FOLDABLE CONTAINER WITH SHELF AND METHOD OF FOLDING THE FOLDABLE CONTAINER

Abstract

The current invention relates to a foldable container comprising a pallet and a foldable sidewall, wherein the pallet forms a loading surface, wherein the foldable sidewall is a rectangular tube with open ends formed by a first, a second, a third and a fourth side panel, wherein the foldable sidewall is detachable installable on the pallet in order to define a loadable volume, wherein the foldable container comprises a shelf suitable to be loaded with objects, wherein the shelf is hinged to the first side panel, wherein the shelf comprises a first fold line parallel to the first side panel, wherein the foldable container comprises support means to support the shelf at the second side panel, opposite to the first side panel. The invention also relates to a method and a kit.

Claims

1. A foldable container for transportation and storage of objects comprising: a pallet and a foldable sidewall: wherein the pallet forms a loading surface, wherein the foldable sidewall is able to be folded in case of no loaded stored objects in the foldable container, wherein the foldable sidewall is a rectangular tube with open ends formed by a first side panel, a second side panel, a third side panel and a fourth side panel, wherein the foldable sidewall is detachable installable on the pallet in order to define a loadable volume; a shelf suitable to be loaded with objects, wherein the shelf is hinged to the first side panel and the shelf includes a first fold line parallel to the first side panel of the foldable sidewall; and support means to support the shelf at the second side panel, opposite to the first side panel.

2. The foldable container according to claim 1, wherein the foldable sidewall is foldable in each corner formed by two adjacent side panels of the foldable sidewall and wherein the foldable sidewall is foldable at a second fold line comprised in the third side panel and a third fold line comprised in the fourth side panel, wherein the second fold line and the third fold line are transverse to the loading surface of the pallet.

3. The foldable container according to claim 2, wherein the shelf includes a bar that is next to the first fold line, wherein the foldable container comprises further support means to support the bar at the third side panel and the fourth side panel.

4. The foldable container according to claim 3, wherein the further support means includes hooks at opposite ends of the bar and eyes at the third side panel and the fourth side panel, wherein a first eye is positioned at the second fold line and a second eye at the third fold line and wherein the first eye is attached to the third side panel aside the second fold line and the second eye is attached to the fourth side panel aside the third fold line.

5. The foldable container according to claim 4, wherein the support means to support the shelf at the second side panel includes of hooks attached to the shelf and of eyes at the second side panel.

6. The foldable container according to claim 1, wherein the shelf is hinged to the first side panel at a height A measured in a direction transverse to the loading surface of the pallet, wherein the first fold line is at a distance B from the first side panel measured in a direction transverse to the first side panel, and wherein A+B is smaller than or equal to the depth of the foldable container.

7. The foldable container according to claim 1, further comprising attachment means for holding the shelf folded against the first side panel.

8. The foldable container according to claim 1, wherein the second side panel comprises a door, wherein the door is positioned above the shelf and further including locking means for holding the door in a closed position.

9. The foldable container according to claim 1, further comprising a lid, wherein the lid has a locking means, wherein in an unfolded state an open top side of the foldable container is coverable by the lid, wherein in a folded state, the lid is attachable with use of the locking means to the pallet and the foldable side wall is containable in a volume formed by the pallet and the lid.

10. The foldable container according to claim 1, wherein the foldable sidewall and the shelf are made of polypropylene plates with a minimum thickness of 5 mm and a minimum weight of 1000 g/m.sup.2.

11. The foldable container according to claim 1, wherein the foldable sidewall is foldable twice in a corner formed by the first side panel and the third side panel and in a corner formed by the first side panel and the fourth side panel.

12. A method for unloading a foldable container, the foldable container comprising a pallet, a foldable sidewall and a shelf, wherein the foldable sidewall is a rectangular tube with open ends formed by a first side panel, a second side panel, a third side panel and a fourth side panel, wherein the shelf is hinged to the first side panel and comprises a first fold line parallel to the first side panel and wherein the shelf is supported at the second side panel, opposite to the first side panel, by support means, comprising the steps of: removing objects from the foldable container placed on the shelf; folding the shelf along the first fold line; folding the shelf against the first side panel; removing objects from the foldable container placed on a loadable surface of the pallet; detaching the foldable sidewall from the pallet; folding the foldable sidewall in a parallel stack of the first side panel, second side panel, third side panel and fourth side panel; and placing the folded foldable sidewall on the pallet in a lying position.

