Field of the Invention

A collapsible courier box, case or container for containing and transporting items. An insert for the collapsible courier box, a protective sleeve and a postal transit bag are also described.

Background to the Invention

Modern commerce requires delivery of items securely and without damage, often over long distances. Long supply chains mean that parts of a product are often delivered from around the globe before being placed in an ultimate product. The ultimate product must then be delivered to a retailer or to the end customer. Accordingly, secure and protective packaging is required to contain or house items during delivery. Preferably the weight of the packaging materials is kept to a minimum, as this increases cost and decreases transport efficiency.

Typically, single use packaging (cardboard boxes, bubble wrap etc.) has been used. However, this is creates a substantial amount of waste, and requires continual purchasing of packaging products. More recently, reusable packaging has been developed. This includes collapsible and foldable boxes or cases. Said collapsible boxes or cases are often formed having hinged rigid or semi-rigid walls of cardboard and/or foam, which may be covered with a fabric such as a flexible polyvinyl chloride (PVC) fabric. The level of protection offered by such cases or boxes can be increased by providing greater thickness or rigidity for the walls, but this also increases the weight of the packaging. Although reusable, this type of packaging has a limited number of reuse cycles before the performance of the box degrades.

Thus, it is the aim of the present invention to provide an improved reusable and collapsible courier box.

Summary of the Invention

There is described a courier box, case or container for containing or transporting goods. The courier box, case or container is formed from a net provided in a selfreinforced polymer material. The net of the self-reinforced polymer can be formed into a three-dimensional shape by connection of fasteners at the perimeter edge of the net. On one surface of the net, additional reinforcing strips are applied adjacent to the fastener. The reinforcing strips provide extra rigidity to the net and the three-dimensional shaped courier box that is formed. However, the reinforcing strips also retain greater flexibility in the net and the walls of the three-dimensional courier box than compared to simply increasing the overall thickness of the self-reinforced polymer panel from which the net is formed. The increased rigidity without extra thickness given by the use of reinforcing strips provides a robust courier box, with superior protective properties for an item housed therein. Moreover, the use of a self-reinforced polymer material for both the net and the reinforcing strips provides a courier box that is unyielding, resistant to penetration, and yet lightweight and waterproof. Ideally, the fasteners are reusable and reversible to allow the courier box to be collapsed when not in use for containing or transporting items.

In a first aspect there is described a courier box or collapsible box, comprising: a panel of a self-reinforced polymer material configured as a net for the courier box, the net having a first and a second planar surface and a perimeter edge; one or more strip of self-reinforced polymer material arranged at the first planar surface of the net, positioned adjacent to and parallel with at least a portion of the perimeter edge of the net; and at least one fastener arranged at the perimeter edge of the net, and configured to releasably couple portions of the perimeter edge to form a three-dimensional shape for the courier box.

The net can be configured to provide a three-dimensional courier box, which is held in a three-dimensional shape by the coupling of the at least one fastener. The fastener is preferably reversible, so that the courier box can be collapsed and re-constructed a number of times. This may be helpful to provide a flat net for the courier box for storage and transportation when not being used to house or contain an item.

A courier box formed with walls comprising self-reinforced polymer may provide a number of advantages. Firstly, the material is robust and yet lightweight. The material may be difficult to penetrate, and also waterproof. Thus, a courier box provided by this material may be durable and reusable a large number of times.

Self-reinforced polymer may provide both a rigid or flexible panel, dependent on its thickness. Ideally, the collapsible courier box will have walls with some flexibility, as this improves the ability to construct and deconstruct the net from its three-dimensional configuration. It also may help absorb some of the energy of impacts to the outer surface of the courier box. However, the courier box must also have sufficient rigidity to hold it shape and avoid being crushed or misshapen during use, and to offer sufficient protection to an item inside. For this reason, the present invention uses strips of self-reinforced material at portions of the net adjacent the perimeter edge. These strips increase the thickness of the self-reinforced polymer walls of the courier box only in certain areas, thereby providing a balance between the required flexibility and rigidity of the walls. The use of reinforcing strips of self-reinforced polymer in only certain areas also reduces the weight of the courier box compared to a box having self-reinforced polymer walls of greater thickness across its whole area.

Preferably, the strip covers less than 50% of the first planar surface of the net, or more preferably the planar strip covers less than 30% of the first planar surface of the net. The coverage of the strip may be increased to improve the rigidity of the walls of the courier box, or may be reduced to increase the flexibility of the courier box.

Preferably, the width of the of the strip is less than 40% the width of the net, the width of the strip extending in a direction perpendicular to the perimeter edge when arranged at the first plane surface of the net, and the width of the net extending in a direction parallel to the width of the strip. Preferably, the width of the of the strip is less than 40%, less than 30%, less than 25%, less than 20% or less than 10% the width of the net. The width of the strip can be reduced if a thicker self-reinforced polymer material is used to form the strip. The interplay between the thickness of the self-reinforced polymer strip (and thickness of the self-reinforced polymer panel) and the width of the strip may be adjusted to balance the desired stiffness or rigidity of the wall, and flexibility of the walls.

Preferably, the panel of the self-reinforced polymer material is formed from 2 to 14 layers of self-reinforced polymer material, or more preferably 2 to 8 layers of self-reinforced polymer material, or more preferably 3 to 6 layers of self-reinforced polymer material. In some examples, 4 layers of self-reinforced polymer material for the panel provides the best balance of rigidity, flexibility and weight considerations of the walls of the courier box.

Preferably, the panel of the self-reinforced polymer material is formed from two or more layers of self-reinforced polymer material that are thermo-compressed to bond, or consolidate, the layers together. In other words, the layers are pressed together, normally after or during application of heat, to bond together the layers of self-reinforced polymer.

Preferably, the self-reinforced polymer layer forming the panel has a thickness of at least 0.15 mm, or of at least 0.2 mm, at least 0.25 mm, at least 0.3 mm, at least 0.4 mm or at least 0.5 mm. The self-reinforced polymer layer forming the panel has a thickness of less than 2 mm. Preferably, the self-reinforced polymer layer forming the panel has a thickness of 0.15 to 0.7 mm.

Preferably, the one or more strip of the self-reinforced polymer material is formed from 2 to 14 layers of self-reinforced polymer material, or more preferably 2 to 8 layers of self-reinforced polymer material, or more preferably 3 to 6 layers of self-reinforced polymer material. As noted above, the width or area of the strip (compared to the area of the face of the net upon which it is mounted) may be adjusted relative to the thickness of (or number of layers comprised within) the strip, to balance flexibility and rigidity. A smaller area strip of thicker self-reinforced polymer material may provide similar rigidity to the larger area strip of thinner self-reinforced polymer material.

Preferably, the one or more strip of the self-reinforced polymer material is formed from two or more layers of self-reinforced polymer material that are thermo-compressed to bond, or consolidate, the layers together.

Preferably, the one or more strip is a single strip that extends adjacent to and parallel with more than 50%, more than 60%, more than 75% or more than 90% of the perimeter edge. In other words, the strip may be formed form a single piece, as this may increase the strength and rigidity of the reinforcing strip. The reinforcing strip may be arranged directly adjacent to the majority, but not all, of the perimeter edge of the net. A portion of the perimeter edge of the net may be left without reinforcement from the strip, in order to provide greater flexibility in these areas (for instance, for easier coupling of the fastener).

Preferably, a portion of the net at the second planar surface is reinforced with a planar section, such that the planar section extends across an inner face of the courier box when the courier box is configured to form a three-dimensional shape. In other words, the planar section may cover, or at least partially cover, an inner face of the courier box. Alternatively, the planar section could cover an outer face of the courier box. Preferably, the planar section may comprise a sheet of foam, and the foam may be one of: expanded polypropylene, ethylene vinyl acetate, EVE, expanded polyethylene, expanded polystyrene, microcellular polypropylene, or polyethylene foam. In this way, the planar section may increase the rigidity of the base (or another face) of the courier box. The planar section may provide greater cushioning or protection for an item within the box.

Preferably, the first planar surface of the net is provided with a three-dimensional surface patterning. In other words the outer surface of the courier box (comprising the first planar surface and, optionally, the outer surface of the strip) may comprise a patterning or texture. This may create a sufficient coefficient of friction between the outer surface of the box and another surface on which it is placed (such as a conveyor belt or table) to avoid slipping and sliding of the courier box.

Preferably, the self-reinforced polymer (used for the net and the strips) is one of: self-reinforced polypropylene, or self-reinforced polyethylene.

Preferably, the net is a T shape and forms a cube or cuboid when configured to form a three-dimensional shape. Preferably, the first planar surface is facing outwards when the net is configured to form the three-dimensional shape.

Preferably, the fastener is a zip fastener, zipper or clasp locker. However, other types of fastener could be envisaged, such as push (popper) fastener at a tab attached to the perimeter edge, or hook and loop fastening at a tab attached to the perimeter edge.

Preferably, the fastener is bonded to the net at the perimeter edge by one of: stitching, sonic welding, heat welding. These provide reliable, controlled and time efficient methods of attachment to the self-reinforced polymer material.

Preferably, a bottom stop and a top stop (in other words, a first and second terminal end) for the zip fastener are arranged at the first planar surface of the net. These may be mounted on the outer surface of the courier box, to be easily accessible for collapse and construction of the courier box. Partial separation of the zip fastener may be used to open a ‘lid’ of the courier box, as well as to deconstruct the courier box when the zip fastener is fully separated.

Preferably, the top stop and/or bottom stop of the zip fastener comprises a security latch. The security latch may provide a mechanism for identifying whether the zip has been opened or tampered with. For example, the zip puller (or pull tab) may be held in the security latch using a breakable insert, which must be snapped or broken off in order to use the zip puller.

Preferably, the security latch is attached to the first planar surface of the net by riveting. This provides a secure method of attachment for the security latch, which should prevent unauthorised removal of the security latch.

Preferably, the net is a T shape and forms a cube or cuboid when configured to form a three-dimensional shape and the fastener is a zip fastener, wherein a first half of the zip fastener is connected on the perimeter edge of the first elongate portion of the T shaped net, and a second half of the zip fastener is connected on the perimeter edge of a second elongate portion of the T shaped net, the first and second elongate portion extending perpendicular to each other to form the T shaped net, and the first and second half of the zip fastener connectable to close the fastener and form the three-dimensional shape.

Preferably, the three dimensional shape for the courier box is one of: a cube, a cuboid, a cylinder, a triangular prism a hexagonal prism.

Preferably, the courier box further comprises a lining layer on the second planar surface of the net. This may provide a soft, scratch-proof surface for housing items within the courier box. Preferably, the panel forming the net comprises a single piece of self-reinforced polymer. Alternatively, the panel forming the net comprises two or more pieces of selfreinforced polymer bonded together.

Preferably, the panel comprises one or more hinges to enable formation of the three-dimensional shape. The hinges provide a position or pivot point at which the net can be folded to form the three-dimensional shape of the courier box.

Preferably, the hinges are formed by one of: application of heat and pressure to a region of the net, a region of stitching at the net, scoring a region of the net. Further information on the formation of hinges in self-reinforcing polymer by application of heat and pressure is provided below.

Preferably, the courier box further comprises straps attached to the second planar surface of the net, for securely holding items placed within the courier box when configured to form the three-dimensional shape. The straps may further comprise buckles, for adjusting the length of the straps. The straps and/or buckles may comprise or be formed from self-reinforced polymer.

Preferably, the courier box further comprises an insert configured to house an item, the insert configured to be contained within the courier box when the courier box is configured to form the three-dimensional shape. A set of inserts may be provided, wherein inserts are interchangeable for a given courier box. The set of inserts my each be dimensioned or contoured to securely hold a different item.

Preferably, the net of the courier box is a first net, and the insert may be formed from a second net, which may be arranged to form a three-dimensional shape for the insert. In other words, the insert may also be reversibly collapsible. Storage and transportation of the insert when not in use may be more efficient if in a flat configuration, for instance.

Preferably, the second net may be formed in a panel of self-reinforced polymer and/or a panel of foam. The self-reinforced polymer or foam may be of the type, and have the characteristics, described above with respect to the net of the courier box and insert.

Preferably, the insert may comprise pockets and/or straps and/or buckles to house an item. The pockets and/or straps and/or buckles may be arranged at an inner face of the insert, for instance.

In a second aspect, there is described an insert for a courier box, comprising: a tubular wall element formed from a panel folded at each of two or more hinges in the panel to arrange the panel in a tubular configuration; wherein at least two or more of the hinges comprise one or more tab connected at the pivot of the respective hinge and cut out from one of the surfaces adjoining the said pivot of the same hinge, each tab arranged to project from the outer surface of the tubular wall element at the respective hinge.

The insert may be used inside or in conjunction with the courier box described above, or with any other types of courier box.

Preferably, the tabs are arranged to act as a spacer such that, when the insert is placed in the courier box the tubular wall element is held at a predetermined distance from the adjacent walls of the courier box. As such, the walls of the insert are spaced apart from the walls of the courier box. This configuration pay provide better shock absorption, and so better protect an item held within the insert inside the courier box. Moreover, the space between the walls of the insert and the courier box may allow a temperature controlled element to be placed inside the courier box.

Preferably, each hinge comprises at least a first and second tab, wherein the first tab is cut out of a first surface adjoining the said pivot of the same hinge and the second tab is cut out of a second surface adjoining the said pivot of the same hinge, wherein the first and second surface are joined at the hinge. In other words, a tab is cut out of a first face of the insert adjoining a hinge, and extends beyond the pivot of the hinge on the plane of a second face of the insert, wherein the second face adjoins the same hinge (so that the first and second face are joined at the hinge).

Preferably, each tab may extend up to 25%, or more preferably up to 15%, of the dimension of the face of the insert from which it is cut-out. The extension of the tab effects the spacing between the walls of the insert and walls of the courier box. Too large a cutout may negatively affect the rigidity of the insert.

Preferably, the panel is arranged in the tubular configuration by joining a first end of the panel with an opposing second end of the panel, wherein the join is formed by interlinking a slot at the first end with a slot at the second end of the panel. Alternatively, the panel is arranged in the tubular configuration by inserting a tab projecting from a first end of the panel into a slot formed at an opposing second end of the panel. The size of the further tab and/or interlinking slot may be equal to the projection of the tabs at the hinges of the panel.

Preferably, the insert may have a base portion and/or a lid portion. The base portion and/or the lid portion may comprise tabs to space the base and/or lid from the respective inner surface of the courier box.

Preferably, the insert comprises self-reinforced polymer. The self-reinforced polymer may have a thickness of at least 0.15 mm, or more preferably at least 0.2 mm, at least 0.25 mm, at least 0.3 mm, at least 0.4 mm, or at least 0.5mm. The insert may comprise two or more consolidated layers of self-reinforced polymer, being around 0.25 to 0.3 mm thick. Preferably, the self-reinforced polymer layer forming the insert has a thickness of 0.15 to 0.7 mm.

Preferably, the panel of the insert comprises a layer of self-reinforced polymer on a layer of polymer foam. Optionally, the panel of the insert comprises a first and a second layer of self-reinforced polymer with a layer of polymer foam therebetween. Preferably, the foam is one of: expanded polypropylene, ethylene vinyl acetate, EVE, expanded polyethylene, expanded polystyrene, microcellular polypropylene, or polyethylene foam.

Preferably, the self-reinforced polymer is one of: self-reinforced polypropylene, or self-reinforced polyethylene.

In a third aspect there is described a kit for courier transportation, comprising: the courier box described above, which in the three-dimensional configuration has walls defining a volume for transporting or storing goods; one or more insert as described above, wherein the insert has appropriate dimensions to fit inside the volume of the courier box such that the outmost edge of the one or more tab makes contact with a respective inner surface of the walls of the courier box. A variety of interchangeable inserts may be provided, each contoured or dimensioned to securely hold a different item, or different size of item within the courier box.

Preferably, the kit further comprises a temperature controlled element, for arranging in a void between the outermost surface of the tubular wall element of the insert and an inner surface of the courier box. In other words, the tabs act as a spacer, creating a void between the inner face of the walls of the courier box and the outer face of the walls of the insert. A temperature controlled element may be placed or housed in this void. The temperature controlled element may be selected from one of: ice, dry ice, a cold pack, a heat pack. A battery or other power source may also be placed in the void, to power the temperature controlled element. A thermostat or thermometer attached to the temperature controlled element may be housed in the void. A transceiver or may be placed in the void, for communication between the temperature controlled element, thermostat, thermometer and/or battery and a user device. Use of a temperature controlled element may allow temperature control of the cavity within the courier bag. This may be useful for transportation of medicines or food items, for instance.

An RFID tag may be placed in the void, for tracking of the courier box.

In a fourth aspect, there is described a method of manufacture of the courier bag, the insert or the kit, as described below.

In another aspect there is described a protective sleeve, comprising: a first portion comprising a first layer of foam and a first layer of self-reinforced polymer, the first layer of self-reinforced polymer bonded to the first layer of foam, the first layer of self-reinforced polymer having relief cuts or indentations or indentations in its surface; a second portion comprising a second layer of foam and a second layer of selfreinforced polymer, the second layer of self-reinforced polymer bonded to the second layer of foam, the second layer of self-reinforced polymer having relief cuts or indentations in its surface; and one or more strap; the first and second portion arranged having the first foam layer opposing the second foam layer, and the strap arranged to hold the first portion and the second portion around an item placed between the first foam layer and the second foam layer.

The protective sleeve may be an insert for a courier box of the type described above, or may be a standalone protective sleeve for transportation of an item. In some examples, the protective sleeve may be bonded to the internal surface of the base panel of a courier box.

Each of the first and second portion comprise a layer of foam and a layer of selfreinforce polymer. The foam may comprise expanded polypropylene, microcellular foam, or ethylene-vinyl acetate foam, for instance. The foam layer may absorb impact energy or shocks, and so protect an item held between the first and second portion. The layer of selfreinforced polymer (which may be self-reinforced polypropylene or self-reinforced polyethylene) provides a particularly hardwearing and resilient layer. Relief cuts or indentations or scores in the self-reinforced polymer layer allow some bend or flex in the first and second portion.

In use, an item (particularly a substantially planar item, such as a mobile telephone or laptop computer) can be sandwiched between the first and second portion (specifically, between the foam layers of each of the first and second portion so that the self-reinforced polymer is on the outer surface). A strap is then used to tighten the first and the second portion around an item therebetween. The relief cuts or indentations allow some bending of the first and second portion to enclose the item, both for superior protection and to hold the item firmly.

Preferably, the strap further comprises one or more buckle or clasp. The buckle or clasp may be used to close, join or tighten the strap around the first and second portion. The buckle or clasp may be formed of self-reinforced polymer.

