 slides across the fold lines 82 of the side walls, into the recess 83 to cover the fold line 82, prevents the side wall from collapsing along the fold line and provides increased rigidity for the walls. Rather than a cave depression, the recess 83 may penetrate through and act as an aperture. The sliding ledge may be made from any rigid material, such as polymer or metal. The sliding mechanism may be through a groove on the edge of the side wall. The sliding ledge may contain locking pins. Alternatively, the sliding ledge may be locked by Toggle pins or Velcro.

Figures 28A and 28B show a locking mechanism to lock the chemical box walls in position. The sliding ledge 91 of a wall 9 may contain locking pins 92. The wall 9 may correspond to wall 14 or 15 of the chemical box in Figure 1C. The wall 9 fits adjacent to another wall 90 with another sliding ledge 93. Sliding ledge 93 has recesses 94 complimentary to locking pins 92. The wall 90 may correspond to wall 12 or 13 of the chemical box in Figures 1A-1E. In the locked configuration, the locking pins 92 slide into and engage with recesses 94. The locking pins may be retractable via springs or other suitable mechanisms. The design should not be limited by its current size and design of its features as it will undergo optimization to achieve its desired function.

Stacking collapsed boxes together

Figure 29A is a side view of two collapsed boxes. The boxes 10 are spaced apart and positioned such that the top plates and caps 100 face inwards in an alternating arrangement. This arrangement minimizes the storage space for empty boxes and transportation costs to the users. The stack can be secured at the edges with Velcro 191, belts or other suitable means (Figure 29B). Figure 29C is a side view of four collapsed boxes 10 positioned similarly to Figure 29 A, but stacked together and secured using suitable means. Velcro may be used to secure the box panels in the erect configuration (180 in Figure IE); secure the wall panels to the base in the collapsed configuration to keep the box compact (192 in Figure 29C); or attach to an adjacent collapsed box to achieve better stacking (191 in Figure 29C). The handles are positioned so that they do not have interference during the stacking procedure. The height of the handles and caps are flushed and leveled to stabilize the stack. Pressure is distributed among the caps and handles to avoid distorting the box panels. It would be appreciated that higher stacks of boxes can be obtained in a similar manner. Figures 30A and 30B are perspective views of two stacked boxes 10 with positioning poles 150. Figure 30C is a front view of the stacked containers with poles inserted through their handles. The handles 151 on the top panel 100 of both containers are aligned to accommodate poles 150. The figures show two poles 150 inserted through each handle 151, but it would be appreciated that this does not exclude the use of a single rod. The cross-section of the rod may be spherical as shown, or of any suitable shape. The rod may engage the handle through a locking mechanism. These poles provide additional structural support for the container and transfer the force from the container to the external container.

Figure 31 A and 3 IB show a top panel 100 with handles 151. The underside of the top panel may contain hooks 152. The hook 152 may be arranged to engage the straps located on the liner bag (not shown). In an alternative embodiment, the hooks may be replaced with handles that engage with hooks or straps on the liner bag. In yet another alternative embodiment, the underside of the top panel may contain Velcro attachments that engage with complementary Velcro attachments on the liner bag. These features reduce the movement of the liner bag within the container during packing, transport, and when emptying contents. It is appreciated that the various embodiments relating to the top plate, top plate wall attachment, liner bag inlet fitting, liner lock attachment, cap, foldable side walls, sliding wall locks can be modified and are interchangeable to form different containers, whilst still falling within the scope of the invention.