13. The method according to claim 12, wherein the method comprises the additional step of placing a lid on the folded foldable sidewall on the pallet, wherein the lid comprises locking means, wherein the lid is locked to the pallet using the locking means and wherein the foldable side wall is contained within a volume formed by the pallet and the lid.

14. The method according to claim 12, wherein the foldable container is loaded in reverse order.

15. A kit comprising: a pallet and a folded sidewall, wherein the pallet forms a loading surface, wherein the folded sidewall in unfolded state is a rectangular tube with open ends formed by a first side panel, a second side panel, a third side panel and a fourth side panel, wherein the foldable sidewall is folded in each corner formed by two adjacent side panels of the foldable sidewall and wherein the third side panel and the fourth side panel are folded between the first side panel and the second side panel, resulting in a parallel stack of the first side panel, second side panel, third side panel and fourth side panel, wherein a shelf is hinged to the first side panel, wherein the foldable sidewall is detachable installable on the pallet in order to define a loadable volume, and the foldable sidewall includes support means to support the shelf at the second side panel, opposite to the first side panel, and that the shelf is folded along a first fold line parallel to the first side panel and folded against the first side panel.

Description

DESCRIPTION OF FIGURES

[0019] FIG. 1 shows a perspective view of a foldable container according to an embodiment of the present invention, with a shelf in a lowered position.

[0020] FIG. 2 shows a perspective view of a foldable container according to an embodiment of the present invention, with a shelf folded against a first side panel of a foldable sidewall.

[0021] FIG. 3 shows a perspective view of a shelf according to an embodiment of the present invention.

[0022] FIG. 4 shows a cross-section of a foldable container according to an embodiment of the present invention, with a shelf in a lowered position.

[0023] FIG. 5 shows a cross-section of a foldable container according to an embodiment of the present invention, with a shelf folded against a first side panel of a foldable sidewall.

[0024] FIG. 6 shows a perspective view of a foldable container according to an embodiment of the present invention, with a partly folded foldable sidewall.

[0025] FIG. 7 shows a perspective view of a foldable container according to an embodiment of the present invention, in a completely folded state.

[0026] FIG. 8 shows a perspective view of a foldable container according to an embodiment of the present invention, in a completely folded state with a lid.

[0027] FIG. 9 shows a detail of an eye at a third side panel of a foldable sidewall according to an embodiment of the present invention.

[0028] FIG. 10 shows a detail of a corner formed by a first side panel and a third side panel of a foldable sidewall according to an embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

[0029] Unless otherwise defined, all terms used in disclosing the invention, including technical and scientific terms, have the meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. By means of further guidance, term definitions are included to better appreciate the teaching of the present invention.

[0030] As used herein, the following terms have the following meanings:

[0031] A, an, and the as used herein refers to both singular and plural referents unless the context clearly dictates otherwise. By way of example, a compartment refers to one or more than one compartment.

[0032] Comprise, comprising, and comprises and comprised of as used herein are synonymous with include, including, includes or contain, containing, contains and are inclusive or open-ended terms that specifies the presence of what follows e.g. component and do not exclude or preclude the presence of additional, non-recited components, features, element, members, steps, known in the art or disclosed therein.

[0033] Furthermore, the terms first, second, third and the like in the description and in the claims, are used for distinguishing between similar elements and not necessarily for describing a sequential or chronological order, unless specified. It is to be understood that the terms so used are interchangeable under appropriate circumstances and that the embodiments of the invention described herein are capable of operation in other sequences than described or illustrated herein.

[0034] The recitation of numerical ranges by endpoints includes all numbers and fractions subsumed within that range, as well as the recited endpoints.