Preferably, the relief cuts or indentations are parallel, spaced apart linear cuts or linear indentations. In most cases, the linear cuts or linear indentations will extend in only one direction across the surface of the first and second portion. The linear relief cuts or linear indentations may be arranged to extend perpendicular to the longitudinal extension of the strap. Preferably, the relief cuts or indentations at the first portion are parallel with the relief cuts or indentations of the second portion. In other words, the relief cuts or indentations may be arranged so that, when the straps are tightened to enclose an item between the first and second portion, the relief cuts or indentations open slightly to allow for bending of the first and second portion to cause the outer surface to become convex.

Preferably, the protective sleeve further comprises a hinge panel, the hinge panel joining a first edge of the first portion with a first edge of the second portion. The hinge panel many be arranged to extend between the first and second portion, to provide a hinge therebetween. When using a hinge panel, the first and second portion may open in the manner of a book, with the hinge panel acting as the pivot or spine of the book. Alternatively, the first and second portion could be joined by way of the strap. For instance, the strap may be bonded to an area of the outer surface of one of the first or the second portion, and connected to the other of the first or the second portion by passing through a loop connected to the outer surface of the respective first or second portion.

Preferably, the protective sleeve further comprises a trim around the perimeter edge of each of the first portion and/or the second portion. The trim may protect the layered structure of the first and/or second portion from delamination.

Preferably, the protective sleeve further comprises a lining layer, extending across at least one surface of the first and/or the second portion. The lining layer can provide an aesthetically pleasing cover for the surfaces of the first and/or second portion. The lining layer may provide a soft, scratch resistant layer. For instance a felt may be used on the surface of the foam layers of the first and second portion, that would otherwise come into contact with an item held between the first and second portion.

Preferably, the protective sleeve further comprises a pocket on the foam layer of at least one of the first portion and the second portion. In other words, the foam layer is between the pocket and the self-reinforced layer. The pocket may be for holding an item, to provide extra security and to prevent the item moving from between the first and second portion when in use. The pocket may be a net pocket, for instance.

In a further aspect there is described a postal transit bag, comprising: a first and a second panel of self-reinforced polymer; and a base panel of self-reinforced polymer, having a fold to divide the base panel into two portions; wherein a first portion of the base panel overlaps a portion of the first panel near a first edge, and wherein a second portion of the base panel overlaps a portion of the second panel near a first edge, and wherein a first seam joins the base panel to the first panel, and a second seam joins the base panel to the second panel, and wherein a third seam at a second edge at each of the first and second panel joins the first and second panel, and a fourth seam at a third edge at each of the first and the second panel joins the first and second panel, the second and third edge being opposing edges, that are each perpendicular to the first edge.

The seams at the first and second edge, and the seams at the first and third edge intersect, to define an open bore cavity in the postal transit bag, between the first and the second panel. The first panel, the second panel and the base panel are preferably shaped as a four sided polygon (such as a rectangle, or square).

The postal transit bag may be considered a bag, sack or sleeve for carrying items (such as items of post including letters and parcels). The postal bags may be used by postal delivery services to transport a large number of grouped or sorted items. Such postal bags are in regular use, and reused a number of times. They may be connected to frames to hold or support the bags during filling with items, and may in some cases be incorporated into automated sorting processes or arranged to collect items from a conveyor belt.

The described postal transit bags (made from self-reinforced polymer material) are highly durable and can carry a weight of much more than 15kg without stress or damage. The bags can be reused a number of times. Moreover, the bags are suitable for mass manufacture. At end of life, the bags formed from self-reinforced polymer can be recycled.

Preferably, the first and second panel of the postal transit bag are formed having a thickness that is 60% or less than the thickness of the base panel. In other words, the first and second panel are formed of a thinner self-reinforced polymer material than the base panel. This means that the first and second panel (which form the walls of the bag) are more flexible than the base panel, but the base panel may be more hard wearing.

The self-reinforced polymer may be formed from a plurality of consolidated layers of self-reinforced polymer, or may be a compound woven self-reinforced polymer. The types and characteristics of self-reinforced polymer are discussed in more detail below. Optionally, the self-reinforced polymer is a self-reinforced polypropylene, and more especially a compound woven self-reinforced polypropylene. An example of compound woven self-reinforced polypropylene is made under the trade name Dewforge ^RTM by James Dewhurst ^RTM .

The first and second panel and the base panel may be joined at seams. The seams may be formed by way of one of: stitching, heat welding, sonic welding, heat and compression. An outer surface of the first and/or second panel may comprise markings for use in sorting machine alignment. The markings may be printed, for instance using a hydro dipping method. Any pattern, logo or colouring may be applied to the panels.

Preferably, the first and/or the second panel further comprises one or more eyelet at the edge adjacent to an opening to the postal transit bag. Said one or more eyelet may be employed to attach the postal transit bag to a frame or trolley during use, or may be used for attachment within an automated postal sorting machine. The bags may be hung from the eyelets (or from a strap attached to the eyelets) when the postal transit bags are empty or full of items.

The eyelets may comprise metal rivets, forming an aperture therethrough. Alternatively, the eyelets may comprise a hanger or loop piece, which is bonded to or attached to the first and/or second panel. Alternatively, the eyelet may be a hole formed through the first and/or second panel. Said hole could be formed by insertion through the first and/or second panel of a heated rod, for example. This cases melting of the selfreinforced polymer material, which, once the rod is removed and the material cooled, provides a hole with an edge or border comprising melted and then solidified polymer material. Due to the self-reinforced nature of polymer from which the first and second panels are formed, the eyelets do not rip through the material, even when heavy weight is placed inside the cavity of the bag.

The postal transit bags may further comprise a reinforcing strip at the first and/or the second panel. The reinforcing strips may be arranged to extend along a fourth edge of the first and the second panel, wherein the fourth edge is opposite the first edge. Each reinforcing strips are boned to either the first or the second panel, and reinforce the edge of said panel. They do not act as a closure or fastener for the cavity within the postal transit bag.

The one or more eyelets may be formed through both the first and/or second panel and the respective reinforcing strip. In other words, a strip may be placed at the lip of the bag, to prevent the eyelets ripping through the first or second side panel when the bag is loaded with heavy items.

Preferably, each of the first panel, the second panel and/or the base panel of the postal transit bag comprises a thermal backing layer extending across the inner surface of said panel. In other words, the postal transit bag may be provided with improved thermal insulation properties by providing the panels with a laminated structure of a layer of selfreinforced polymer and a layer of thermal insulation (for instance a foam or wadding, or a reflective thermal blanket). Alternatively or additionally, a fire retardant layer may be incorporated, or a fire retardant additive may be incorporated into the self-reinforced polymer. Alternatively or additionally, a infra-red disruptive additive (such as TiC>2 or black carbon nanoparticles) may be incorporated into the self-reinforced polymer.

In a still further aspect, the is described a method of manufacture for a postal transit bag, as described herein.

In a further aspect, there is a courier box, comprising a panel of a self-reinforced polymer material configured as a net for the courier box, the net comprising a plurality of two-dimensional portions, each two-dimensional portion joined to at least one other two- dimensional portion by a hinge, wherein the net has a perimeter edge; and at least one fastener arranged at the perimeter edge of the net, and configured to releasably couple portions of the perimeter edge to form a three-dimensional shape for the courier box, wherein each two-dimensional portion of the net is a face of the three-dimensional shape; wherein at least one hinge comprises two or more folds (which could also be considered as or two or more bends, or two or more creases). The hinge having two or more folds allows formation of a curved corner for the courier box when in its three-dimensional configuration. This can be especially useful to allow easier coupling of different portions of the zip fastener (in particular, because the stiffness of the self-reinforced polymer means that coupling of a zip fastener around a sharp corner can be more difficult).

Preferably, the two or more folds are linear. Preferably, the two or more folds are substantially parallel. Linear, parallel folds allow a rounded or curved corner to be formed between two two-dimensional portions, wherein the portions are both upright and perpendicular to a common (base) plane. Linear folds that are arranged at an angle to each other allow a rounded corner to be formed between two two-dimensional portions so that the corner is part conical, wherein the portions are arranged at an angle to a common (base) plane.

Preferably, each of the two or more folds are formed by one of: application of heat and pressure to a region of the net, a region of stitching at the net, scoring a region of the net, perforations thorough a region of the net. Each of the folds can be formed by any of the methods described above and below for formation of hinges in self-reinforced polymer. In particular, the hinges comprise a plurality of folds, each fold can be formed by using a press to melt and reform an area of the self-reinforced polymer, or each fold can be formed by scoring through a proportion (up to 70%, but more preferably up to 50%) of the thickness of the self-reinforced polymer material, or each fold can be formed by stitching a line or area of the self-reinforced polymer material. If stitching is used, a polymer compound or self-reinforced polymer strip may be placed over the stitching, in order to waterproof the hinge. Preferably, a portion of the perimeter edge of the net intersecting each of the at least one hinge comprising two or more folds is configured to releasably couple to a curved portion of the perimeter edge. Preferably, the curved portion of the perimeter edge is a curved corner of one of the two-dimensional portions of the net. In other words, the hinge comprising two or more folds can form a curved corner at the three-dimensional configuration of the courier box, which can be coupled (via the fastener) to a curved corner of a portion of the net. The curved corner makes coupling of the zip fastener (and other types of fastener) to be easier for the user. The curved corner could be at a polygon shaped two-dimensional portion, or at a circle or oval shaped two-dimensional portion for instance.

Preferably, the two or more folds comprises three or more folds. Any number of folds could be used, to generate a smooth corner for coupling to a curved corner at another portion of the net. The number of folds may be chosen to achieve a specific arc at a curved corner.

Preferably, the panel of the self-reinforced polymer material is formed from 2 to 14 layers of self-reinforced polymer material, or more preferably 2 to 8 layers of self-reinforced polymer material, or more preferably 3 to 6 layers of self-reinforced polymer material. The layers are consolidated (or thermo-compressed together) by application of heat and pressure. In general, the layers will be consolidated before formation of the self-reinforced polymer panel into the net. A larger number of consolidated layers will provide a thicker and stiffer self-reinforced polymer material. However, an increased number of layers will also increase the weight of the courier box.

Preferably, a planar surface of the net is provided with a three-dimensional surface patterning. The planar surface may be the surface of the net which provides the outer surface of the courier box when the courier box is in its three-dimensional configuration. The three-dimensional surface patterning may be any patterning, contouring or undulations which create a higher coefficient of friction at the surface. This can reduce slippage of the courier box during transit. The patterning may also improve the aesthetic appearance of the courier box.

Preferably, the net has a first planar surface and an opposing second planar surface, and the net further comprises one or more strip of self-reinforced polymer material arranged at the first planar surface of the net. The strip of self-reinforced polymer material increases the stiffness of certain faces of the courier box over which the strips extend. Increasing the stiffness of said faces can improve the robustness of the structure of the courier box when it is in its three-dimensional configuration. This can in turn reduce the likelihood that the courier box could be crushed or disfigured. Preferably, the one or more strip of self-reinforced polymer material is positioned adjacent to and parallel with at least a portion of the perimeter edge of the net. For instance, the strip of self-reinforced polymer material may be arranged at the edge of the planar face of one or more two-dimensional portion of the net, so as to be arranged at the edge of one or more face of the courier box when it is in its three-dimensional configuration. Equally, the strip of self-reinforced polymer material could be arranged to extend across the planar surface of one or more two-dimensional portion of the net, but arranged away from an edge.

Preferably, the one or more strip of self-reinforced polymer material is positioned to extend across a planar surface of at least one two-dimensional portion of the net so as to pass over the centre-point of the planar surface of the at least one two-dimensional portion. For instance, the strip of self-reinforced polymer material can extend across the centre of the certain faces of the courier box, when in its three dimensional configuration. The strip of self-reinforced polymer material may be arranged to extend only across the two- dimensional portions of the net having the largest area, or having an area over a certain threshold.

Preferably, the one or more strip of the self-reinforced polymer material is formed from 2 to 14 layers of self-reinforced polymer material, or more preferably 2 to 8 layers of self-reinforced polymer material, or more preferably 3 to 6 layers of self-reinforced polymer material. As above, the layers may be consolidated, or thermo-compressed, prior to applying the strip to the net of the courier box. A greater number of layers of self-reinforced polymer provides a strip that is thicker and stiffer, and may provide a more robust reinforcement to the courier box.

Preferably, the strip covers less than 50% of the first planar surface of the net, or more preferably the strip covers less than 30% of the first planar surface of the net. The strip of self-reinforced polymer material may cover less than 10% of the first planar surface of the net. More specifically, the strip of self-reinforced polymer material may cover less than 40%, or less than 25% of any given face of the courier box when the courier box is in its three-dimensional configuration. Coverage of a greater area can provide a more robust structure for the courier box, but increased weight. Thus, there is a balance between the area over which the strip of self-reinforced polymer material covers, and the desire to keep the courier box lightweight and easily collapsible.

Preferably, the self-reinforced polymer is one of: self-reinforced polypropylene, or self-reinforced polyethylene. The self-reinforced polymer may be a compound woven selfreinforced polymer. More details of the characteristics of a self-reinforced polymer material are provided elsewhere in this description. Preferably, the fastener is bonded to the net at the perimeter edge by one of: stitching, sonic welding, heat welding. Any suitable method of bonding to the selfreinforced polymer material could be used.

Preferably, the fastener is a zip fastener. Other types of fastener could be used, including push studs (poppers), or flaps having hoop-and-loop fastening. Coupling using all of these types of fastener may be improved using the hinge comprising a plurality of folds, as described above. In particular, ease of coupling of all types of fastener may be improved by implementation of hinges having multiple folds for providing rounded or smooth-curved corners at the courier box.

Preferably, a top stop and/or bottom stop of the zip fastener comprises a security latch. The security latch may be of a type that is tamper-proof, or that allows previous tampering or opening of the fastener to be visible to the user.

In a further aspect, there is a method of manufacture of the courier box described above.

In a still further aspect there is a collapsible box, the collapsible box having a collapsed state and a containing state, the box comprising: a panel of self-reinforced polymer, configured as a net for the reusable box, the net comprising a planar at least eight sided portion and a planar lid portion, an edge of the lid portion hingedly connected to the at least eight sided portion at an edge at a first side of the at least eight sided portion; wherein folds are arranged in the at least eight sided portion to define a base, four side walls, and four gusset portions, each gusset portion extending between a fold defining an edge of a side wall and a fold defining an edge of an adjoining side wall; and wherein in the collapsed state each of the four side walls are folded over the base, and the lid is configured to wrap around at least part of the base and/or at least part of the folded side walls; and wherein in the containing state a cavity is contained, the cavity defined between the base, the four side walls and the lid, each of the four gusset portions being folded in half, and a half of each folded gusset portion being fastened to an adjoining side wall.

The collapsible box can be reversible transformed between the collapsed and the containing state. This allows the box to be reusable. In particular, transformation of the box into the collapsed state allows for the box to be compactly stored, or to be compactly transported back to an original supplier. The particular configuration of the box provides an especially compact and lightweight format in the collapsed state, but also a relatively robust and rigid format in the containing state. Use of self-reinforcing polymer to form the net of the box allows for the box to be strong but lightweight and resistant to impacts and piercing. Furthermore, although the material is durable (and so allows for reuse), the material is easily recyclable at end of life.

The folded gusset portion may be reversibly fastened to the adjoining side wall (for instance using hoop-and-loop fastening), or may be permanently fastened (for instance by stitching). The two halves of the gusset may be folded together and fastened using a reversible fastener, in order to provide greater stability to the box in the containing state (as described below).

In other words, the half of each folded gusset portion may be permanently or reversibly fastened to an adjoining side wall. The permanent fastening may be via a fastener such as stitching or adhesive, whereas the reversible fastening may be via a fastener such as hook-and-loop fastening. In either case, the half of each folded gusset portion that is fastened to the adjoining side wall may be fastened to the adjoining side wall inside the cavity.

Furthermore, the half of each folded gusset portion may be coupled to an adjoining other half of the same gusset portion when the box is in the containing state. This coupling may be by a fastener, and the fastener may be a hoop-and-loop fastener. The hook-and- loop fastener described for use in the collapsible box may be bonded to the panel of selfreinforced polymer forming the net of the box by stitching (in particular, using an automatic, or auto-programmed sewing or stitching machine).

The folds in the at least eight sided portion may comprise two pairs of parallel folds, a first pair of parallel folds arranged perpendicular to and intersecting the second pair of parallel folds, the folds extending across the at least eight sided portion so that the base is a quadrilateral (or four sided shape) arranged at the centre of the at least eight sided portion, each side wall is an quadrilateral arranged having an edge connected to a different edge of the quadrilateral base, and each gusset portion is connected to (and extending between) an edge of a side wall and an edge of an adjoining side wall. The folds may extend between opposite corners of the at least eight sided shape

The at least eight sided portion may have eight sides, wherein each side of the at least eight sided portion is an edge of a different one of the four side walls and the four gusset portions. In this case, each gusset portion is triangular.

The at least eight sided portion may be an eight sided portion having a first to an eighth corner sequentially labelled clockwise around the eight sided portion. In this case, the folds comprise: a first fold between a first corner of the eight sided portion and the fourth corner; a second fold between the second corner and the seventh corner; a third fold between the third corner and the sixth corner; and a fourth fold between the fifth corner and the eighth corner. The lid is hingedly connected to an edge extending between the eighth and the first corner of the eight sided portion.

The four gusset portions may each comprise a dividing fold to fold each gusset portion in half. In some case, each gusset portion may further comprise a linear opening extending in line with the dividing fold. The linear opening or cut-out reduces the weight of each gusset portion, and also reduces the bulk of the dividing fold, especially when the box is in the collapsed state. However, it has been found that the linear openings or cut-outs do not significantly reduce strength or rigidity of the box in the containing state.

The lid portion may further comprise a further fold extending in a direction parallel to the edge hingedly connected to the at least eight sided portion. The further fold may allow the lid to wrap around at least part of the base and at least part of the folded side walls when the reusable box is in the collapsed state.

The lid portion may further comprise one or more tab extending from an edge of the lid portion, each tab configured for insertion into the cavity when the reusable box is in the containing state, and/or to couple to one or more of the side walls and/or the base portion when the reusable box is in the containing state or the collapsed state. The one or more tabs may be used to close the lid (or connect the lid to the side walls) when the collapsible box is in the containing state. The one or more tabs may also be used to secure the box in the collapsed state (for instance when used in conjunction with hook-and-loop fastener), and prevent the various portions unfolding from the collapsed state.

The one or more tab may comprise: one or more tab extending from the lid portion at an edge opposite the edge hingedly connected to the at least eight sided portion; and/or one or more tab extending from the lid portion at an edge perpendicular to the edge hingedly connected to the at least eight sided portion.

Each of the one or more tab may be arranged to fit through a respective opening, aperture or slit at side wall of the four side walls, the opening or slit adjoining the position of the tab when the box is in the containing state. The opening, aperture or slit may be formed in an additional lip connected to each side wall.

At least one of the one or more tabs may be arranged as a hook or ‘L’ shape. In this case, the corresponding aperture at the side wall into which the tab can be inserted may be sized so that the hook shaped tab hooks through the aperture, so as to provide a more secure coupling.

Each of the one or more tab may further comprise a hook-and-loop fastener, arranged to couple to a cooperating hook-and-loop fastener at a surface at one of the side walls when the box is in the containing state and/or to couple to a cooperating hook-and- loop fastener at a surface at the base and/or one or more of the folded side walls when the box is in the collapsed state. This may secure the box in the collapsed or containing state more securely.

The panel of self-reinforced polymer may comprises two to six consolidated layers of the self-reinforced polymer. Alternatively, the panel may comprise up to eight consolidated layers of the self-reinforced polymer, or just a single layer of self-reinforced polymer. The consolidated layers will have been heated and compressed together to form a laminated structure that is not intended to have separable layers. Increasing the number of layers increases the thickness and rigidity of the panel, but also increases the weight of the collapsible box overall. Therefore, the number of layers is selected to balance durability of the box and the desire to reduce its overall weight.

The panel of self-reinforced polymer may have a thickness of 0.4 mm to 1.5 mm, or of 0.1 to 1 mm, or of 0.2 to 1.5 mm, or of 0.1 to 2 mm. The thickness is chosen to balance the rigidity and robustness of the box with its overall weight.

The self-reinforced polymer may be a self-reinforced polymer woven composite, or a standard formation of self-reinforced polymer formed from heating and/or compression of threads or extruded strands of the polymer (as described elsewhere in this disclosure). The self-reinforced polymer may be self-reinforced polypropylene, or self-reinforced polyethylene.

Folds may be applied within the panel by application of heated and compressed linear regions, or by application of scores in the surface of the panel. In some cases, one score or fold line could be used, or two or three closely spaced parallel fold lines could be used.

The collapsible box may further comprise a reinforcing panel, on the base of the box. The reinforcing panel improves the stability and rigidity of the box, especially in the containing state. The reinforcing panel may be arranged on top of the surface of the base that is inside the cavity when the box is in the containing state.

The reinforcing panel may comprise a substrate layer arranged on the base. The substrate layer may be foam. The reinforcing panel may further comprise a layer of selfreinforced polymer covering at least a portion of the substrate layer. The layer of selfreinforced polymer covering at least a portion of the substrate layer may itself comprise up to four consolidated layers of self-reinforced polymer. Ideally, the layer of self-reinforced polymer covering at least a portion of the substrate layer, the substrate layer, and the panel of self-reinforced polymer are made of the same type of polymer. This aids end of life recycling, as well as providing better adhesion of the layers.

The reinforcing panel (including the substrate layer and covering layer of selfreinforced polymer) may be bonded to the base by heat and compression (to melt the polymer at the interface between the layers, and form a bond therebetween). In one example, the layers of the reinforcing panel may bonded to the base by compression in a heated press at 125°C for 5 minutes, or at 105°C for 6 minutes. Alternatively, the bonding may be by stitching, or by adhesive. Other bonding techniques could be used.

Apertures may be arranged through the layer of self-reinforced polymer covering at least a portion of the substrate layer, to expose the substrate layer through the apertures. For instance, this exposes regions of foam on a surface within the cavity of the box in the containing state, which acts to provide grip and friction to hold items within the box in place.

Alternatively, one or more islands or regions of foam could be applied to one or more inner surfaces (when the box is in the containing state) of the base, reinforcing panel or side wall of the box. For instance, one or more foam regions may be arranged on the layer of self-reinforced polymer covering at least a portion of the substrate layer.

Straps or fasteners may be arranged to be within the cavity of the box when in the containing state. These can hold goods within the cavity when the box is in use for containing items. The straps may be permanently attached within the box, or may have coupling or fixing points thereto. In one example, a bungee strap can be coupled to the base of the box. The bungee strap may be removabley coupled, for instance by hooking to cut-outs in the reinforcing panel.

In a still further aspect there is a method of manufacture of the collapsible box as described above.

In yet another aspect there is a reusable envelope, comprising self-reinforced polymer. Preferably, the walls of the envelope are formed from at least one panel of selfreinforced polymer.

The at least one panel may be a panel of self-reinforced polymer, having two folds to divide the panel into a first portion, a second portion and a lip portion; wherein a first fold divides the first portion from the second portion, and the second fold divides the second portion from the lip portion. The panel may be folded at the first fold to overlap the first portion with the second portion, wherein a first seam bonds a first edge region of the first portion to a first edge region of the second portion, and wherein a second seam bonds a second edge region of the first portion to a second edge region of the second portion. The first edge region of the first and the second portion may be an edge perpendicular to the first fold, and the second edge region of the first and the second portion may be an edge perpendicular to the first fold and opposite the first edge region. An opening may be defined between the first and the second portion, at an edge of the first and second portion opposite the first fold. The panel may be folded at the second fold to cause the lip portion to overlap with the first portion, so as to close the opening. Preferably, the reusable envelop comprises a fastener, arranged to reversibly couple the lip portion to the first portion when overlapped.

The fastener may be hoop-and-loop fastener. The fastener may comprise a tab at the lip portion, for insertion into an aperture in the second portion.

The seams may be formed by stitching, by heating and/or compression of the first and the second edge regions of the first and second portions, or by adhesive. In other words, the seams may be bonded by these methods.

Preferably, the first and second portion have equal dimensions.

The at least one panel may be a first panel and a second panel, the first panel having a first portion and a lip portion, divided by a fold. The second panel and the first portion may be arranged to overlap, and bonded together around a portion of a perimeter edge, leaving an opening at a portion of the perimeter edge of the second panel that is adjacent the fold, in order to allow insertion of items between the first portion and the second panel. The first panel may be folded at the fold to cause the lip to overlap the second panel, in order to close the opening.

Preferably, the reusable envelop comprises a fastener, arranged to reversibly couple the lip portion to the second panel when overlapped

The fastener may be hoop-and-loop fastener. The fastener may comprise a tab at the lip portion, for insertion into an aperture in the second panel.

The bonding may be by stitching, by heating and/or compression, or by adhesive. In other words, the seams may be formed between the first portion and the second panel by these methods.

In another aspect there is a case comprising one or more walls having a concertina fold, wherein the one or more wall are configured to permit the case to transform from a first position to a second position, wherein in the first position the concertina fold in the one or more wall is extended to increase the size of a cavity within the case, and wherein in the second position the concertina fold in the one or more wall is at least partially contracted to reduce the size of the cavity within the case. The cavity is a volume defined within the walls of a case, and the volume may contain an item. The concertina fold being extended comprises the concertina fold being open, whereas the concertina fold being at least partially contracted comprises at least one fold of the concertina fold being closed (or in the folded position).

The concertina fold may comprise at least one fold. In other cases, the concertina fold may comprise at least two folds, the at least two folds being parallel with each other for at least part of their length and arranged so that alternate folds are folded in opposite directions. This creates a ‘zig-zag’ formation in the one or more wall. In some cases, the concertina fold comprises two or more folds, and the concertina fold may be partially contracted so that only some of the two or more folds are closed, or fully contracted so that all of the two or more folds are closed. This allows the capacity of the case to be changed by varying the volume of the cavity defined within the case. In particular, the case can be configured to have a maximum capacity (when the concertina fold is fully extended), to have a medium capacity (when only some of two or more folds of the concertina fold are closed), or to have a minimum capacity (when all of the folds of the concertina fold are closed).

The at least one fold of the concertina fold may divide the one or more wall having the concertina fold into two or more portions. When the case is in the second position having the concertina fold in a contracted configuration, a first and second adjoining portion may face or oppose each other. One or more fastener may be arranged on the one or more wall having a concertina fold, so that when the one or more fastener is coupled together the concertina fold is secured in a contracted configuration. In one instance, the fastener may couple the first and second adjoining portion. For instance, the fastener may be a hook-and-loop fastener that couple when the first and second adjoining portion oppose each other. Where the capacity of the case is varied by closure of only some of two or more folds of the concertina fold, then a fastener may be used to secure closed only some of the two or more folds, whilst allowing others of the two or more folds to extend or open.

A reinforcing panel may be arranged on one or more portion of the one or more wall having the concertina fold. The reinforcing panel may extend across a surface of one or more portion. The reinforcing panel may be used to increase the stiffness of each portion compared to the region of the one or more wall comprising the fold.

The case or box may comprise three of more walls having a concertina fold, wherein said walls are joined at seams substantially perpendicular to the at least one fold of the concertina fold, so that the said walls together form side walls for a tube with the cavity therethrough.

The case may further comprise opposing top and bottom walls, arranged to connect to the side walls so that the top and the bottom walls close the cavity at each end of the tube. The top and/or bottom walls may be removable from the side walls via an openable, reversible fastening. Alternatively, one of the top and/or bottom walls may be permanently fixed to the side walls (for instance, at the perimeter of the tube forming the side walls).

The one or more walls (and/or one or more reinforcing panel) may comprise or be formed of self-reinforced polymer or self-reinforced polyolefin. The self-reinforced polymer may be self-reinforced polypropylene or self-reinforced polyethylene. Further detail of these types of material is provided elsewhere in this disclosure. The self-reinforced polymer may be a self-reinforced polymer woven composite (such as a self-reinforced polypropylene woven composite for example known by the trade name Dewforge ^RTM ). In some cases, the one or more walls (and/or one or more reinforcing panel) may comprise or be formed of one or more laminated layers of self-reinforced polymer and/or foam layer (the foam such as expanded polypropylene, or a microcellular foam). Alternatively, the one or more walls (and/or one or more reinforcing panel) may comprise any nylon, polymer or natural fibre fabric.

The following numbered clauses define illustrative examples of the courier box:

1. A courier box, comprising: a panel of a self-reinforced polymer material configured as a net for the courier box, the net having a first and a second planar surface and a perimeter edge; one or more strip of self-reinforced polymer material arranged at the first planar surface of the net, positioned adjacent to and parallel with at least a portion of the perimeter edge of the net; and at least one fastener arranged at the perimeter edge of the net, and configured to releasably couple portions of the perimeter edge to form a three-dimensional shape for the courier box.

2. The courier box of clause 1 , wherein the strip covers less than 50% of the first planar surface of the net, or more preferably the strip covers less than 30% of the first planar surface of the net.

3. The courier box of clause 1 or clause 2, wherein the panel of the self-reinforced polymer material is formed from 2 to 14 layers of self-reinforced polymer material, or more preferably 2 to 8 layers of self-reinforced polymer material, or more preferably 3 to 6 layers of self-reinforced polymer material.

4. The courier box of any preceding clause, wherein the one or more strip of the selfreinforced polymer material is formed from 2 to 14 layers of self-reinforced polymer material, or more preferably 2 to 8 layers of self-reinforced polymer material, or more preferably 3 to 6 layers of self-reinforced polymer material. 5. The courier box of any preceding clause, wherein the one or more strip is a single strip that extends adjacent to and parallel with more than 50%, more than 60%, more than 75% or more than 90% of the perimeter edge.

6. The courier box of any preceding clause, wherein the first planar surface of the net is provided with a three-dimensional surface patterning.

7. The courier box of any preceding clause, wherein the self-reinforced polymer is one of: self-reinforced polypropylene, or self-reinforced polyethylene.

8. The courier box of any preceding clause, wherein the fastener is bonded to the net at the perimeter edge by one of: stitching, sonic welding, heat welding.

9. The courier box of any preceding clause, wherein the fastener is a zip fastener.

10. The courier box of clause 9, wherein a top stop and/or bottom stop of the zip fastener comprises a security latch.

11. The courier box of any preceding clause, wherein the net is a T shape and forms a cube or cuboid when configured to form a three-dimensional shape and the fastener is a zip fastener, wherein a first half of the zip fastener is connected to the perimeter edge of a first elongate portion of the T shaped net, and a second half of the zip fastener is connected to the perimeter edge of a second elongate portion of the T shaped net, the first and second elongate portion extending perpendicular to each other to form the T shaped net, and the first and second half of the zip fastener connectable to close the fastener and form the three-dimensional shape.

12. The courier box of any preceding clause, wherein the panel comprises one or more hinges to enable formation of the three-dimensional shape.

13. The courier box of any preceding clause, further comprising an insert configured to house an item, the insert configured to be contained within the courier box when the courier box is configured to form the three-dimensional shape.

14. The courier box of clause 13, wherein the net is a first net, and the insert may be formed from a second net, and the insert is collapsible. 15. The courier box of clause 14, wherein the second net may be formed in a panel of self-reinforced polymer or a panel of foam.

16. An insert for a courier box, the insert comprising: a tubular wall element formed from a panel folded at each of two or more hinges in the panel to arrange the panel in a tubular configuration; wherein at least two or more of the hinges comprise one or more tab connected at the pivot of the respective hinge and cut out from one of the surfaces adjoining the said pivot of the same hinge, each tab arranged to project from the outer surface of the tubular wall element at the respective hinge.

17. The insert of clause 16, wherein the tabs are arranged to act as a spacer such that, when the insert is placed in the courier box the tubular wall element is held at a predetermined distance from the adjacent walls of the courier box.

18. The insert of clause 16 or clause 17, wherein each hinge comprises at least a first and second tab, wherein the first tab is cut out of a first surface adjoining the said pivot of the same hinge and the second tab is cut out of a second surface adjoining the said pivot of the same hinge, wherein the first and second surface are joined at the hinge.

19. The insert of any one of clauses 16 to 18, wherein the panel is arranged in the tubular configuration by joining a first end of the panel with an opposing second end of the panel, wherein the join is formed by interlinking a slot at the first end with a slot at the second end of the panel.

20. The insert of any one of clauses 16 to 19, wherein the insert comprises selfreinforced polymer.

21. The insert of any one of clauses 16 to 20, wherein the panel of the insert comprises a layer of self-reinforced polymer on a layer of polymer foam.

22. A kit for courier transportation, comprising: the courier box according to any one of clauses 1 to 15, which in the three- dimensional configuration has walls defining a volume for transporting or storing goods; and one or more insert according to any one of clauses 16 to 21, wherein the insert has appropriate dimensions to fit inside the volume of the courier box such that the outmost edge of the one or more tab makes contact with a respective inner surface of the walls of the courier box.

23. The kit of clause 22, further comprising a temperature controlled element, for arranging in a void between the outermost surface of the tubular wall element of the insert and an inner surface of the courier box.

24. The kit of clause 23, wherein the temperature controlled element is selected from one of: ice, dry ice, a cold pack, a heat pack.

25. A postal transit bag, comprising: a first and a second panel of self-reinforced polymer; and a base panel of self-reinforced polymer, having a fold to divide the base panel into two portions; wherein a first portion of the base panel overlaps a portion of the first panel adjacent a first edge of the first panel, and wherein a second portion of the base panel overlaps a portion of the second panel adjacent a first edge of the second panel; and wherein a first seam joins the base panel to the first panel, and a second seam joins the base panel to the second panel; and wherein a third seam at a second edge at each of the first and second panel joins at least the first and second panel, and a fourth seam at a third edge at each of the first and the second panel joins at least the first and second panel, the second and third edge being opposing edges that are each perpendicular to the first edge.

26. The postal transit bag of clause 25, wherein the first and second panel of the postal transit bag are formed having a thickness that is 60% or less than the thickness of the base panel.

27. The postal transit bag of clause 25 or clause 26, wherein the self-reinforced polymer is formed from a plurality of consolidated layers of self-reinforced polymer, or is a self-reinforced polymer woven composite.

28 The postal transit bag of any one of clauses 25 to 27, wherein the seams are formed by way of one of: stitching, heat welding, sonic welding, heat and compression. 29. The postal transit bag of any one of clauses 25 to 28, wherein the first and/or the second panel further comprises one or more eyelet at an edge adjacent to an opening to the postal transit bag.

30. The postal transit bag of any one of clauses 25 to 29, further comprising a reinforcing strip at the first and/or the second panel, at an edge adjacent to an opening to the postal transit bag.

31. The postal transit bag of any one of clauses 25 to 30, wherein each of the first panel, the second panel and/or the base panel of the postal transit bag comprises a thermal backing layer and/or fire retardant layer extending across the inner surface of said panel.

32. A protective sleeve, comprising: a first portion comprising a first layer of foam and a first layer of self-reinforced polymer, the first layer of self-reinforced polymer bonded to the first layer of foam, the first layer of self-reinforced polymer having relief cuts or indentations in its surface; a second portion comprising a second layer of foam and a second layer of selfreinforced polymer, the second layer of self-reinforced polymer bonded to the second layer of foam, the second layer of self-reinforced polymer having relief cuts or indentations in its surface; and one or more strap; the first and second portion arranged having the first foam layer opposing the second foam layer, and the strap arranged to hold the first portion and the second portion around an item placed between the first foam layer and the second foam layer.

33. The protective sleeve of clause 32, wherein the strap further comprises one or more buckle or clasp.

34. The protective sleeve of clause 31 or clause 33, wherein the relief cuts or indentations are parallel, spaced apart linear cuts or linear indentations.

35. The protective sleeve of clause 34, wherein the linear cuts or linear indentations are arranged to extend perpendicular to the longitudinal extension of the strap. 36. The protective sleeve of clause 34 or clause 35, wherein the linear cuts or linear indentations at the first portion are parallel with the linear cuts or linear indentations of the second portion.

37. The protective sleeve of any one of clauses 32 to 36, further comprising a hinge panel, the hinge panel joining a first edge of the first portion with a first edge of the second portion.

38. The protective sleeve of any one of clauses 32 to 37, further comprising a trim around the perimeter edge of each of the first portion and/or the second portion.

39. The protective sleeve of any one of clauses 35 to 38, further comprising a lining layer, extending across at least one surface of the first and/or the second portion.

40. The protective sleeve of any one of clauses 32 to 39, further comprising a pocket on the foam layer of at least one of the first portion and the second portion.

41. A courier box, comprising: a panel of a self-reinforced polymer material configured as a net for the courier box, the net comprising a plurality of two-dimensional portions, each two-dimensional portion joined to at least one other two-dimensional portion by a hinge, wherein the net has a perimeter edge; and at least one fastener arranged at the perimeter edge of the net, and configured to releasably couple portions of the perimeter edge to form a three-dimensional shape for the courier box, wherein each two-dimensional portion of the net is a face of the three- dimensional shape; wherein at least one hinge comprises two or more folds.