[0035] Reference throughout this specification to one embodiment or an embodiment means that a particular feature, structure or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, appearances of the phrases in one embodiment or in an embodiment in various places throughout this specification are not necessarily all referring to the same embodiment, but may. Furthermore, the particular features, structures or characteristics may be combined in any suitable manner, as would be apparent to a person skilled in the art from this disclosure, in one or more embodiments. Furthermore, while some embodiments described herein include some but not other features included in other embodiments, combinations of features of different embodiments are meant to be within the scope of the invention, and form different embodiments, as would be understood by those in the art. For example, in the following claims, any of the claimed embodiments can be used in any combination.

[0036] In the context of this document, a living hinge is an integrated, narrow, thin, flexible connection between two rigid plastic or cardboard parts, creating a hinge line. A living hinge is also known as a film hinge.

[0037] In a first aspect, the invention relates to a foldable container for transportation and storage of objects.

[0038] In a preferred embodiment, the foldable container comprises a pallet and a foldable sidewall.

[0039] The pallet is a portable platform for handling, storing or moving materials and packages, for instance in warehouses, factories and vehicles. The pallet is suited to be lifted by a forklift or pallet truck. Preferably the pallet is suited to be lifted from four different sides. The pallet has dimensions corresponding to known standards like a Europallet or has custom dimensions. The pallet is made from wood or plastic. Preferably the pallet is made from plastic. The pallet forms a loading surface. The loading surface is a substantially rectangular or square shape.

[0040] The foldable container is substantially beam-shaped. The foldable container has a width, depth and height. The width, depth and height of the foldable container are measured along three orthogonal axes. In the context of this document, width direction is a direction parallel to the axis along which the width of the foldable container is measured. In the context of this document, depth direction is a direction parallel to the axis along which the depth of the foldable container is measured. In the context of this document, height direction is a direction parallel to the axis along which the height of the foldable container is measured. The height direction is transverse to the loading surface of the pallet. Each side of the rectangular or square shape of the loading surface is parallel to the width direction or parallel to the depth direction.

[0041] The foldable sidewall is being able to be folded in case of no loaded stored objects in the foldable container. The foldable sidewall is a rectangular tube with open ends formed by a first side panel, a second side panel, a third side panel and a fourth side panel. The first side panel and the second side panel of the foldable sidewall are parallel to the width direction of the foldable container. The second side panel of the foldable sidewall is opposite to the first side panel. The third side panel and the fourth side panel of the foldable sidewall are parallel to the depth direction of the foldable container. The fourth side panel of the foldable container is opposite to the third side panel. The first side panel is attached to the third side panel and the fourth side panel. The second side panel is attached to the third side panel and the fourth side panel. The foldable sidewall is detachable installable on the pallet in order to define a loadable volume. The first side panel, the second side panel, the third side panel and the fourth side panel are transverse to the loading surface of the pallet. In other words, the first side panel, the second side panel, the third side panel and the fourth side panel are parallel to the height direction. The loadable volume is consequently beam-shaped, corresponding to the substantially beam-shape of the foldable container. The loadable volume is open at a side opposite to the pallet. This means that the foldable container is top loaded. Optionally the foldable container comprises a lid to cover the open side of the loadable volume. The pallet comprises preferably a groove and/or an upstanding edge to retain the foldable sidewall on the pallet.

[0042] The foldable sidewall is made of wood, plastic, cardboard, metal or another suited material.

[0043] The foldable container comprises a shelf suitable to be loaded with objects. The shelf is hinged to the first side panel. The shelf is hinged to the first side panel by the use of a hinge, preferably a living hinge. The shelf is attached to the first side panel by use of for instance screws, bolts and nuts, rivets or another suitable means. The shelf is made of wood, plastic, cardboard, metal or another suited material. The shelf comprises a first fold line parallel to the first side panel of the foldable sidewall, meaning parallel to the width direction of the foldable container. The first fold line is preferably positioned at a distance of at most 10 cm from a middle of the shelf seen along the depth direction of the foldable container, preferably at a distance of at most 8 cm, more preferably at most 6 cm, even more preferably at most 4 cm and most preferably at most 3 cm. The first fold line is preferably formed by a hinge, more preferably by a living hinge. The shelf is thanks to the first fold line foldable in two parts. The shelf is foldable in two parts towards the inside of the loadable volume or alternatively away from the inside of the loadable volume, meaning towards the open side of the loadable volume. It is clear for a skilled person in the art that this depends on which side of the shelf the hinge is positioned. A shelf foldable in two parts away from the inside of the loadable volume is advantageous to access a volume inside the foldable container below the shelf, without having to remove all objects loaded on the shelf. Only objects on a part of the shelf near the second side panel of the foldable sidewall need to be removed.