42. The courier box of clause 41 , wherein the two or more folds are linear.

43. The courier box of clause 42, wherein the two or more folds are substantially parallel.

44. The courier box of any one of clauses 41 to 43, wherein each of the two or more folds are formed by one of: application of heat and pressure to a region of the net, a region of stitching at the net, scoring a region of the net. 45. The courier box of any one of clauses 41 to 44, wherein a portion of the perimeter edge of the net intersecting each of the at least one hinge comprising two or more folds is configured to releasably couple to a curved portion of the perimeter edge.

46. The courier box of clauses 45, wherein the curved portion of the perimeter edge is a curved corner of one of the two-dimensional portions of the net.

47. The courier box of any one of clauses 41 to 46, wherein the two or more folds comprises three or more folds.

48. The courier box of any one of clauses 41 to 47, wherein the panel of the selfreinforced polymer material is formed from 2 to 14 layers of self-reinforced polymer material, or more preferably 2 to 8 layers of self-reinforced polymer material, or more preferably 3 to 6 layers of self-reinforced polymer material.

49. The courier box of any one of clauses 41 to 48, wherein a planar surface of the net is provided with a three-dimensional surface patterning.

50. The courier box of any one of clauses 41 to 49, wherein the net has a first planar surface and an opposing second planar surface, and the net further comprises: one or more strip of self-reinforced polymer material arranged at the first planar surface of the net.

51. The courier box of clause 50, wherein the one or more strip of self-reinforced polymer material is positioned adjacent to and parallel with at least a portion of the perimeter edge of the net.

52. The courier box of clause 50, wherein the one or more strip of self-reinforced polymer material is positioned to extend across a planar surface of at least one two- dimensional portion of the net so as to pass over the centre-point of the planar surface of the at least one two-dimensional portion.

53. The courier box of any one of clauses 50 to 52, wherein the one or more strip of the self-reinforced polymer material is formed from 2 to 14 layers of self-reinforced polymer material, or more preferably 2 to 8 layers of self-reinforced polymer material, or more preferably 3 to 6 layers of self-reinforced polymer material.

54. The courier box of any one of clauses 50 to 53, wherein the strip covers less than 50% of the first planar surface of the net, or more preferably the strip covers less than 30% of the first planar surface of the net.

55. The courier box of any one of clauses 41 to 54, wherein the self-reinforced polymer is one of: self-reinforced polypropylene, or self-reinforced polyethylene.

56. The courier box of any one of clauses 41 to 55, wherein the fastener is bonded to the net at the perimeter edge by one of: stitching, sonic welding, heat welding.

57. The courier box of any one of clauses 41 to 56, wherein the fastener is a zip fastener.

58. The courier box of clause 57, wherein a top stop and/or bottom stop of the zip fastener comprises a security latch.

59. A method of manufacture of the courier box of any one of clauses 41 to 58.

List of Figures

The disclosure will now be put into practice in a number of ways, and preferred embodiments will now be described by way of example only and with reference to the accompanying drawings, in which:

FIGURE 1 shows schematic views of a two-dimensional net of the courier box, and the net in a three-dimensional configuration to provide the courier box;

FIGURE 2 is a photograph of the first planar surface of the net of the courier box;

FIGURE 3 is a photograph of the second planar surface of the net of the courier box;

FIGURE 4 is a photograph of the net configured in its three dimensional configuration to provide the courier box;

FIGURE 5 is a photograph providing a magnified view of the reinforcing strips and bottom stop of the zip fastener; FIGURE 6 is a photograph of the face of the courier box on which the terminal ends of the zip fastener are mounted;

FIGURE 7 is a photograph of the courier box including hinges or folds;

FIGURE 8 is a photograph of an example courier box with an integrated handle;

FIGURE 9 is a photograph of a goods strap at the second planar face of the net of the courier box;

FIGURE 10A shows schematic views of a further example for a two-dimensional net of the courier box, and the net in a three-dimensional configuration to provide the courier box;

FIGURE 10B shows a photograph of the courier box according to the example shown in FIGURE 10A;

FIGURE 11A shows schematic views of another example for a two-dimensional net of the courier box, and the net in a three-dimensional configuration to provide the courier box;

FIGURE 11 B shows photographs of the example courier box of FIGURE 11 A, in various stages of transformation into a compact and packaged formation;

FIGURE 12 shows schematic views of a still further example for a two-dimensional net of the courier box, and the net in a three-dimensional configuration to provide the courier box;

FIGURE 13 shows photographs of the net of FIGURE 12. FIGURE 13(a) is a photograph of the net of FIGURE 12 configured in its three dimensional configuration to provide the courier box, and FIGURE 13(b) is a photograph of the terminal ends of the fastener of the courier box according to the example shown in FIGURE 12;

FIGURE 14 shows photographs of the net of FIGURE 12. FIGURE 14(a) is a photograph of the net of FIGURE 12 configured in its three dimensional configuration, although partially opened, to provide the courier box, and FIGURE 14(b) is a photograph of the net of FIGURE 12;

FIGURE 15 is a photograph of a goods strap at the second planar face of the net of the courier box according to the example of FIGURE 12;

FIGURE 16 shows schematic views of a still further example for a two-dimensional net of the courier box, and the net in a three-dimensional configuration to provide the courier box, the courier box having some hinges comprising two or more folds;

FIGURE 17 shows views of the net of the courier box. FIGURE 17(a) is a photograph of the first planar surface of the net of a courier box, and FIGURE 17(b) is a photograph of the second planar surface of the net of the same courier box; FIGURE 18 (comprising FIGURES 18(a), 18(b) and 18(c)) shows different views of a hinge comprising a plurality of folds;

FIGURE 19 (comprising FIGURES 19(a), 19(b), 19(c) and 19(d)) shows photographs of different views of the courier box having the net shown in FIGURE 17(a) and 17(b), in its three-dimensional configuration;

FIGURE 20 shows schematic views of a still further example for a two-dimensional net of the courier box, and the net in a three-dimensional configuration to provide the courier box, the courier box comprising additional strips of self-reinforced polymer;

FIGURE 21 (comprising FIGURES 21(a), 21(b), 21(c) and 21(d)) shows photographs of different views of a courier box in its three-dimensional configuration;

FIGURE 22 is a schematic diagram showing the net of an example insert for the courier box;

FIGURE 23 is a photograph showing a first view of the example insert for the courier box;

FIGURE 24 is a photograph showing a second view of the example insert for the courier box;

FIGURE 25 is a photograph showing a fourth view of the example insert for the courier box;

FIGURE 26 is a photograph showing views of the net of the example insert for the courier box;

FIGURE 27 is an example of a panel of self-reinforced polymer having relief cuts;

FIGURE 28 shows photographs of a second type of insert for the courier box;

FIGURE 29 shows further photographs of the second type of insert for the courier box;

FIGURE 30 is a schematic diagram of a postal transit bag;

FIGURE 31 shows photographs of aspects of the postal transit bag.;

FIGURE 32 shows a schematic diagram of a first face of a net of a first example of a collapsible box;

FIGURE 33 shows a schematic diagram of a second face of a net of the first example of a collapsible box;

FIGURE 34 shows a schematic diagram of a configuration of the first example of a collapsible box during transformation from the collapsed to the containing state;

FIGURE 35 shows a schematic diagram of a further configuration of the first example of a collapsible box during transformation from the collapsed to the containing state; FIGURE 36 shows a schematic diagram of the first example of a collapsible box in the collapsed state;

FIGURE 37 shows a schematic diagram of the first example of a collapsible box in the containing state;

FIGURE 38 shows schematic diagrams of a second example of a collapsible box;

FIGURE 39 shows a schematic diagram of a net of third example of a collapsible box;

FIGURE 40 shows a photograph of a net of a further example of a collapsible box;

FIGURE 41 shows photographs of an example of a collapsible box in the collapsed state;

FIGURE 42 shows photographs of a configuration of the example collapsible box during transformation from the collapsed to the containing state;

FIGURE 43 shows photographs of a further configuration of the example collapsible box during transformation from the collapsed to the containing state;

FIGURE 44 shows a photograph of a still further configuration of the example collapsible box during transformation from the collapsed to the containing state;

FIGURE 45 shows photographs of the process of insertion of tabs for configuration of the example collapsible box during transformation from the collapsed to the containing state;

FIGURE 46 shows a photograph of the example collapsible box in the containing state;

FIGURE 47 depicts a first example of an envelope formed from self-reinforced polymer;

FIGURE 48 depicts a second example of an envelope formed from self-reinforced polymer;

FIGURE 49 depicts a third example of an envelope formed from self-reinforced polymer;

FIGURE 50 depicts a fourth example of an envelope formed from self-reinforced polymer;

FIGURE 51 depicts a first view of an example of another configuration for a collapsible box, including a concertinaed wall section;

FIGURE 52 depicts a second view of the example collapsible box including a concertinaed wall section;

FIGURE 53 depicts a third view of the example collapsible box including a concertinaed wall section;

FIGURE 54 depicts a view of an internal side of the concertinaed wall section; FIGURE 55 depicts a view of an external side of the concertinaed wall section;

FIGURE 56 depicts a view of another external side of the concertinaed wall section;

FIGURE 57 depicts another view of an internal side of the concertinaed wall section;

FIGURE 58 depicts view of the collapsible box including a concertinaed wall section in a collapsed configuration;

FIGURE 59 depicts another view of the collapsible box including a concertinaed wall section in a collapsed configuration;

FIGURE 60 depicts a still further view of the collapsible box including a concertinaed wall section in a collapsed configuration; and

FIGURE 61 depicts yet another view of the collapsible box including a concertinaed wall section in a collapsed configuration.

In the figures, like parts are denoted by like reference numerals. The figures are not drawn to scale.

Description of Specific Embodiments with Reference to the Figures

The figures illustrate a number of examples of types of packaging or boxes, cases and bags for containing or transporting items or goods. Each example is described in turn below. Where like features are considered (for instance where similar materials are used, including a self- reinforced polymer and/or polymer foam) the description below is considered to apply to each of the described examples.

A courier box

Referring to FIGURE 1 (a), there is shown a net 100 for a courier box 110. The net 100 is divided into six portions 112 by five hinges 114. The net 100 is formed in a panel of self-reinforced polymer. The net 100 is arranged to fold along the hinges 114, so as to be configured as a three-dimensional shape. Here, the net 100 can be arranged to provide the faces of a cuboid which forms the courier box 110, as shown in FIGURE 1(b).

A fastener 116a, 116b, which in this case is a zip fastener, is arranged around and coupled to the perimeter edge of the net shape. In the present example, a first half of the zip fastener 116a is arranged around the top ‘horizontally’ extending portion of the T shaped net, and a cooperating second half of the zip fastener 116b is arranged around the bottom ‘vertically’ extending portion of the T shaped net. Thus, when the first 116a and second 116b half of the zip fastener are secured together, the net 100 of the courier box is configured as the three-dimensional courier box 110.

Strips of self-reinforced polymer material 118a, 118b are arranged on a first planar face of the net 100, directly adjacent a portion of the perimeter edge of the net 100 and the fastener 116a, 116b. The strips 118a, 118b provide extra stiffness to the net shape, which is helpful to form the structure and improve the rigidity of the courier box 110 when constructed. However, as the thickness of the panel forming the net shape 100 is not increased across its whole area, the net shape 100 still retains sufficient flexibility to allow folding at the hinges 114, and to improve ease of securing the fasteners 116a, 116b. Moreover, compared to increasing the thickness of the panel forming the net shape 100 across its whole area, the weight of the net 100 (and so courier box 110) are minimised whilst still having the described advantageous properties for the courier box 110.

In the present example, the strips 118a, 118b are formed of a self-reinforced polymer. Ideally, each strip 118a, 118b is a single, continuous strip. Each strip 118a, 118b has a width up to around % the width of the panel 112 of the net 100 on which it has been arranged. However, it will be understood that a thicker self-reinforced polymer material used for the strips 118a, 118b will allow a narrower width strip to be used to achieve the same level of reinforcement for the stiffness of the net 100.

As shown in FIGURE 1(a) and 1 (b), the strips 118a, 118b do not extend around the whole perimeter edge of the net 100, although they may do so. In particular, the strips 118a, 118b do not extend to the portion of the perimeter edge adjacent the terminal ends 120a, 120b (or top and bottom stops) of the zip fastener 116a, 116b. This has been found to be beneficial, to allow some extra flexibility near to the terminal ends 120a, 120b of the zip fastener 116a, 116b which is helpful for securing and coupling these portions of the zip fastener. However, the skilled person will understand that the strips 118a, 118b may extend around the whole perimeter edge, especially if a different type of fastener is used. The strips 118a, 118b (and fastener 116a, 116b) can be bonded to the planar surface of the net 100 by stitching, sonic welding, or heat welding, for instance.

In the example of FIGURE 1 , both the net 100 and the strips 118a, 118b are formed from a self-reinforced polymer. Self-reinforced polymers (or polyolefins) are a particular family of thermocomposite materials in which both the reinforcing fibre and the polymer matrix are formed from the same polymer family. The fibres are manufactured as highly orientated form of the same polymer matrix. Self-reinforced polymeric composite materials possess many advantages including thermoformability, high stiffness, high tensile strength, and outstanding impact resistance at low density. Self-reinforced materials are particularly impact resistant for a given weight or density of material. This may allow thinner sheets of material to be used, thereby reducing the overall weight of the courier box compared to manufacture from other materials. Furthermore the material can be melted and recycled, thus fulfilling requirements for use of more sustainable materials. Moreover, the selfreinforced material is waterproof.

It will be understood that, although the term ‘polymer’ and ‘self-reinforced polymer’ are used within this description, this could refer to any thermoplastic composite material or self-reinforced thermoplastic composite material. It could also refer to any polymer or selfreinforced polymer or self-reinforced polymer composite or self-reinforced polyolefin. Particular examples of materials that could be used include self-reinforced polypropylene, or self-reinforced polyethylene.

Typically, sheets or panels of self-reinforced polymer comprise one layer or multiple laminated layers of a self-reinforced polymer material. For instance, a self-reinforced polymer material may comprise a type of polymer produced from a simple olefin (also called an alkene with the general formula C _n H2n) as a monomer. Thicker or multiple layers of the self-reinforced polymer material can be formed to produce a stiffer or more rigid sheet of the material, although fewer or thinner layers can be used to provide a panel that is more deformable and foldable. Generally, the multiple layers are consolidated, by the application of heat and pressure.

In the presently described courier box 110, both the net 100 and the strips 118a, 118b are formed from self-reinforced polymer formed using four consolidated layers of selfreinforced polypropylene, providing a self-reinforced polymer layer having a thickness of around 0.56 mm. However, a different number of layers could be used, either to increase the flexibility of the courier box (by reducing the number of layers) or increasing the rigidity of the courier box (by increasing the number of layers). Increasing the number of layers also increases the weight of the box. For some courier boxes according to the invention, it may be appropriate to reduce the number of layers in the net 100 to increase flexibility of the walls of the courier box 110, whilst also increasing the number of layers in the strip 118a, 118b to increase the rigidity of just these reinforcing sections. As noted above, narrower strips 118a, 118b can be used by increasing the thickness (e.g. the number of layers of self-reinforced polymer) from which the strips 118a, 118b are formed.

It will be understood that in an alternative example, the self-reinforced polymer could be a self-reinforced polymer woven composite. In this case, the woven material comprises only a single layer. However, the weight and density of the woven material can be varied to increase or decrease the thickness of the self-reinforced polymer net. In an example, the self-reinforced polymer woven composite is used having a weight of 350g per cubic metre, and having a thickness of around 0.35 mm. In the present example, the net 100 is formed from a single panel of self-reinforced polymer. The hinges 114 are added by applying heat and/or pressure to at least one area on the surface of the net shape 100 formed of the self-reinforced polymer, to heat at least one portion of the panel at the at least one area to a temperature above or equal to a melting point of the at least one portion. Once the at least one portion of the net 100 has cooled to a temperature below the melting point, a hinge 114 is formed. The heat and/or pressure is applied only at the required position of the pivot of the hinge 114.

It will be understood that the self-reinforced polymer discussed here is formed of stretched, molecularly oriented strands or fibres of the polymer material, for example of polypropylene or other crystalline or semi-crystalline thermoplastic material. After a layer, sheet or panel of self-reinforced polymer has been thermo-compressed, the highly oriented strands or fibres of the polymer are embedded in a matrix of the same polymer (wherein the matrix is not highly oriented). For example, self-reinforced polypropylene comprises fibres of polypropylene embedded in a polypropylene matrix.

Two main methods can be used for processing of self-reinforced polymer composites. In a first method, hot compaction is used, in which aligned, stretched fibres or stands of the polymer are layered. The layers are compressed together and heated to a precise temperature. This heating results in melting of only the outer layer or ‘skin’ of each strand or fibre, which has a lower melting point than the core of the strand or fibre. Heating causes around 10% of the strand or fibre to melt (at its outermost surface), and the applied pressure causes the molten polymer to flow around and between the fibres to form a continuous matrix. Once cooled, the polymer material of the matrix solidifies, and contains the strands or fibres. This method results in tapes of self-reinforced polymer material.

A second method that can be used is co-extrusion. In this process, fibres or strands of the polymer in a highly-oriented form can be formed by extrusion. In addition, another grade of the same polymer can be extruded or coated on the surface of each fibre or strand. The polymer used for coating each strand is a lower melting point grade of the polymer than the higher melting point grade of the same polymer used for the fibres. As such, this results in coated stands of the same polymer material, which can be aligned and then compacted whilst heated to form tapes of self-reinforced polymer material.

Said tapes of self-reinforced polymer material can be built up in layers. The laminated structure can then be heated and compressed, in order to form sheets of selfreinforced polymer material. Use of different numbers of layers of thermo-compressed tapes can provide self-reinforced polymer material sheets having different thickness. In turn, the thickness of the self-reinforced polymer sheet determines the rigidity, or the flexibility of the sheet. In an alternative, the fibres of self-reinforced polymer as described above can be forms into strands. The strands can be woven to form a fabric. The fabric may be heated and compressed after weaving, such that the outer coating of each strand or fibre (comprising the lower-melting point type of the same polymer) melts, but the core of each fibre remains solid. Compression during heating again causes the melted polymer of the outer coating to flow, and form a matrix in which the strands of the polymer are contained. This is a particular form of self-reinforced polymer, named self-reinforced polymer woven composite. An example of self-reinforced polypropylene woven composite is Dewforge ^RTM by James Dewhurst ^RTM . The self-reinforced polymer woven composite can be beneficial as it does not suffer from delamination. Different thicknesses or densities of self-reinforced polymer woven composite can be provided by varying the density of the interwoven stitched in the woven fabric, or by creating strands before weaving that are thicker by twisting together multiple strands. However, the self-reinforced polymer woven composite may be limited in the maximum thickness of a sheet formed in this way, compared to the layered self-reinforced polymer which may be formed with almost any thickness. A single layer of self-reinforced polypropylene woven composite may be around 0.35 mm, for instance.

In view of these methods of forming the self-reinforced polymer material, a panel or sheet of self-reinforced polymer will comprise strands of the polymer either woven or bonded, wherein each strand is surrounded by polymer of the same type but having a slightly lower melting point. Each panel comprises at least one layer of self-reinforced polymer strands, being woven or bonded via a matrix. The difference in temperature of the melting point of the polymer material surrounding each of the strands or cores may be close to the melting point of the cores of the strands (with just a few degrees Celsius difference), and so precise heating (for instance, when forming hinges 114) will be required to avoid melting of the core material.

The melting temperature for forming hinges 114 may be reached by application of heat and/or pressure. The melting temperature (or melting point) is the temperature that a material changes from solid to liquid. Cooling below the melting point causes the material to return to a solid.

Preferably, when forming hinges 114 the least one portion of the panel in which the net 100 is formed comprises a polymer material surrounding one or more reinforcing fibres of the self-reinforced polymer. Here, the at least one portion of the panel is the at least one portion of the net 100 heated to a temperature above or equal to its melting point. For example, the polymer material surrounding one or more reinforcing fibres may be the polymer matrix material, meaning a polymer of the same type as the polymer fibres, but that is not molecularly aligned and which encases or contains the fibres. Alternatively, the polymer material surrounding one or more reinforcing fibres may be a coating on the outer surface of each polymer fibre, which, when melted under compression and then cooled, could form a polymer matrix encasing the fibres. Said coated fibres may be woven together to form a panel (prior to forming the polymer matrix), so that the panel is not necessarily already heated and compressed so as to have formed the polymer matrix. Therefore the self-reinforced polymer panel may have the polymer matrix already formed, or merely be woven.

The least one portion of the panel (being the polymer material surrounding one or more reinforcing fibres) that is heated to a temperature above or equal to its melting point will be the same type of polymer as used to form the fibres of the self-reinforced material. However, the least one portion of the panel that is heated to a temperature above or equal to its melting point will be of a different grade of the polymer, and have a lower temperature melting point, than the grade of the polymer used for forming the polymer fibres.

In one example, the self-reinforced polymer is self-reinforced polypropylene. In other words, the self-reinforced polypropylene has highly oriented polypropylene strands or fibres surrounded by polypropylene (being either a polypropylene coating on the strands, or the strands being encased in a polypropylene matrix). Typically, the highly oriented polypropylene strands or fibres have a higher melting point than the surrounding polypropylene material. Preferably, in this case to form the hinges 114 as described, the heat and/or pressure are applied to heat the at least one portion of the panel (being the surrounding polypropylene material) at the at least one area to a temperature of 90°C to 200°C. More preferably, the at least one portion of the panel at the at least one area is heated to a temperature of 140°C to 200°C, or to 140°C to 180°C. Preferably, to form the hinges the pressure applied is a pressure of 0.5 to 5 tonne, or more preferably 2 to 4 tonne.

Applying heat and/or pressure to form the hinges 114 may comprise applying heat and pressure, and causing the at least one area to cool may comprise cooling the at least one area (or allowing the at least one area to cool) whilst maintaining the pressure applied to the at least one area. The cooling may be active (in other words, via applied cooling means such as fan cooling), or non-active (allowing the temperature to reduce as heat is transferred to the surroundings). Cooling causes any melted portion of the panel to return to its solid form. Maintaining applied pressure during cooling causes any melted portion to flow, and thereby surround fibres of the panel to create a polymer matrix. The applied pressure also causes any melted portion to solidify in a shape determined by the press applying the pressure. Applying heat and/or pressure (to form hinges 114) may comprise compressing the at least one area between a cooperating first and second portion of a press, wherein the first and/or second portion of the press is heated. The first and second portion may form part of the jaws of a press, for instance. The first and second portion provide steady and consistent heating and pressure to the panel. The first portion may be a bed (such as a flat metal bed, or a planar metal bed having raised contours to cooperate with the second portion). The second portion may comprise a metal pressing ram or rod, or may be a plate having contours or protuberances. The first and second portion may be cooperating such that bringing together of the first and second portion compresses the at least one area therebetween. The first and/or second portion may be actively heated (via internal heating elements, so that a predefined temperature is maintained throughout the process) or may be heated prior to the contact with the panel but without continuous heating throughout the pressing. The panel or net may be held in the press during cooling of the panel, so that pressure is maintained even whilst heat is allowed to transfer away from the panel.

To form the hinge 114, the at least one area may be a linear series of two or more areas on the surface of the panel. In other words the heated areas may create dots or dashed regions extending across the surface of the panel. In some cases, the at least one area is at least one linear area extending across the surface of the panel. In other words, a continuous, linear area is heated and/or compressed to form the hinge.

As an alternative, hinges 114 could be formed by a region of stitching in the net 100 of the courier box. Moreover, the net 100 of the courier box could be formed by stitching smaller, separate panels of self-reinforced polymer together, wherein the stitches form the hinges 114 between panels 112.

In an advantageous example, at least the first planar surface of the net 100 (which forms the outer surface of the courier box when in its three-dimensional configuration) is provided with a three-dimensional surface patterning. The outward facing surface of the strips 118a, 118b may also be provided with a three-dimensional surface patterning. The three dimensional surface patterning may provide slight contours or texture to the surface, so that it is not smooth. This can be advantageous for providing some friction between the outer surface of the courier box 110 and a surface on which it is placed, for instance on a conveyor belt or when stacked on top of another courier box. Such surface patterning can be applied by pressing of the panel forming the net 100 of the courier box between plates with patterning indentations (for example, when the layers of self-reinforced polymer are consolidated to form the panel before cutting out of the net 100). Alternatively, the surface patterning can be formed by compression of the panel forming the net 100 under heat and pressure with a stamp and a patterned mould (or even just a stamp and a sheet of parchment paper). However, it should be noted that such surface patterning is not essential. In some case, it has been found that the surface texture provided simply by the application of strips 118a, 118b to the first planar surface of the net 100, and/or stitching for applying the strips 118a, 118b and/or fastener 116a, 116b to the net 100 provides a sufficient coefficient of friction to the outer surface of the courier box 110 to avoid sliding and slipping of the courier box.

FIGURE 2 is a photograph of the net 100 of the courier box, as illustrated schematically in FIGURE 1(a). FIGURE 2 shows the first planar surface of the net 100 of the courier box, on which the strips 118a, 118b are mounted (and which, in this example, forms the outer surface of the courier box 110 when it is in its three-dimensional configuration). In this example, the strips 118a, 118b have a width of around 45 mm, although other widths could be used. The zip fastener 116a, 116b arranged around the perimeter edge of the net 100 is also visible.

FIGURE 3 is a photograph of the same net 100 as FIGURE 2, but showing the opposite, second planar face. The stitching 122 used to connect the strips 118a, 118b to the first planar face are visible on this second planar face of the net 100. In this image, it can be seen that a lining layer 124 is applied to cover a portion of an inner surface of the courier box. Said lining layer 124 may be a soft material (such as a nylon or fleece) in order to protect any goods within the courier box. The lining layer 124 may be bonded to the net shape. In the example of FIGURE 3 (although not shown as it is underneath the lining layer 124) is a foam panel bonded to and extending across the portion of the net that forms the bottom of the courier box 110 when the courier box is in its three-dimensional constructed configuration 110. Said foam panel may stiffen the base of the box, and may provide additional padding to an item within the courier box.

FIGURES 4, 5, 6 and 7 are photographs of different views of the courier box 110 when in its three dimensional configuration. The strips 118a, 118b and zip fastener 116a, 116b are visible in all these photographs.

FIGURE 5 shows a photograph of a portion of the case 110 including the bottom stop 120a (or first terminal end) of the zip fastener 116a, 116b. This is maintained on the outer surface of the courier box, and includes a tab 126 formed of self-reinforced polymer. The tab may be bonded to the outer surface of the courier box 110, as shown in FIGURE 5.

FIGURE 6 shows a photograph of the view of the case in which the bottom stop 120a and the top stop 120b of the zip fastener 116a, 116b (or the first 120a and second 120a terminal ends of the zip fastener 116a, 116b) are visible. The top stop 120a of the zip may comprise a security latch 128, which is bonded to the outer surface of the courier box. In this example, the security latch 128 is riveted to the first planar surface of the self- reinforced polymer material of the net 100, and so mounted on the outer surface of the courier box 110. The security latch 128 is of a type that holds the puller of the zip 116a, 116b by a latch, wherein an insert 130 to the latch must be snapped or broken to retrieve the zip puller and open the zip fastener 116a, 116b. As such, it will be visible to the user of the courier box whether the latch 128 has been tampered with, as a broken insert 130 indicates the courier box 110 has been opened. A new insert 130 to the security latch 128 can be used each time the courier box 110 is refilled and reused. Alternatively or additionally, a zip fastener 116a, 116b with two pullers (and even two security latches 128) could be used.

In use, it will be understood that the courier box 110 can be repeatedly and reversibly be collapsed (by undoing the fastener 116a, 116b and reducing the three- dimensional courier box 110 to its flat net shape 100). This may be useful for storage or transportation of the courier box when empty. However, the courier box can be reformed into the three-dimensional configuration 110 (by coupling the fastener 116a, 116b), and thus be reused may times.

Beneficially, the described courier box 110 provides the benefits of known courier boxes, including being sufficiently rigid for protection of items contained within the courier box, and to allow stacking of courier boxes. However, the presently described courier box is both more durable and more lightweight. The thickness of the walls of the proposed courier box are around % the thickness of the walls of boxes in typical prior art designs. The weight of the proposed courier box is around 300g compared to around 1.8kg for a typical prior art courier box of the same volume. Furthermore, the described courier box is especially durable, not least due to its formation in self-reinforced polymer. This allows the box to be reused (including collapsing and constructing) for more cycles than prior art courier boxes. Typically, prior art courier boxes had an average use cycle of around 40 times. However, the proposed box will have a number of use cycle significantly greater than this. Finally, self-reinforced polymer is fully recyclable, and so provides a courier bag that is more environmentally friendly at end of life.

FIGURE 8 shows an example courier box 110a having a handle 132, of a type that could be applied to the courier box described herein. In particular, the handle 132 can be stitched or bonded to a portion of the net of the courier box, so as to be on the outer surface of the ‘lid’ of the courier box when it is in its three-dimensional configuration.

FIGURE 9 is a further photograph of the net 100 of the courier box as shown in FIGURE 3. Here, the net 100 includes straps 134, bonded to the inner surface of the courier box (for instance by stitching, sonic welding or heat bonding). The straps 134 can be used to secure an item within the courier box, when in use. The straps 134 include buckles 136, for securing the straps 134 around an item and for adjusting the length of the straps 134 to hold the item more securely. The buckles 136 and/or straps 134 may be formed from a self-reinforced polymer material. For instance, the straps 134 may use a self-reinforced polymer material comprising only 1-3 polymer layers to maintain flexibility, whilst the buckles 136 may be formed of a self-reinforced polymer using 4-10 polymer layers, to provide a stiff buckle body.

A removable, exchangeable insert may be provided. The insert may be configured to be housed inside the described courier box 110 whilst in use, or may be used within known courier boxes for transportation of items. The insert may have a basic, common configuration, but the shape, size and dimensions of different elements of the insert may be adapted for use with a specific item. The insert may be configured to fit courier boxes of a predetermined size. Example inserts are described below.

FIGURE 10A shows an alternative configuration for the courier box. In this configuration, the courier box does not comprise strips of self-reinforced polymer on the first planar face of the net 100.

FIGURE 10A(a) shows a net 100 for a courier box 110. The net 100 is divided into six portions 112 by five hinges 114. The net 100 is formed in a panel of self-reinforced polymer. The net 100 is arranged to fold along the hinges 114, so as to be configured as a three-dimensional shape. Here, the net 100 can be arranged to provide the faces of a cuboid which forms the courier box 110, as shown in FIGURE 10A(b). The net is formed from self-reinforced polymer, such as self-reinforced polypropylene, having properties as described above.

A fastener 116a, 116b, which in this case is a zip fastener, is arranged around and coupled to the perimeter edge of the net shape. When the first 116a and second 116b half of the zip fastener are secured together, the net 100 of the courier box is configured as the three-dimensional courier box 110.

The illustrated configuration of the courier box allows the zip fastener 116a, 116b to be partially opened in a manner that opens just a lid portion of the courier box. Thus, the box can be retained in a three dimensional configuration as a lid is opened and closed, for addition and removal of goods from the courier box.

In the present example, the net 100 is formed from a single panel of self-reinforced polymer. The hinges 114 are added by applying heat and/or pressure to at least one area on the surface of the net shape 100 formed of the self-reinforced polymer, to heat at least one portion of the panel at the at least one area to a temperature above or equal to a melting point of the at least one portion. Once the at least one portion of the net 100 has cooled to a temperature below the melting point, a hinge 114 is formed. The heat and/or pressure is applied only at the required position of the pivot of the hinge 114. Formation of hinges in self-reinforced polymer is discussed in more detail above.

FIGURE 10B shows a photograph of the courier box of FIGURE 10A in its three- dimensional, constructed form.

FIGURES 11 A and 11 B show another configuration for a courier box. This configuration is substantially the same as the configuration shown in FIGURE 10A and 10B. However, there are some differences. In the following description, the features of the courier box are identical to those described above with reference to FIGURE 10A and 10B, unless otherwise stated.

FIGURE 11A(a) shows a net 100 for a courier box 110. The net 100 is divided into six portions 112 by five hinges (or hinge regions) 115. The net 100 is formed in a panel of self-reinforced polymer, having properties as described elsewhere in this disclosure. The net 100 is arranged to fold along the hinge regions 115, so as to be configured as a three- dimensional shape. Here, the net 100 can be arranged to provide the faces of a cuboid which forms the courier box 110, as shown in FIGURE 11A(b).

In contrast to the embodiment of FIGURE 10A, some of the hinge regions 115 comprise two separate folds (and could comprise two or more separate folds). This is useful to allow for a slightly relaxed or curved bend or corner at certain edges of the courier box, when in its constructed configuration. A similar arrangement for the hinge regions 115 is discussed in more detail below with respect to the embodiment of FIGURE 20 and 21, which show three separate folds at a hinge region.

As in the example of FIGURE 10A, a fastener 116a, 116b, which in this case is a zip fastener, is arranged around and coupled to the perimeter edge of the net shape. When the first 116a and second 116b half of the zip fastener are secured together, the net 100 of the courier box is configured as the three-dimensional courier box 110.

In contrast to the example of FIGURE 10A, the example of FIGURE 11A includes some additional folds 119a, 119b extending across some of the portions 112. These additional folds 119a, 119b can be used in order to allow the courier box, in its collapsed form, to be folded into a compact package. In particular, when the net is in the collapsed form, the net can be folded first along a first additional fold 119a so that three of the side portions 112a, 112b, 112c are folded over the fourth side portion 112d of the courier box. A base portion 112e can then be folded over the folded side portions 112a, 112b, 112c, 112d. Finally, the lid portion 112f can be folded over the folded side portions 112a, 112b, 112c, 112d and base portion 112e. A fastener 121 can be used to securely hold the courier box in its compact packaged configuration. This provides a compact form for the courier box when not in use to contain an item. FIGURE 11 B shows photographs of the courier box of FIGURE 11 A, in various stages of transformation into the compact packaged configuration. FIGURE 11 B(a) shows the courier box in its three-dimensional, constructed form. The two additional folds 119a, 119b can be seen. FIGURE 11 B(b) shows the courier box in a configuration in which the net (in the collapsed form) has the first 112a, second 112b and third 112c side portion folded over the fourth side portion 112d. FIGURE 11 B(c) shows the base portion 112e of the courier box fold up and over the folded side portions 112a, 112b, 112c, 112d. FIGURE 11 B(d) shows the lid portion 112f being folded down over the folded side portions 112a, 112b, 112c, 112d and base portion 112e. Finally, FIGURE 11B(e) shows a side view of the courier box securely held in its compact packed form. In particular, the fastener 121 is secured around the folded portions of the courier box, to hold them in place. In this example, the fastener 121 is an elasticated retaining band to hold the folded portions in place. Said elasticated retaining band is arranged connected at the inner face of the courier box (the inner face being a face inside the cavity of the courier box when in its constructed form), in order to avoid obstruction of the zip fastener 116a, 116b when the courier box is in use.

The additional folds 119a, 119b described with reference to FIGURE 11A and 11 B enable the collapsed courier box to be folded and secured in a more compact packed configuration. Similar additional folds could be used with respect to any of the other examples for the courier box described with reference to FIGURE 1 to 10B or FIGURE 12 to 21. In particular, the additional folds could be incorporated into examples having features other than those shown in FIGURE 11A and 11B. For instance, the additional folds could be used within an example for the courier box that uses a single fold in hinge regions 115, rather than multiple folds as shown in the example of FIGURE 11 A and 11 B.

It will be understood that the configuration of the courier box as described with respect to FIGURE 11A and 11B will formed from a panel of self-reinforced polymer as described elsewhere in the disclosure. The courier box may also include reinforcement strips or reinforcement panels as described with respect to FIGURE 12 to 14 or FIGURE 20 and 21. Furthermore the courier box as discussed with reference to FIGURE 11 A and 11 B may include straps, buckles or other securing devices for a load within the courier box, as shown in FIGURE 15 with respect to other embodiments of the courier box.

FIGURE 12 shows a still further example configuration of the courier box. In particular, FIGURE 12(a) shows the courier box as a net, and FIGURE 12(b) shows the courier box with the net in its three-dimensional, constructed form. FIGURES 13 to 15 show photographs of a variety of aspects of the courier box described with reference to FIGURE 12(a) and 12(b). The courier box of FIGURES 12 to 15 share the features of the courier box of FIGURE 1 (a) to FIGURE 9.

In particular, the courier box of FIGURE 12(a) is a net 100 divided into six portions 112 by five hinges 114, and formed in a panel of self-reinforced polymer. A fastener 116a, 116b, which in this case is a zip fastener, is arranged around and coupled to the perimeter edge of the net shape. When the first 116a and second 116b half of the zip fastener are secured together, the net 100 of the courier box is configured as the three-dimensional courier box 110, as shown in FIGURE 12(b). The net of FIGURE 12(a) further includes strips of self-reinforced polymer material 118a, 118b arranged on a first planar face of the net 100, directly adjacent a portion of the perimeter edge of the net 100 and the fastener 116a, 116b. A photograph of the net formed in self-reinforced polymer is shown in FIGURE 14(b).