[0044] The foldable container comprises support means to support the shelf at the second side panel of the foldable sidewall. This is advantageous to avoid that the shelf folds in two parts when loaded with objects, especially in the case that the shelf is foldable in two parts towards the inside of the loadable volume. In either case, this remains beneficial to reduce stress on the first fold line and the hinge at the first side panel of the foldable sidewall. The support means can be for instance a bar attached inside the loadable volume to the second side panel of the foldable sidewall, hooks and eyes attached to the shelf and the second side panel of the foldable sidewall or another suitable means.

[0045] A foldable container according to the current embodiment is advantageous because the shelf extends completely from the first side panel to the second side panel of the foldable side wall. The foldable container is hereby subdivided in two volumes by this single shelf. So less structural elements are required compared to a container according to the prior art for obtaining this subdivision. Also, less actions are required to fold the foldable container. Only the shelf needs to be folded against the first side panel before the foldable sidewall can be folded, instead of requiring multiple steps to rotate mounting means and at least two shelves in case of a container according to the prior art. Due to the first fold line, the shelf can be folded first along the first fold line in two parts before being folded against the first side panel. This limits the size of the shelf in a folded state of the foldable sidewall, enabling to store the foldable sidewall in a folded state on the loading surface of the pallet. This also avoids that the shelf needs to be detached to fold the foldable sidewall, which would increase the number of steps to fold the foldable container. This would also introduce the risk that parts of the foldable container are lost.

[0046] In a preferred embodiment the foldable sidewall is foldable in each corner formed by two adjacent side panels of the foldable sidewall. Two adjacent side panels are the first side panel and the third side panel, the first side panel and the fourth side panel, the second side panel and the third side panel and the second side panel and the fourth side panel. Preferably the adjacent side panels are attached by a hinge, more preferably by a living hinge. The foldable sidewall is foldable at a second fold line comprised in the third side panel. The foldable sidewall is foldable at a third fold line comprised in the fourth side panel. The second fold line and the third fold line are parallel to the height direction of the foldable container. The second fold line and the third fold line are preferably positioned at a distance of at most 10 cm from a middle of respectively the third side panel and the fourth side panel seen along the depth direction of the foldable container. Preferably the second fold line and the third fold line are positioned at a distance of at most 8 cm from the middle of respectively the third side panel and the fourth side panel, more preferably at a distance of at most 6 cm, even more preferably at a distance of at most 4 cm and most preferably at a distance of at most 3 cm. The second fold line and the third fold line are preferably formed by a hinge, more preferably by a living hinge. The second fold line and the third fold line are advantageous for approximately folding the third side panel and the fourth side panel in half, in between the first side panel and the second panel side. This means that the third side panel and the fourth side panel are foldable towards the inside of the loadable volume. This reduces a total surface taken by the foldable sidewall in a folded state.

[0047] In a preferred embodiment the shelf comprises a bar that is next to the first fold line. Because the bar is next to the first fold line, it does not hamper folding the shelf in two parts. The bar is for instance a full wooden bar, a plastic profile or a metal profile. The profile may or may not be hollow. The foldable container comprises further support means to support the bar at the third side panel and the fourth side panel of the foldable sidewall. These support means can be for instance a L-shaped profile. This embodiment is advantageous to avoid that the shelf folds in two parts when loaded with objects, especially in the case that the shelf is foldable in two parts away from the inside of the loadable volume. In either case, this embodiment is beneficial to reduce stress on the first fold line and the hinge at the first side panel of the foldable sidewall.