FIGURE 12(b) shows the net constructed to form the three-dimensional courier box. A photograph showing the courier box in three-dimensional configuration according to FIGURE 12(b) is shown in FIGURE 13(a). It can be seen from FIGURE 12(b) that the arrangement of the terminal ends 120a, 120b relative to the walls, base and lid of the courier box allow the courier box to have an openable lid. Partially unzipping the fastener (for instance, from terminal end 120b to point 121) allows the courier box to be opened in the manner of a lid, whilst maintaining its three-dimensional shape. The partially open configuration is shown in more detail in FIGURE 14(a), for instance.

FIGURE 13(b) shows the terminal ends 120a, 120b of the zip fastener in more detail. It can be seen that the top stop 120a of the zip comprises a security latch 128, which is bonded to the outer surface of the courier box. In this example, the security latch 128 is riveted to the first planar surface of the self-reinforced polymer material of the net 100, and so mounted on the outer surface of the courier box 110. The security latch 128 is of a type that holds the puller of the zip 116a, 116b by a latch, wherein an insert 130 to the latch must be snapped or broken to retrieve the zip puller and open the zip fastener 116a, 116b. As such, it will be visible to the user of the courier box whether the latch 128 has been tampered with, as a broken insert 130 indicates the courier box 110 has been opened. A new insert 130 to the security latch 128 can be used each time the courier box 110 is refilled and reused. Alternatively or additionally, a zip fastener 116a, 116b with two pullers (and even two security latches 128) could be used.

FIGURE 15 shows is a further photograph of the net 100 of the courier box as shown in FIGURE 14(b). Here, the net 100 includes straps 134, bonded to the inner surface of the courier box (for instance by stitching, sonic welding or heat bonding). The straps 134 can be used to secure an item within the courier box, when in use. The straps 134 include buckles 136, for securing the straps 134 around an item and for adjusting the length of the straps 134 to hold the item more securely. The buckles 136 and/or straps 134 may be formed from a self-reinforced polymer material. For instance, the straps 134 may use a self-reinforced polymer material comprising only 1-3 polymer layers to maintain flexibility, whilst the buckles 136 may be formed of a self-reinforced polymer using 4-10 polymer layers, to provide a stiff buckle body. The straps may include an elasticated portion, for easier tightening of a strap around an item.

In a further example embodiment (not shown) further fasteners (such as zip fasteners or other fasteners, such as hoop-and-loop fasteners) could be applied at the outer surface (first planar surface) of the courier box. These further fasteners can be connected to a cooperating fastener at another courier box. In this way, multiple courier boxes can be connected together (in a stacked configuration, for instance) for easier transportation.

FIGURE 16(a) and 16(b) show yet another example configuration of a courier box. In particular, FIGURE 16(a) shows the courier box as a net, and FIGURE 16(b) shows the courier box with the net in its three-dimensional, constructed form. FIGURES 17, 18 and 19 show photographs of a variety of aspects of a courier box similar to that described with reference to FIGURE 16(a) and 16(b). The courier boxes of FIGURES 16 to 19 for the most part share the features of the courier boxes of FIGURE 1(a) to FIGURE 15.

Just as in previously described examples, the courier box of FIGURE 16(a) is a net 500 divided into six portions 512 by five hinges 514, and formed in a panel of selfreinforced polymer. Each portion is a two dimensional shape, similar to a polygon (although some corners may be rounded). A fastener 516a, 516b, which in this case is a zip fastener, is arranged around and coupled to the perimeter edge of the net shape. When the first 516a and second 516b half of the zip fastener are secured together, the net 100 of the courier box is configured as the three-dimensional courier box 510, as shown in FIGURE 16(b). It can be seen from FIGURE 16(b) that the arrangement of the terminal ends of the zip fastener 520a, 520b relative to the walls, base and lid of the courier box allow the courier box to have an openable lid. Partially unzipping the fastener (for instance, from terminal end 520b to point 521) allows the courier box to be opened in the manner of a lid, whilst maintaining its three-dimensional shape.

It can be seen that a number of the hinges 514 in the net shown in FIGURE 16(a) comprise three separate folds 530a, 530b, 530c (which could also be considered as three separate bends, or three separate creases). The folds can each be formed separately according to the description of the formation of a hinge above (including forming each fold separately by stitching, by scoring the material, or by applying heat and pressure). Nevertheless, the three folds together provide the function of the hinge 514 between separate portions 512 of the net. In the example of FIGURE 16(a), each of the three folds is linear, and the three folds are arranged in parallel with each other.

Once constructed into the three-dimensional configuration for the courier box, it will be understood that hinges with three folds (or similarly with two folds, or four folds, or multiple folds) allow for a curved corner at the courier box. The perimeter edge adjoining the three-fold hinge (being the portion of the perimeter edge with which the three folds intersect) can be coupled to a curved corner at an adjacent face or portion of the courier box, when the courier box is configured in its three-dimensional configuration. The use of a curved corner in this way can be helpful for smooth operation of a zip fastener or other reversible fastener when coupling different sections of the perimeter edge. The curved corner can also help to strength the corners upon impact.

FIGURE 17 shows views of the net of a courier box. A photograph of a net formed in self-reinforced polymer panel is shown with a first planar face upwards in FIGURE 17(a), and the same net is shown with the opposing second planar face upwards in FIGURE 17(b). The first planar face forms the outer surface of the courier box when it is constructed in its three-dimensional configuration, and the second planar face forms the inner surface of the courier box when it is constructed in its three-dimensional configuration. The net is similar to that in FIGURE 16(a), except some hinges comprise four, rather than three, folds. FIGURES 18(a), 18(b) and 18(c) show in greater detail some of the hinges comprising four folds 530a, 530b, 530c, 530d. A photograph showing the courier box in its three-dimensional configuration is shown in FIGURE 19(a), 19(b) and 19(c), each image showing a different view.

It will be understood that a different number of folds (or bends, or creases) could be used within each hinge. Moreover, the arrangement of the folds could be arranged differently than shown in FIGURE 16(a) and 16(b), or FIGURE 18(a), 18(b) or 18(c), which both have the folds arranged in parallel. For instance, to create a hinge that provides a three dimensional surface that is conical, the folds could be arranged at an angle to each other (perhaps arranged at an angle to each other and intersecting at the perimeter edge of the net).

As described in relation to other examples for the courier box above, the courier box of FIGURE 19(d) has terminal ends 520a, 520b of the zip fastener comprising a security catch or latch. It can be seen that the top stop 520a of the zip comprises a security latch 128, which is bonded (in this case, riveted) to the outer surface of the courier box. The security latch is of the same type as described above. Alternatively or additionally, a zip fastener 516a, 516b with two pullers (and even two security latches 128) could be used. Furthermore, the courier box includes straps attached at an inner surface (as shown in FIGURE 17(b)), as discussed above with reference to FIGURE 15.

FIGURE 20 shows a still further example configuration of the courier box. In particular, FIGURE 20(a) shows the courier box as a net, and FIGURE 20(b) shows the courier box with the net in its three-dimensional, constructed form. FIGURE 21 shows photographs of a variety of views of a courier box similar to that described with reference to FIGURE 20(a) and 20(b) (all with the courier box in its three-dimensional configuration). However, the courier box of FIGURE 21 includes four folds 530a, 530b, 530c, 530d at a number of hinges 514, compared to three folds in the courier box of FIGURE 20(a) and 20(b). The courier boxes of FIGURES 20 and 21 for the most part share the features of the courier boxes of FIGURE 1(a) to FIGURE 19.

As with the examples above, the courier box of FIGURE 20(a) is a net 500 divided into six portions 512 by five hinges 514, and formed in a panel of self-reinforced polymer. A number of the hinges comprise three folds 530a, 530b, 530c, as described above with respect to the example of FIGURES 16(a) to 19 (although a different number of folds could be used). Each portion is a two dimensional shape, similar to a polygon (although some corners may be rounded). A fastener 516a, 516b, which in this case is a zip fastener, is arranged around and coupled to the perimeter edge of the net shape. When the first 516a and second 516b half of the zip fastener are secured together, the net 100 of the courier box is configured as the three-dimensional courier box 510, as shown in FIGURE 16(b).

The example courier box of FIGURE 20(a) and 20(b) also comprises a reinforcement strip 550. This reinforcement strip 550 is similar to the reinforcement strips described above with respect to FIGURES 1 to 9 and FIGURES 12 to 15. However, in the example of FIGURE 20, the reinforcement strip extends across the centre (centre- point) of three of the two-dimensional portions of the net. In particular, the three two-dimensional portions over which the strip extends include the top (lid) portion and the bottom (base) portion of the courier box, when the courier box is in the three-dimensional configuration. The reinforcement strip 550 provides stiffening and strengthening to the given two- dimensional portions or faces of the courier box, whilst minimising the added weight. It will be understood that the reinforcing strip 550 could be arranged in a number of positions on the surface of the net.

FIGURE 20(b) shows the net constructed to form the three-dimensional courier box. A photograph showing the courier box in three-dimensional configuration similar to that of FIGURE 20(b) is shown in FIGURE 21(a), 21(b), 21(c) and 21(d), each from different angles. It can be seen from FIGURE 20(b) that the arrangement of the terminal ends of the zip fastener 520a, 520b relative to the walls, base and lid of the courier box allow the courier box to have an openable lid. Partially unzipping the fastener (for instance, from terminal end 520b to point 521) allows the courier box to be opened in the manner of a lid, whilst maintaining its three-dimensional shape.

An insert for a box, case or container

Items carried within the courier box may have certain requirements. In one example, the items may need to be held at a particular temperature. In another example, the items (such as delicate electronic equipment), may require extra protection. Thus, it can be useful to have inserts for the courier box, adapted to perform these specific functions. The inserts may be sized to fit closely within the cavity of a given courier box. In some cases, the inserts may be permanently fixed within the wall of a courier box, or may be entirely removable. If removable, they may act as a standalone sleeve or package.

FIGURE 22 shows a schematic diagram of a net for a particular example insert to the courier box. FIGURES 23 to 25 are photographs of various views of the prototype for the example insert 200. In use, said insert 200 is tubular (as shown in FIGURE 23), with tabs 210 positioned at each corner edge. The tabs 210 cause the tubular walls of the insert to be held spaced apart from the inner surface of walls of a courier box in which it is placed. In this way, the walls 212 of the insert 200 may be slightly flexible compared to the walls of the courier box and so absorb some of the energy of any impact to the courier box. Accordingly, an item held within the walls 212 of the insert 200 can be protected from damage from impact to the outer surfaces of the courier box. Although not shown in FIGURE 23, the insert 200 may also have a base, held from the floor of a courier box by tabs 210 similar to those shown in FIGURE 23, as well as a lid, again having tabs 210 as shown.

Considering the insert 200 in FIGURE 23 in more detail, the insert 200 comprises a tubular formation, formed from a single panel with three hinges 220 to separate the panel into four portions, as shown in FIGURE 22 and 26. A first 224a and second 224b end of the panel 222 can be joined (by inserting a tab 226a at the first end into a slot 226b adjacent to the second end), in order to provide the tubular formation of the insert. This allows for a reversible connection between the first 224a and the second 224b end, allowing the insert to be collapsed (for instance, for storage) and then reconstructed.

At each hinge 220, cut-outs 230 are made from a first face of the tubular portion adjoining the hinge 220. The cut-outs 230 create the tab 210 that project along the plane of a second face of the tubular portion adjoining the same hinge 220. Although FIGURE 22 and 23 shows three cut-outs 230 made at each hinge 220, one or more cut-outs 230 at each hinge 220 could be used. Increasing the number of cut-outs 230 may reduce the structural integrity of the hinge 220, and so should be balanced with the possible greater stability achieved for the insert within the courier box. Ideally, the tabs 210 are configured such that at least one tab 210 makes contact with each internal face of the courier box.

The cut-outs 230 forming tabs 210 can be seen in more detail in FIGURES 24 and 25, which show different views of different faces of the same insert as shown within FIGURE 23.

The insert 200 in FIGURES 22 to 26 is formed in self-reinforced polymer. This material is highly durable, allowing for an insert that can be constructed and collapsed many times, and so reused. An insert made with self-reinforced polymer has a sufficient stiffness to provide rigidity to the insert, although also has sufficient flexibility to absorb shock or impact energy rather than transferring all such energy to an item held within the insert. This balance of rigidity and flexibility may be provided by a self-reinforced polymer with 2 to 8 consolidated layers, as described above. Alternatively, the insert may be formed using a foam layer (such as expanded polypropylene) between two layers of selfreinforced polymer (which may each comprise just one or two layers of self-reinforced polymer). This latter configuration may better absorb energy due to impacts or shocks.

The hinges 220 may be formed in the described insert of self-reinforced polymer, or of layers of self-reinforced polymer and foam, by the methods described above for forming hinges in the net of the courier box 110 (such as by application of heat and/or pressure).

In a further example, a temperature controlled element (such as a heat pack, cold pack, ice or dry ice, not shown) can be placed in a void between the walls 212 of the insert 200 and the walls of the courier box, the void being created by the presence of the tabs 210. In this way, the region inside the insert 234 (in which an item can be placed when the insert in configured in its three-dimensional configuration, and placed within a courier box) can be temperature controlled. This may be useful of transportation and delivery of temperature sensitive goods, such as medicines, or food items. Advantageously, the selfreinforced polymer material from which the inset is made is waterproof, and not affected by low temperatures (below 0°C).

As an alternative to the inserts shown in FIGURES 22 to 26, a net shape formed of a semi-rigid (for instance, moulded) foam could be provided. Said net shape can be configured to fold into a three-dimensional shape, which fits snugly and closely within a courier box, such as described the courier box 110. The walls of the foam insert formed in this way may be thicker than the insert discussed with respect to FIGURES 22 to 26, and thus may provide more padding. At the inner faces of the courier box or at the inner faces of any insert, straps, pockets or lugs, may be provided for housing or holding items within the courier box. As such, the described inserts may be custom made to securely hold particular items, or may be highly adaptable to fit many items. The exchangeable nature of the insert for any given courier box provides even more adaptability for a kit comprising one or more courier boxes, or one or more inserts.

A sleeve for a case, box or container

FIGURE 27(a), 27(b) and 27(c) shows a schematic diagram of a wall of an alternative configuration for an insert to the courier box of FIGURES 1(a) to 21. The wall comprises a layer of self-reinforced polymer 300, bonded to a layer of foam 310. Here, the layer of self-reinforced polymer 200 has relief cuts or indented ribs 320 as shown as dotted lines in FIGURE 27(a). When the wall is held in a flat plane, the relief cuts or indented ribs 320 are closed as shown in FIGURE 27(b). However, if required the wall can be gently bent to form a convex curve or contour, causing the relief cuts or indented ribs to open 325 slightly as shown in FIGURE 27(a).

FIGURE 28(a) and 28(b) applies the wall described within 27(a), 27(b) and 27(c) to form a second type of insert for the courier box. As can be seen in FIGURE 28(a), a first 340 and second 345 wall as described with respect to FIGURE 27(a), 27(b) and 27(c) are arranged having foam layers 300 opposing each other, with the self-reinforced polymer layer 310 on the outer surface. A strap 350 is wrapped around the first 340 and second 345 wall, as shown in FIGURE 28(b). The strap 350 could be attached or bonded to one of the walls, or could pass through a loop attached to an outer face of each wall, for instance. The strap 350may comprise a buckle 355, to allow the strap to be shortened.

In use, an item requiring protection during transportation (including, for instance a mobile telephone (cell phone) or a laptop can be inserted between the opposing foam layers 300 of the first 340 and second 345 wall. The strap 350 can then be tightened around the outside of the first and second wall. The relief cuts 325 in the walls allow the otherwise rigid foam 300 and self-reinforced polymer 310 walls to bend or flex around the item. As such, the item is held securely between the walls 340, 345 of the insert.

FIGURE 29(a), 29(b) and 29(c) show further photographs of an insert having the configuration shown in FIGURE 28(a) and 28(b). In this example, the first 340 and second 345 walls have the same foam and self-reinforced polymer layered construction as described above. However, in this example, the walls are covered in a lining layer 360 (such as a felt or nylon lining, although in an alternative a further thin self-reinforced polymer layer could be used). This can help to prevent scratching and can provide some friction with an item held within the insert. The edges of the layered walls are covered by a trim or tape 365, such as a self-reinforced polymer trim or tape. This can help to prevent delamination of the layered wall structure.

The first 340 and the second 345 wall are hingedly connected by a hinge panel 365. The hinge panel is bonded at an edge of each of the first 340 and the second 345 wall, to connect the two walls. Buckles 355 and respective clasps are arranged at the outer surface of the walls, and are configured such that, in use, they can tighten the straps 350 and so the walls around an object (held within a narrow cavity 370 between the walls). In other words, the straps 350 are pulled tightly to ‘sandwich’ an item between the walls 340, 345.

In a beneficial example, the insert shown in FIGURES 28(a) to 29(c) could form the base panel of the courier box shown in FIGURES 1 to 21. It will be understood that such an insert could be bonded to the inner wall of the base of the courier box, in order to hold items requiring additional protection.

In addition, it will be understood that the insert of FIGURES 28(a) to 29(c) could be a standalone packaging sleeve for an item to be transported. The insert of FIGURES 28(a) to 29(c) is not necessarily to be used in conjunction with the courier boxes described.

A postal transit bag

In a further aspect, FIGURES 30 and 31 show a postal transit bag or postal sack (or mail sack). Typically, postal transit bags or postal sacks are used to carry or store items within the postal system. Within postal sorting offices, items may be sorted according to type, destination etc. Sorted groups of items may be placed in a postal bag or sack, for transit to the recipient or another post office. In some cases, the sorting process within a sorting office makes use of mechanical sorting processing, including conveyor belts. The described postal transit bags or postal sacks are suitable for attachment to robotic or automated sorting systems and the like. The postal sacks may also be connected to frames or trolleys for support whilst in use. Typically, such postal sacks have an opening without a fastener or closure, and does not have any security or locking mechanism to protect items carried therein.

Such postal bags are used multiple times, and must be robust and durable. However, they are also used in large quantities, and so must be comparatively straightforward to manufacture in bulk at a relatively low cost. Commonly, such bags are made using a fabric formed from woven plastic tapes (woven polypropylene, although not self-reinforced polymer or self-reinforced polypropylene). A typical postal sack is formed using a single sheet of the woven plastic fabric, arranged in a tube with a seam joining two edges to form a cavity inside the sack. The fabric is rolled or folded over (sometimes twice) to form the seam, and the seam is stitched with a double stitch line. Hems can be formed at any open edges. However, such bags are prone to tears in the material. The seams also often unravel or fray, causing holes in the base and side of the bag. Once a hole is formed in the side or panel of said bag, the material quickly unravels, and the hole gets bigger, making the sack unusable.

In contrast, postal sacks formed from self-reinforced polymer material are much more durable. First, they can withstand greater wear and tear, without ripping or damage. Even if a hole is made in the body of a bag formed from self-reinforced polymer, the selfreinforced nature of the material (and the polymer matrix surrounding the reinforcing strands) means that holes do not readily open and expand. Thus the bags can continue to be used, even with a small amount of damage. The weight that can be carried in bags formed of self-reinforced polymer is much greater that the traditional equivalent postal sacks.

FIGURE 30(a) shows the components of a postal transit bag (or postal bag) formed from a first panel 410, second panel 415 and a base panel 420 of self-reinforced polymer, as an exploded view. FIGURE 30(b) shows the constructed postal transit bag 400. The base panel 420 is separated into a first portion 422 and second portion 424 by a fold or hinge 426 extending across the base panel 420.

The base panel 420 is connected to each of the first 410 and second 420 panel, so that a portion of the first panel 410 overlaps with the first portion 422 of the base panel 420, and a portion of the second panel 415 overlaps the second portion 424 of the base panel 420. A first edge 430 at each of the first 410 and second 415 panel is arranged approximately in parallel with the hinge 426 in the base panel 420. A first and second seam 432 connects the base panel 420 to each of the first 410 and the second 415 panel.

The base panel 420 is then folded at the hinge 426 until the first 410 and second 415 panel are arranged in parallel and opposing each other. The first 410 and second 415 panel are joined at second edge 434 and third edge 436, via respective seams 438, 440. Second 434 and third 436 edges are opposing edges, approximately perpendicular to the first edge 430. The seams may be formed using stitching, or using heat welding or sonic welding, for instance.

The self-reinforced polymer for each of the first 410 and second 415 panels may be a thin flexible sheet, having a thickness of less than 2mm for instance. The base panel 420 may comprise a self-reinforced polymer of greater thickness, for instance up to 4mm. Said thicker panel may be formed by bonding (via heat and compression) two layers of selfreinforced polymer together, or may be formed from a compound woven self-reinforced polymer material. The self-reinforced polymer provides a highly durable fabric for the postal bag, which is less easily penetrated or ripped than the conventional bags and so has a longer life with more potential reuses.

A postal bag formed of self-reinforced polymer cannot be manufactured using the same process as a typical postal bag. This is due to the resilience of the self-reinforced polymer material. In particular, the base panel 420 must be joined to each of the first 410 and the second 415 panel first, before the first 410 and second 415 panel are connected at opposing edge seams 438, 440.

In FIGURE 30(a) and 30(b), an optional reinforcing strip 445 is shown. The reinforcing strips can be arranged at the top lip of the bag, and boned to each of the open edge first 410 and second 415 panel. The reinforcing strip reinforce said edge. In an example, the reinforcing strips are bonded to the panel by seams 446 and 448. In an alternative, the reinforcing strips could be tapes, covering or wrapping around the edge. The reinforcing strips may be formed of self-reinforced polymer material.

The postal bag depicted in FIGURE 30(b) further comprises eyelets 450. The eyelets are arranged at a top edge of the bag or sack, close to the lip at the opening to the cavity within the bag or sack. Said eyelets 450 may be used within the postal services for attachment to sorting machines or supporting frames or trolley. The eyelets 450 may simply be formed as a hole in the side panel at the top edge (for instance, by insertion through the side panel of a heated rod). Alternatively, said eyelets 450 may be a hollow metal rivet passed through the side panel 410, 415, or may be another form of loop or connector attached to each side panel. In an example in which reinforcing panels 445 are used, the eyelets may be placed to pass through the panel 410, 415 and its reinforcing strip 445. Said reinforcing strip 445 reduces the likelihood of ripping of the eyelet 450 from the bag when a heavy weight is placed therein.

FIGURE 30(a), 31(b) and 31(c) shows photographs of aspects of the postal transit bag or postal sack described with reference to FIGURE 30. In particular, the panel and base panel can be seen, together with joining seams. In this example, eyelets are formed by a plastic loop 452, connected to the lip of the panel by stitching.

Postal bags formed from self-reinforced polymer as described have been shown to be able to carry much greater weights than prior art postal bags having the same or similar capacity and dimensions. For instance for a typical postal bag, the weight limit before damage or ripping to the bag occurs is typically around 15 kg. However, for the bag described here and formed from panels of self-reinforced polymer, the weight capacity is more than 40kg before damage occurs. Nevertheless, the bags are relatively straightforward to manufacture, even in large qualities. Known manufacturing techniques (including stitching) can be used to form the seams described.

The panels 410, 415, 420 forming the bag may comprise further layers. For instance, each panel 410, 415, 420 may comprise a laminated structure having a selfreinforced polymer layer and a thermal or insulative material layer. Such postal bags are suitable for containing and carrying heat sensitive items. A fire retardant layer could also be applied.

In any of the examples for the courier box, the inserts or sleeves, and/or the postal transit bags described above, further coatings could be applied to the outer surface, or a fabric or film could be pressed on to the surface of the self-reinforced polymer material. Said coatings or films pay provide additional properties, including improving the aesthetics of the courier box, insert or postal transit bag, or providing anti-bacterial properties. Patterns or designs can be applied to the outer surface of the courier box, insert or insert, and/or postal transit bag by hydro-dipping, for instance. Alternatively or additionally, one or more additional layers may be included in the walls of the courier box, the insert or sleeve, and/or the postal transit bag. In one example, a reflective layer could be added to prevent scanning or x-ray of the contents of said courier box, insert or sleeve, or postal transit bag. Alternatively or additionally, additives can be included in the self-reinforced polymer material of the courier box, insert or sleeve, or postal transit bag, such as an additive that disrupts near infra-red, or that is a fire retardant.

A collapsible, reusable box

FIGURES 32 to 46 consider a collapsible and reusable box. The collapsible and reusable box is for use within a circular, environmentally friendly delivery and packaging model. In particular, the collapsible box has a collapsed state and a containing state. In its containing state the collapsible box can be used to transport items within a cavity contained in the collapsible box. However, in its collapsed state the collapsible box can be reduced in size, with the walls of the box folded together. In the collapsed state the box takes up only a compact volume and can easily be returned from a consumer (who has received an item in the box in its containing state) to the original sender or packaging manufacturer in order to be reused. In one example, the collapsible box in its collapsible state is sufficiently small that it can fit through an opening of a standard size letterbox, in order to allow for easy return by a consumer. FIGURE 32 shows a first face of a net 3000 for the collapsible box. The net 3000 is formed from a panel of self-reinforced polymer. FIGURE 33 shows a second face of the same net 3000 for the collapsible box, the second face being on the opposite side of the panel than compared to the first face. When the collapsible box is in the containing state the first face will be contained inside the cavity of the box, whereas when the box is in the containing state most of the second face will be an outside surface for the box.

The panel of self-reinforced polymer from which the net 3000 is formed may be, for instance, self-reinforced polypropylene or self-reinforced polyethylene. The self-reinforced polymer may be a formed as a standard self-reinforced polymer, or as a self-reinforced polymer woven composite, as described elsewhere in this disclosure. In the particular example described with reference to FIGURE 32 and 33, the net 3000 is formed from a panel of four consolidated (thermocompressed) layers of self-reinforced polymer, having a thickness of around 0.5mm. However, it will be understood that the panel could be formed from a single layer of self-reinforced polymer, or up to and including eight layers of selfreinforced polymer. The thickness of the panel may be between 0.1 and 1.5 mm.

The net 3000 comprises a planar eight sided portion 3010 and a planar lid portion 3020. The lid portion 3020 is a quadrilateral, and connected at one edge to a first edge 3025 of the eight sided portion 3010. The eight sided portion 3010 and the lid portion 3020 may be formed as a single piece (in other words, in a single panel of self-reinforced polymer), with the connection between then formed as a fold (or hinge) in the single piece. In an alternative, the lid portion 3020 could be cut out separately and subsequently connected to the eight-sided portion 3010. The lid portion 3020 comprises a further fold 3030, extending across the surface of the lid portion 3020 parallel to the first edge 3025 of the eight sided portion 3010 (to which the lid is hingedly connected).

The eight sided portion 3010 itself comprises a number of folds. Four folds 3035a, 3035b, 3035c, 3035d define a base 3040, four side walls 3045a, 3045b, 3045c, 3045d and four gusset portions 3050a, 3050b, 3050c, 3050d in the eight-sided portion 3010. In particular, the four folds 3035a, 3035b, 3035c, 3035d comprise two pairs of parallel folds 3035a, b, 3035c, d, wherein the first pair is arranged perpendicular to the second pair and extending between corners of the eight-sided portion 3010. Each of the base 3040 and side walls 3045a, 3045b, 3045c, 3045d are formed as a quadrilateral and the gusset portions 3050a, 3050b, 3050c, 3050d extend between the edges of adjoining side walls (and to a corner of the base). In the example shown, the gusset portions 3050a, 3050b, 3050c, 3050d are triangular, but it will be understood that they could equally be chevrontype shape (for instance, without a straight outer edge joining the outermost corners of the adjoining side walls), giving rise to a ten-sided portion in the net. Each gusset portion 3050a, 3050b, 3050c, 3050d can be folded in half at a dividing fold 3055a, 3055b, 3055c, 3055d (at least when the box is in a containing state, as described below).

The net of FIGURES 32 and 33 further comprises a number of fasteners 3060a, 3060b, 3060c, 3060d, 3070, 3075a, 3075b, 3075c, 3075d, 3080. In this example, the fasteners are regions of hoop-and-loop fastener. The regions of hook-and-loop fastener couple with respective other regions of the hook-and-loop fastener when the collapsible box is in a collapsed or containing state, as described below.

The collapsible box may be transformable from a collapsed state to a containing state. In the collapsed state, the box can be folded into a compact volume, for instance for storage, or for easy return to a supplier for subsequent reuse. In the containing state, the box contains a cavity, in which items can be carried or stored.

The transformation of the net 3000 to the collapsed state is considered in FIGURES 34 to 36. In a first step, starting from the net as illustrated in FIGURE 32, two side walls 3045b, 3045d are folded over the base 3040, as shown in FIGURE 34. The two side walls 3045b, 3045d are folded to overlap or face the base 3040, so that the folded side walls 3045b, 3045d and base 3040 are substantially parallel. In a second step, a third side wall 3045c (connected to the edge of the eight sided portion 3010 opposite to the edge 3025 at which the lid portion 3020 is connected) is folded over the base 3040. The third side wall 3045c is folded to cover the two side walls 3045b, 3045d previously folded over the base 3040, as shown in FIGURE 35. Next, the fourth side wall 3045a is folded down over (to overlap) the base 3040, and over (to overlap) the first two folded side walls 3045b, 3045d. Finally, as shown in FIGURE 36, the lid portion 3020 is wrapped over the remaining planar surfaces of the folded side walls 3045b, 3045c, 3045d, and around so as to also cover a portion of the base 3040 at the second face of the net. The further fold 3030 in the lid is arranged so as to pivot at the edges of the base 3045 and the folded side walls 3045b, 3045c, 3045d. The lid portion 3020 can then be coupled to the base 3040 by use of the hook-and-loop fastening 3070, 3080 at the surface of the base at the second face of the net.

FIGURE 37 shows the net partially transformed to the containing state for the collapsible box. In this configuration, each of the gusset portions 3050a, 305b, 3050c, 3050d are folded in half at the central dividing fold 3055a, 3055b, 3055c, 3055d. This causes the edges of adjoining side walls to come together, and the side walls 3045a, 3045b, 3045c, 3045d to be arranged substantially perpendicular to the plane of the base 3040. The side walls are retained in this portion by coupling of the hook-and-loop fasteners at the gusset portions. More specifically, corresponding regions of hook-and-loop fastener 3060a, 3060b, 3060c, 3060d are coupled at a surface of a half of each gusset portion to an adjoining side wall, to retain the folded gusset portion to face said adjoining side wall. Furthermore, corresponding hook-and-loop fasteners 3075a, 3075b, 3075c, 3075d are coupled to join the two halves of each gusset portion, to retain the gusset portions in the folded state.

Once the net is partially transformed to the containing state for the collapsible box as shown in FIGURE 37, a cavity 3090 is defined between the base 3040 and the side walls 3045a, 3045b, 3045c, 3045d, into which an item can be placed. The cavity 3090 can then be closed by folding of the lid portion 3020 down to meet the uppermost edges of the side walls 3045a, 3045b, 3045c, 3045d. The lid portion 3020 can be secured to the side walls, in order to enclose the cavity 3090 and any item placed therein.

It will be understood that the net of the collapsible box as described is reversibly convertible between the collapsed and the containing state. This allows the collapsible box to be repeatedly transformed between the two states.

An alternative example for the collapsible box is shown in FIGURE 38. This example has the same features as described above with reference to FIGURES 32 to 36, except that in this example the gusset portions 3050a, 3050b, 3050c, 3050d are permanently coupled (e.g. not reversibly) to an adjoining side. Therefore, the hook-and- loop fastening 3060a, 306b, 3060c, 3060d for coupling the gusset portions 3050a, 3050b, 3050c, 3050d to the side wall are not present. More specifically, a half (only) of each gusset portion 3050a, 3050b, 3050c, 3050d, being the half that faces the surface of the side wall when the collapsible box is in its containing state, is permanently connected to the side wall (as shown in the partially constructed containing state in FIGURE 38(a). This is also illustrated part way through the transformation between the collapsed and containing state in FIGURE 38(b), in which stitching 3085 is shown permanently joining a half of each gusset portion to an adjoining side wall.

It will be understood that in the alternative configuration for the collapsible box shown in FIGURE 38, the net cannot revert to the entirely flat configuration shown in FIGURES 32 and 33. Nevertheless, the collapsible box can transform from the collapsed to the containing state as described above with respect to FIGURES 34 to 36. The box may be transformed from the broadly planar configuration of FIGURE 38(b) to the partially constructed containing state of FIGURE 38(a) by arrangement of the side walls to be perpendicular to the base, and coupling of the hook-and-loop fastening 3075a, 3075b, 3075c, 3075d between the two halves of each gusset portion, in order to retain the walls of the box in place. Use of a permanent fastening 3085 of the halves of the gusset portion adjacent to a side wall may increase the rigidity of the box in its containing state. FIGURE 39 shows a still further example of the collapsible box. FIGURE 39 shows the first face of the net of the box (similar to FIGURE 32), However, some features (shown as dashed lines) on the second face (similar to FIGURE 33) are also shown in FIGURE 39.

The example of FIGURE 39 has a lid portion and an eight sided portion as described above with respect to the examples of FIGURES 32 to 38. Similarly, a base 3040, four side walls 3045a, 3045b, 3045c, 3045d and four gusset portions 3050a, 3050b, 3050c, 3050d are defined by folds 3035a, 3035b, 3035c, 3035d, as described above with respect to the examples of FIGURES 32 to 38. However, the example of FIGURE 39 includes some additional features.

Firstly, each gusset portion in the example of FIGURE 39 has a longitudinal opening, cut-out or hole 3100 extending in line with the dividing fold. The opening 3100 does not entirely bisect the gusset portion, and a connecting portion (having the dividing fold therein) is retained at the outermost edge of the gusset portion. The opening 3100 in the gusset portion helps to reduce the weight of the box, and also reduce bulk of the folded gusset portion in the collapsed and the containing states.

Secondly, the example of FIGURE 39 includes a reinforcing panel 3110 on the base. The reinforcing panel 3110 may be fastened to the surface of the base 3040, for instance at the face of the base 3040 that would be contained inside the box in the containing state. The reinforcing panel 3110 in this example comprises a substrate (for instance, a layer of foam, such as expanded polymer foam, or microcellular polymer foam). The substrate is further covered with a layer of self-reinforced polymer (causing this layer of self-reinforced polymer to be the innermost layer inside the cavity at the base of the box in the containing state). Ideally, the substrate and covering layer of self-reinforced polymer is the same type of polymer as the panel of self-reinforcing polymer from which the net is formed. The reinforcing panel 3110 provides additional rigidity and stability to the box (especially in the containing state). Use of the foam substrate and covering layer of the self-reinforced polymer provides the required reinforcement whilst minimising the additional weight to the box overall.

Another additional feature shown in the example of FIGURE 39 is the inclusion of tabs. Two pairs of tabs are shown in FIGURE 39. A first pair of tabs 3115 includes a tab extending from each edge of the lid portion that is perpendicular to the edge hingedly connected to the eight sided portion. When the box is in the containing state, the first pair of tabs 3115 may be inserted into apertures 3122 through an additional lip at two side walls, the position of the aperture corresponding to the position of the first pair of tabs. When the box is in the collapsed state, the first pair of tabs 3115 (having hook-and-loop fastening on one surface, may be coupled to corresponding portions of hook-and-loop fastening 3120 on the (second face of the) base. As such, the first pair of tabs 3115 act to secure the box in the collapsed and in the containing state.

A second pair of tabs 3125 is shown in the example of FIGURE 39. The second pair of tabs 3125 extends from an edge of the lid portion 3020, the edge being opposite and parallel to the edge 3025 of the lid portion 3020 that is hingedly connected to the eight sided portion 3010. In the containing state for the box, the second pair of tabs 3125 may be inserted into apertures 3130 through an additional lip at the side wall, wherein the position of the apertures 3130 corresponds to the position of the second pair of tabs 3125. These tabs 3125 act to hold the lid closed in the containing state. Beneficially, the second pair of tabs 3125 have a hooked or ‘L’ shape. This shape, when paired with an aperture 3130 at the side wall that is sized smaller than the lateral extent of the tab (the lateral extent being in the direction of the edge of the lid portion to which the tabs are attached), cause the tab 3125 to ‘hook’ into the aperture 3130. This provides a more secure closure for the lid of the box in the containing state.