[0048] In a further embodiment, the further support means exist of hooks at opposite ends of the bar and eyes at the third side panel and the fourth side panel of the foldable sidewall. The eyes are openings suited for receiving the hooks at the opposite ends of the bar. The openings are lying in a plane. A first eye is positioned at the second fold line comprised in the third side panel of the foldable sidewall. A second eye is positioned at the third fold line comprised in the fourth side panel of the foldable sidewall. The first eye is attached to the third side panel of the foldable sidewall aside the second fold line inside the loadable volume. The second eye is attached to the fourth side panel of the foldable sidewall aside the third fold line inside the loadable volume. The first eye and the second eye comprise to that end a longitudinal plate with mounting holes. The first eye and the second eye are attached respectively to the third side panel and the fourth side panel of the foldable sidewall by the use of screws, bolts and nuts, rivets or another suitable means. The longitudinal plate is transverse to the plane in which the openings lie. This is beneficial because it allows to receive the hooks in the eyes, while the eyes do not hamper folding the third side panel and the fourth side panel of the foldable sidewall towards the inside of the loadable volume. This embodiment is advantageous because it prevents the foldable sidewall from bulging at the third side panel and the fourth side panel when the foldable container is loaded. This is especially advantageous when the foldable sidewall is made from relatively flexible materials like cardboard and plastic.

[0049] In a preferred embodiment the support means to support the shelf at the second side panel of the foldable sidewall exists of hooks attached to the shelf and of eyes at the second side panel of the foldable sidewall. This embodiment is advantageous because it prevents the foldable sidewall from bulging at the first side panel and the second side panel when the foldable container is loaded. This is especially advantageous when the foldable sidewall is made from relatively flexible materials like cardboard and plastic.

[0050] In a further embodiment the first side panel of the foldable sidewall comprises protection plates. The protection plates are preferably made of hard plastic material, more preferably of metal. The protection plates are positioned as such that the hooks attached to the shelfs are touching the protection plates when the shelf is folded in two parts and against the first side panel of the foldable sidewall. The protection plates are beneficial to avoid damage to the first side panel of the foldable sidewall by the hooks. This is especially beneficial when the foldable sidewall is made of materials such as cardboard, plastic or wood.

[0051] In an embodiment the height of the sidewall, measured along the height direction, is smaller than or equal to the depth of the pallet. This is beneficial because after folding the foldable sidewall, the foldable sidewall in folded state can be placed lying on the loading surface of the pallet without sticking out of the pallet.

[0052] In a preferred embodiment the shelf is hinged to the first side panel at a height A measured in a direction transverse to the loading surface of the pallet. This is for instance the height direction. The first fold line is at a distance B from the first side panel measured in a direction transverse to the first side panel. This is for instance the depth direction. A+B is smaller than or equal to the depth of the foldable container. The shelf can protrude through the open side of the loadable volume after being fold in two parts and against the first side panel of the foldable sidewall. However, a shelf according to this embodiment will in folded state not protrude far enough through the open side of the loadable volume, such that when the foldable sidewall in folded state is placed lying on the loading surface of the pallet, the shelf in folded state would stick out of the pallet. This is especially beneficial in combination with a previous embodiment wherein the height of the sidewall is smaller than or equal to the depth of the pallet.

[0053] In a preferred embodiment the foldable container comprises attachment means for holding the shelf folded against the first side panel of the foldable sidewall. The attachment means comprises for instance a hook, a clamp, a snap button, magnetic means or another suitable means for detachably attaching the shelf to the first side panel of the foldable sidewall. Preferably the attachment means are magnetic means. The magnetic means comprise at least one magnet and at least one plate of ferromagnetic material. The at least one magnet is installed on the first side panel of the foldable sidewall and the at least one plate of ferromagnetic material on the shelf or vice versa. It is clear to a skilled person that the at least one magnet and the at least one plate of ferromagnetic material are positioned as such that the at least one magnet and the at least one plate of ferromagnetic material are in contact with each other when the shelf is folded against the first side panel of the foldable sidewall. When the shelf or the first side panel are made of ferromagnetic material, the plate of ferromagnetic material can be omitted.