FIGURES 40 to 46 show photographs of a version of the collapsible box, having aspects as described above with respect to the examples of FIGURES 32 to 39. FIGURE 40 shows the net of a collapsible box, similar to that shown in FIGURE 32 (although without regions of hook-and-loop fastener). The lid 3020 (having an additional fold 3030), as well as the eight sided portion 3010 can be seen. The eight sided portion 3010 is divided by two pairs of folds into a base 3040, four side walls 3045a, 3045b, 3045c, 3045d and four gusset portions 3050a, 3050b, 3050c, 3050d. Moreover, as described with respect to FIGURE 39, the example net shown in FIGURE 40 additionally includes apertures or openings 3100 at the dividing fold 3055a, 3055b, 3055c, 3055d of each gusset portion as well as the second pair of tabs 3125 for closure of the lid of the box in the containing state. Furthermore, as described with respect to FIGURE 39, the example net shown in FIGURE 40 includes a reinforcing panel 3110 at the base. In this case, openings 3150 have been cut in the layer of self-reinforced polymer covering the substrate of the reinforcing panel, to provide a pattern and to expose a portion of the substrate therethrough. The exposed portions of the substrate (being foam) provide some frictional grip to items placed on the base and inside the cavity of the box.

In an additional feature, the net of FIGURE 40 includes a bungee strap 3155 coupled to or hooked between cut-outs at the reinforcing panel. The bungee strap could be used to secure a load within the cavity of the box in the containing state.

FIGURE 41 to 46 show a collapsible box having a net similar to that in FIGURE 40, but in different configurations for transformation between the collapsed and the containing state. The main differences between a net (not shown) of the collapsible box shown in FIGURE 41 to 46 compared to the net in FIGURE 40 are: a) the inclusion of a first pair of tabs as described with reference to FIGURE 39; b) the inclusion of hook shaped tabs as the second pair of tabs as described with reference to FIGURE 39; c) the permanent fastening of half of each gusset portion to an adjoining side wall, as discussed with reference to FIGURE 38; and the inclusion of hoop-and-loop fastening to couple together the two folded halves of each gusset portion in the containing state, as described above with reference to FIGURE 38.

FIGURE 41(a) shows the collapsible box in the collapsed state (similar to FIGURE 36). In particular, the side walls 3045a, 3045b, 3045c, 3045d are folded over the base 3040, and the lid portion 3020 is wrapped around the side walls and base. The lid portion is secured to the second face of the base by use of hook and loop fastening, and by use of the first pair of tabs 3115. FIGURE 41 (b) shows the first pair of tabs, which can be secured around the side of the folded collapsible box to secure the box in the collapsed state.

FIGURE 42(a) and 42(b) shows steps in the transformation of the collapsible box from the collapsed to the containing state. In particular, the lid 3020 is uncoupled from the second face of the base 3040 (FIGURE 42(a)), and then unfolded to expose the folded over side walls 3045a, 3045b, 3045c, 3045d (FIGURE 42(b)). Further, in FIGURE 43(a) and then FIGURE 43(b), the folded side walls are shown being further opened outwards.

Next, in FIGURE 44 the collapsible box is shown partially transformed into the containing state (similar to FIGURE 38, discussed above). A first half of each gusset portion 3050a, 3050b, 3050c, 3050d is permanently coupled to each adjoining side wall, and the regions of hook-and-loop fastening 3075a, 3075b, 3075c, 3075d between folded together halves of each gusset portion are coupled together in order to retain the side walls 3045a, 3045b, 3045c, 3045d in a position perpendicular to the base 3040. As such, a cavity is defined by the base 3040 and side walls 3045a, 3045b, 3045c, 3045d of the collapsible box in the configuration shown in FIGURE 44, with the lid portion open to allow insertion of an object into the cavity.

Next, the lid 3020 of the box can be closed. FIGURE 45(a), 45(b) and 45(c) show images at different stages of the lid closure. In particular, the hook-shaped second pair of tabs 3125 (as shown in more detail in FIGURE 45(a) is inserted (or ‘hooked’) through a corresponding aperture at an additional lip of the adjoin side wall (as shown in FIGURE 45(b)). The first pair of tabs 3115 are also inserted through a corresponding aperture at an additional lip of the adjoining side wall (as shown in FIGURE 45(c)).

Finally, FIGURE 46 shows the box in the containing state (with the lid 3020 securely closed). As such, the cavity is enclosed between the base 3040, the side walls 3045a, 3045b, 3045c, 3045d and the lid 3020, allowing items to be contained or stored within the cavity. It will be understood that the steps shown in FIGURES 41 to 46 are easily reversible, in order to return the box to the collapsed state.

As such, there is provided a robust but lightweight reusable box. The box can be easily transformed from a compact collapsed state to a containing state, the containing state for holding or transporting items or equipment. The example shown in FIGURE 41 to 46 may provide a box having a weight of less than 300g (when not containing an item), but which folds in the collapsed state to a parcel having a thickness of less than 16-18 mm. Therefore, the box in the collapsed state could be easily returned to a supplier or manufacturer for reuse, simply via standard easily accessible postal systems. In particular, the box in the collapsed state could be easily posted through the opening of a typical sized UK post box, allowing easy and convenient return. This promotes an encourages reuse of the collapsible box and avoids wastage and unnecessary disposal of such packaging items.

Envelope

FIGURES 47 to 50 shows a lightweight reusable envelope formed from selfreinforced polymer. For instance, the envelope may be used for containing documents. The polymer may be self-reinforced polypropylene, or self-reinforced polyethylene. The self-reinforced polymer may be a self-reinforced polymer woven composite.

As shown in FIGURE 47(a), the envelopes may comprise a first 4000 and a second 4010 panel of self-reinforced polymer. The panels 4000, 4010 may be quadrilaterals. The first 4000 and the second 4010 panel can be overlaid, and the panels 4000, 4010 are bonded together at three edges 4015, 4020, 4025 of the second panel 4010. The fourth edge 4030 of the second panel 4010 is not bonded to the first panel 4000, to provide an opening between the first 4000 and second 4015 panel for insertion of items therebetween.

The first panel 4000 has a lip 4035 extending from the main body of the first panel 4000, beyond the fourth edge 4030 of the second panel 4010 when it is overlaid. The lip 4035 is defined in the first panel 4000 by a fold 4040. The lip 4035 can be folded over to cover a portion of the second panel 4010 when the first and second panel are bonded together, so that that the said portion of the second panel is arranged between the lip 4035 and the body of the first panel 4000. The lip 4035 can be fastened to the second panel 4010, to provide a closure and contain an item inserted between the first 4000 and second 4010 panel. The fastener may be provided by hook and loop fastening 4045 at corresponding surfaces of the lip 4035 and the second panel 4010, as shown in FIGURE 47(c). The example envelope shown in FIGURE 47(c) may have a weight of around 24g.

An alternative fastener is shown in the example envelope at FIGURE 48(a) to 48(d). Here, a tab and opening fastener is used. More specifically, a tab 4050 is formed as a cutout at the lip of the envelope. The envelope may be fastened closed by insertion of the tab through a corresponding slit or opening 4055 in the second panel. An adhesive, peelable seal (security seal) 4060 could be applied over the join of the lip 4035 and the second panel 4010, in order to improve security and provide visibility whether the envelope had been opened.

Compared to the use of a hook-and-loop fastener 4045, the tab 4050 and opening 4055 fastener avoids the requirement for additional material or components for the envelope, and so reduces the weight of the envelope. By comparison, the envelope shown in FIGURE 48(b) to 48(d) (having the same dimensions as the envelope of FIGURE 47(c)) has a weight of around 19g.

A still further reduction In the weight of the envelope may be possible by changing the method of bonding of the first and second panel. In particular, the examples of FIGURES 47(c) to 48(c) bond the first and second panel by stitching the panels together at the three edges 4015, 4020, 4025. An alternative is shown in FIGURE 49.

In FIGURE 49, the envelope is formed from a single panel 4500 of self-reinforced polymer, in which are defined two folds 4505, 4510, as shown in FIGURE 49(a). The panel is folded together at a first fold 4505, and the side seams (in regions 4515, 4520 when overlaid) are joined by application of heat and pressure. This melts a portion of the selfreinforced polymer at an interface between the two portions of the panel facing each other at the seam, causing intermixing of the melted polymer at the interface and so bonding at the seam once the polymer solidifies.

In the example of FIGURE 49, the second fold 4510 in the single panel defines a lip 4530. The lip can be folded to close an opening between the first two portions of the panel, into which items can be inserted. The lip can be fastened using a tab 4535 and opening 4540 fastening as described above with respect to FIGURE 48, although other types of fastener could be used. Once again, an adhesive, peelable seal could be applied over the join of the lip and the panel, in order to improve security. Photographs of the envelope are shown in FIGURE 49(b), (c) and (d).

This version of the envelope is particularly lightweight, but also robust and reusable. By way of comparison, the envelope shown in FIGURE 49(b), (c) and (d) (having the same dimensions as the envelope of FIGURE 47(c) and 48(a) and (b)) has a weight of around 9.8g.

It will be understood that still further versions of the envelope could be provided, as shown in FIGURE 50. In this example, no sections of the envelope are bonded but instead items are contained by folding of leaves of a self-reinforced polymer panel around an item, and securing said leaves with a fastener (such as the tab and opening fastener described above with reference to FIGURE 48).

The panels of self-reinforced polymer used within the envelopes may be a single layer of self-reinforced polymer, or up to five layers of self-reinforced polymer that are consolidated (laminated together with heat and pressure). The thickness of the panels may be between 0.1 and 1 mm. The number of layers and thickness of the panels can be selected to balance the desired rigidity of (and inability to bend) the envelope, compared to the required weight.

A concertinaed collapsible case

A collapsible case or box for containing of items. The case or box is adaptable to adjust the volume within the walls of the case or box. The case or box is adaptable to collapse the walls of said case or box to a minimal volume, when not in use for containing items. This makes the case or box particularly convenient, especially for storage and transportation when not in use.

The case or box comprises one or more walls having a concertina fold (also known as a zig-zag fold, accordion fold or z-fold). The concertina fold comprises at least one fold in the one or more wall. Where at least two folds are provided in the one or more wall, the at least two folds are parallel with each other and arranged so that alternate folds are in opposite directions (in other words, to provide a zig-zag fold). When the folds are fully open, the one or more wall is fully extended in a first direction. However, when at least one of the folds is closed, surfaces forming part of the one or more wall are closed together, thereby reducing the extension of the one or more wall in the first direction. When all the folds are closed, the extension of the one or more wall in the first direction is minimised.

The case or box may comprise three of more walls having a concertina fold, wherein said walls are joined at a seams substantially perpendicular to the at least one fold in each wall, so that the said walls together form side walls for a tube with a cavity therethrough. The case may further comprise opposing top and bottom walls, arranged to connect to the side walls each having a concertina fold so that the top and the bottom walls close the cavity at each end of the tube. In other words, each of the top and/or bottom walls may connect at their perimeter to a corresponding perimeter of an end of the tube formed from the side walls having a concertina fold.

The top and/or bottom walls may be removable from the side walls having a concertina fold (fixable using a reversible fastening, such as a zip), or may be permanently fixed along a portion of the perimeter, and have a openable, reversible fastening (such as a zip) at the remaining portion of the perimeter. This allows one or both of the top or bottom walls to form a lid opening. In one example, the top and/or bottom walls are connected to the one or more walls having a concertina fold by way of a hook and loop fastening, connected to hook and loop fastening at one or more tabs at a perimeter of an end of the tube formed from the side walls having a concertina fold.

Portions of each of the one or more side wall having a concertina fold are separated by the at least one fold. Hook and loop fastening (e.g. Velcro ^RTM ) may be applied at a face of each of the portions, such that hoop and loop fastening at a face of a first portion cooperates with hook and loop fastening at a face of an opposing, second portion when one of the at least one fold is closed. In this example, the hook and loop fastening acts to hold together the first and the second portion, and to securely hold closed the one of the at least one fold in the given side wall.

The one or more side wall having a concertina fold may have different configurations. In a first configuration the portions of the one or more side wall (the portions being separated by the at least one fold) are each rectangular in shape. Broadly, each portion within a side wall having the first configuration has a similar shape and dimension. In a second configuration, the one or more portions of the side wall are each trapezoid in shape. This allows for a (broadly triangular) gusset portion to be formed at a region at each end of the at least one fold. Side walls of the first configuration can be arranged to alternate with side walls of the second configuration when connected together so as to form a tube with a cavity therethrough. If so, there will typically be an even number of side walls of each of the first and the second configuration (for instance, two of each). Moreover, side walls of the same configuration will be arranged to oppose of face each other.

The case or box may be made from one or more materials. Examples of materials from which the walls (being the side walls having a concertina fold, the top wall and the bottom wall) can be made include: cardboard, nylon, natural fibre fabric, self-reinforced polymer (including self-reinforced polyolefins such as self-reinforced polypropylene and self-reinforced polyethylene), pressed starch based fabrics, fabrics formed from pressed leaves. Where self-reinforced polymer is used, the material may be thin (for instance comprising thermocompressed (e.g. laminated) 1-3 layers of the self-reinforced polymer). In an advantageous embodiment, regions of some of the walls may be reinforced with a reinforcing panel. The reinforcing panels may extend across a surface of the wall, but typically will not extend across a fold in the wall. In a side wall having a concertina fold, a reinforcing panel may extend across each portion (the portions being separated by the at least one fold). The reinforcing panel may comprise a stiffer or more rigid material than the material from which walls are made. For instance, the reinforcing panel may be formed of a stiff cardboard. Alternatively, the reinforcing panels may comprise self-reinforced polymer (including self-reinforced polyolefins such as self-reinforced polypropylene and self-reinforced polyethylene). Where self-reinforced polymer is used, the material may be thin (for instance comprising thermocompressed (e.g. laminated) 1-3 layers of the selfreinforced polymer), which creates a lightweight reinforcing panel, or may be thicker (for instance comprising thermocompressed (e.g. laminated) 3-10 layers of the self-reinforced polymer) to provide a stiffer and more resilient reinforcing panel. Reinforcing panels at the top and/or bottom walls may be stiffer (e.g. comprise a thicker material) than reinforcing panels arranged at the side walls having a concertina fold. The reinforcing panels are helpful to provide rigidity to the walls, but, as result of not extending across each of the folds, still allow sufficient travel and bending at the fold.

Overall, the described case or cover is highly adaptable. The case may be easily collapsed, to reduce its volume when not in use to transport items. Where two or more folds are included at each wall having a concertina fold, the internal volume of the case may be adapted from its maximum (when one of the folds are closed) to an intermediate volume (when some, but not all the folds are closed) to being fully collapsed (when all the folds are closed).

Despite its adaptability, the case or box does not comprise a large number of separate portions that must be secured together before use. This is helpful to avoid a user from losing or damaging different portions of the case or box. It also allows a number of walls of the box to be secured together with permanent, more robust seams, thereby increasing the number of possible reuses and longevity of the case or box.

Appropriate selection of materials for the walls and reinforcing panels allows the box to be made lightweight and yet still rigid. For instance, use of self-reinforced polymer in reinforcing panels offers a particularly good balance of strength versus weight.

FIGURES 51 to 61 illustrate different views of embodiments of the described collapsible case or box, as follows:

FIGURE 51 shows the case 5010 in its constructed and fully expanded configuration. In this example, the case comprises four side walls 5012a, 5012b (only two walls are visible in FIGURE 51) having concertina folds, together with a top 5014 and a bottom wall (bottom wall not visible in FIGURE 51, but opposes top wall 5014). The four side walls having concertina folds are joined together at seams 5013 that are perpendicular to the direction of the folds therein, to form a tube with a cavity therethrough. The folds in the four side walls having concertina folds are fully open in FIGURE 51 , so that the side walls 5012a, 5012b having concertina folds are fully extended in a direction perpendicular to the plane of the top 5014 and the bottom walls. The top wall 5014 is permanently connected to one of the side walls having concertina folds at one portion 5016 of its perimeter edge, to provide a hinged opening. The remaining perimeter edge of the top wall can be reversibly connected to the walls having concertina folds by use of a zip fastening 5018. The walls are formed of a nylon fabric.

FIGURE 52 shows a view from an alternative direction of the case of FIGURE 51 , the case being in the constructed and fully expanded configuration.

FIGURE 53 shows a view of the case of FIGURE 51 and FIGURE 52, but with the top wall open to show the cavity 5020 inside the case, the cavity for containing items. It can be seen that regions of each of the walls comprise reinforcing panels 5024, 5026. The concertina folds 5022 in the side walls can be observed. Reinforcing panels 5024 extend across the portions of the side walls between each fold, but not across each fold. A reinforcing panel 5026 also extends across the top panel.

A reinforcement tab 5028 is shown, joining the top wall 5014 to one of the side walls (the side walls being the walls having a concertina fold). The reinforcement tab 5028 is arranged at the portion of the top wall that is permanently connected to a side wall. The reinforcement tab 5028 look to improve the longevity and reuse of the case or box, by reinforcement of the hinge between the top wall and the given side wall.

FIGURE 54 shows an image of the inner surface of one of the side walls having a concertina fold. Folds 5022 of the concertina fold can be seen, each in the open position so that the wall is fully extended. Portions separated by the folds 5022 are reinforced with a reinforcing panel 5024 formed of self-reinforcing polymer. The side panel has the first configuration, as described above, in which each portion has a rectangular shape.

FIGURE 55 shows the outer surface of the same side wall as that shown in FIGURE 54. Here the folds 5022 of the concertina can be seen once again. Alternate folds have opposite directions, to form a concertina in the side wall. Stitching 5030 can be seen where the reinforcing panels 5024 are secured to the inner surface of each portion of the side wall.

Hook 5032 and loop 5034 fastening is applied at the outer surface at each portion. The hook fastening 5032 is arranged at the surface of one portion so as to cooperate with the loop fastening 5034 at a portion that will be opposing once the fold between the two portions is closed.

FIGURE 56 shows the outer surface of a different side wall. This side wall has the second configuration, as described above, having portions 5042 that are trapezoid in shape and having a gusset configuration 5044 therebetween. The gusset configuration 5044 results in broadly triangular regions of the side wall between portions 5042. The portions 5042 may be reinforced with a reinforcing panels, wherein the gusset regions are not reinforced.

FIGURE 57 shows the inner surface of the side wall shown in FIGURE 56. The reinforcement panels 5046 (having a trapezoid shape) are clearly visible, with the gusset regions 5044 therebetween.

FIGURE 58 shows the case or box in its collapsed configuration. It can be seen that all of the concertina folds 5050 at the side walls are folded (or closed), so that the volume within the case or box is minimised.

FIGURE 59 shows an alternate view of the case or box in its collapsed configuration.

FIGURE 60 shows a still further alternate view of the case or box in its collapsed configuration. This view more clearly shows the concertina folds 5050 in the side walls.

FIGURE 61 shows a yet further alternate view of the case or box in its collapsed configuration, and more especially a side wall 5012a having closed concertina folds 5050.

A number of combinations of the various described embodiments could be envisaged by the skilled person. All of the features disclosed herein may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive. In particular, the preferred features of the invention are applicable to all aspects of the invention and may be used in any combination. Likewise, features described in non-essential combinations may be used separately (not in combination).