[0054] The attachment means are beneficial to improve the ease of folding the foldable container. After folding the shelf to the first side panel, the shelf will not drop while folding the foldable sidewall, forcing a user to restart folding the foldable container. It is also not required to hold the shelf manually against the first side panel. The user has his two hands available for folding the foldable sidewall. This is also beneficial when unloading the foldable container, to avoid that the shelf drops while unloading objects from a volume below the shelf in lowered position.

[0055] In a preferred embodiment the second side panel of the foldable sidewall comprises a door. The door is positioned above the shelf. The door extends to the open side of the loadable volume. The foldable container comprises locking means for holding the door in a closed position. The locking means are for instance slidable U-shaped profiles at an edge of the second side panel of the foldable sidewall at the open side of the loadable volume. The door is beneficial to lower the second side panel when unloading the foldable container, especially when removing objects from a volume below the shelf.

[0056] In a preferred embodiment the foldable container comprises a lid. In an unfolded state of the foldable container, an open top side of the foldable container is coverable by the lid. The open top side of the foldable container corresponds with the open side of the loadable volume. The lid comprises locking means. The lid is attachable with use of the locking means to the pallet. In a folded state of the foldable container, the foldable sidewall is containable in a volume formed by the pallet and the lid. This is advantageous to protect the foldable sidewall against damage when the foldable container is not in use for transporting or holding objects. This embodiment is especially advantageous in combination with previously described embodiments wherein the height of the sidewall is smaller or equal to the depth of the pallet and wherein the shelf is hinged to the first side panel at a height A.

[0057] In a preferred embodiment the foldable sidewall and the shelf are made of polypropylene plates. The polypropylene plates have a minimum thickness of 5 mm, preferably a minimum thickness of 6 mm, more preferably a minimum thickness of 8 mm, even more preferably a minimum thickness of 9 mm and most preferably a minimum thickness of 10 mm. The polypropylene plates have a minimum weight of 1000 g/m.sup.2, preferably a minimum weight of 2000 g/m.sup.2, more preferably a minimum weight of 3000 g/m.sup.2, even more preferably a minimum weight of 3500 g/m.sup.2 and most preferably a minimum weight of 4000 g/m.sup.2. The use of polypropylene plates is advantageous for a low-cost foldable container that can be reused and recycled, while suited for carrying a heavy load of objects. This embodiment is preferably realized using living hinges.

[0058] In an embodiment the shelf comprises at least two handles at a part of the shelf at the second side panel of the foldable sidewall. A first handle is at a side of said part of the shelf orientated towards the open side of the loadable volume when the shelf is in unfolded state. The first handle is beneficial to fold the shelf in two parts. A second handle is at a side of said part of the shelf orientated towards the pallet when the shelf is in unfolded state. The second handle is beneficial to unfold the shelf when the shelf is folded in two parts. When the shelf comprises a bar next to the first fold line, as described in a previous embodiment, the shelf preferably comprises a third handle on the bar. The third handle is beneficial to unfold the shelf when folded against the first side panel of the foldable sidewall. Said handles can be made of a rigid material, such as a plastic material or a metal. Alternatively said handles can be loops of flexible material, such as textile.

[0059] In an embodiment the shelf is folded over twice at the first side panel of the foldable sidewall. This is beneficial because it forms a reinforcement of the shelf at the first side panel of the foldable sidewall, reducing the risk the shelf fails when loaded with objects, due to the tearing out of for instance screws, bolts and nuts, rivets or another suitable means, with which the shelf is attached to the first side panel of the foldable sidewall. The use of a reinforcement bar at the first side panel of the foldable sidewall is unnecessary.

[0060] In an embodiment the foldable container comprises a second shelf. The second shelf is hinged to the second side panel of the foldable sidewall. The second shelf is hinged to the second side panel of the foldable sidewall lower than the shelf hinged to the first side panel of the foldable sidewall. The second shelf comprises a fourth fold line parallel to the first side panel, meaning parallel to the width direction of the foldable container. The fourth fold line is preferably positioned at a distance of at most 10 cm from a middle of the second shelf seen along the depth direction of the foldable container, preferably at a distance of at most 8 cm, more preferably at most 6 cm, even more preferably at most 4 cm and most preferably at most 3 cm. The foldable container comprises support means to support the second shelf at the first side panel of the foldable sidewall. The support means can be similar as in previously described embodiments. It is clear that at previously described embodiments of the shelf hinged to the first side panel of the foldable sidewall can be applied mutatis mutandis for the second shelf, with similar advantages. This embodiment is advantageous because a foldable container is obtained with similar advantages as described before, but wherein the loadable volume is subdivided in three separate volumes.

[0061] In an embodiment the foldable container comprises locking means to lock the third side panel and the fourth side panel of the foldable sidewall in an unfolded state. The locking means are for instance slidable U-shaped profiles at an edge of the third side panel and an edge of the fourth side panel of the foldable sidewall at the open side of the loadable volume. The locking means are advantageous to avoid that the third side panel and the fourth side panel fold again inside the first side panel and the second side panel while unfolding the foldable container.

[0062] In an embodiment, the foldable sidewall is foldable twice in a corner formed by the first side panel and the third side panel of the foldable sidewall and in a corner formed by the first side panel and the fourth side panel of the foldable sidewall. Preferably the first side panel and the third side panel are attached by two parallel hinges, more preferably by two parallel living hinges. Preferably the first side panel and the fourth side panel are attached by two parallel hinges, more preferably by two parallel living hinges. Said two parallel hinges are parallel to the height direction. A distance between said two parallel hinges, measured transverse to the height direction is at least 2 cm, preferably at least 3 cm, more preferably at least 4 cm and even more preferably at least 5 cm.

[0063] This embodiment is advantageous when folding the third side panel and the fourth side panel between the first side panel and the second side panel, to fold the third side panel and the fourth side panel around the shelf, folded against the first side panel. When the foldable sidewall is not foldable twice in said corners, the third side panel and the fourth plate panel have to bend around the shelf. This would result in a lot of tension in the folded foldable sidewall, increasing a volume taken by the folded foldable sidewall.

[0064] In an embodiment, the foldable sidewall is foldable twice in a corner formed by the second side panel and the third side panel of the foldable sidewall and in a corner formed by the second side panel and the fourth side panel of the foldable sidewall. Preferably the second side panel and the third side panel are attached by two parallel hinges, more preferably by two parallel living hinges. Preferably the second side panel and the fourth side panel are attached by two parallel hinges, more preferably by two parallel living hinges. Said two parallel hinges are parallel to the height direction. Preferably a distance between said two parallel hinges, measured transverse to the height direction is at least 2 cm, more preferably at least 3 cm, even more preferably at least 4 cm and most preferably at least 5 cm. This embodiment simplifies folding the foldable sidewall in a corner formed by the second side panel and the third side panel and in a corner formed by the second side panel and the fourth side panel. It is clear that this embodiment can be combined with a previously described embodiment wherein the foldable sidewall is foldable twice in a corner formed by the first side panel and the third side panel of the foldable sidewall and in a corner formed by the first side panel and the fourth side panel of the foldable sidewall. This embodiment is especially advantageous in combination with a foldable container comprising a second shelf.

[0065] In a second aspect, the invention relates to a method for unloading a foldable container.

[0066] In a preferred embodiment the foldable container comprises a pallet, a foldable sidewall and a shelf.

[0067] The foldable container is substantially beam-shaped. The foldable container has a width, depth and height. The width, depth and height of the foldable container are measured along three orthogonal axes. The axes are parallel to the width direction, the depth direction and the height direction, as defined in the first aspect of the invention.

[0068] The pallet is a portable platform for handling, storing or moving materials and packages, for instance in warehouses, factories and vehicles. The pallet forms a loading surface. The loading surface is a substantially rectangular or square shape. Each side of the rectangular or square shape of the loading surface is parallel to the width direction or parallel to the depth direction.

[0069] The foldable sidewall is a rectangular tube with open ends, formed by a first side panel, a second side panel, a third side panel and a fourth side panel. The first side panel and the second side panel of the foldable sidewall are parallel to the width direction of the foldable container. The second side panel of the foldable sidewall is opposite to the first side panel. The third side panel and the fourth side panel of the foldable sidewall are parallel to the depth direction of the foldable container. The fourth side panel of the foldable container is opposite to the third side panel. The first side panel is attached to the third side panel and the fourth side panel. The second side panel is attached to the third side panel and the fourth side panel. The foldable sidewall is detachable installed on the pallet and defines a loadable volume. The first side panel, the second side panel, the third side panel and the fourth side panel are transverse to the loading surface of the pallet. The loadable volume is open at a side opposite to the pallet.

[0070] The shelf is hinged to the first side panel. The shelf is hinged to the first side panel by the use of a hinge, preferably a living hinge. The shelf is attached to the first side panel by use of for instance screws, bolts and nuts, rivets or another suitable means. The shelf comprises a first fold line parallel to the first side panel. The shelf is supported at the second side panel by support means.

[0071] The method comprises the steps of: [0072] removing objects from the foldable container placed on the shelf; [0073] folding the shelf along the first fold line; [0074] folding the shelf against the first side panel; [0075] removing objects from the foldable container placed on the loadable surface of the pallet; [0076] detaching the foldable sidewall from the pallet; [0077] folding the foldable sidewall; [0078] placing the folded foldable sidewall on the pallet.

[0079] This method is beneficial because it allows to unload safely a foldable container that is divided in two volumes. The shelf will not unfold while unloading a volume below the shelf. It is also not required to partly dismantle the foldable container to unload the foldable container below the shelf. Not even all objects need to be removed from the shelf to be able to unload the volume below the shelf. The method is additionally beneficial because the foldable container can be folded after unloading in less steps. Only the shelf needs to be folded against the first side panel before the foldable sidewall can be folded, instead of requiring multiple steps to rotate mounting means and at least two shelves in case of a container according to the prior art. Particular advantageous is that thanks to the first fold line, the shelf can be folded first along the first fold line in two parts before being folded against the first side panel. This limits the size of the shelf in a folded state of the foldable sidewall, enabling to store the foldable sidewall in a folded state on the pallet. This also avoids that the shelf needs to be detached to fold the foldable sidewall, which would increase the number of steps of the method to fold the foldable container.

[0080] In an embodiment the foldable sidewall is simultaneously folded in each corner formed by two adjacent side panels of the foldable sidewall and at a second fold line and a third fold line. This can be advantageously executed by a single person. Two adjacent side panels are the first side panel and the third side panel, the first side panel and the fourth side panel, the second side panel and the third side panel and the second side panel and the fourth side panel. Preferably the adjacent side panels are attached by a hinge, more preferably by a living hinge. The second fold line is comprised in the third side panel of the foldable sidewall. The third fold line is comprised in the fourth side panel of the foldable sidewall. The second fold line and the third fold line are parallel to the height direction of the foldable container. The second fold line and the third fold line are positioned at a distance of at most 10 cm from a middle of respectively the third side panel and the fourth side panel seen along the depth direction of the foldable container. Preferably the second fold line and the third fold line are positioned at a distance of at most 8 cm from the middle of respectively the third side panel and the fourth side panel, more preferably at a distance of at most 6 cm, even more preferably at a distance of at most 4 cm and most preferably at a distance of at most 3 cm. The second fold line and the third fold line are preferably formed by a hinge, more preferably by a living hinge. The folded foldable sidewall is placed in a lying position on the pallet. The second fold line and the third fold line are advantageous for approximately folding the third side panel and the fourth side panel in half, in between the first side panel and the second panel side. This means that the third side panel and the fourth side panel are foldable towards the inside of the loadable volume. This reduces a total surface taken by the foldable sidewall in a folded state.

[0081] In a preferred embodiment the method comprises the additional step of placing a lid on the folded foldable sidewall on the pallet. The lid comprises locking means. The lid is locked to the pallet using the locking means. The foldable sidewall is contained within a volume formed by the pallet and the lid. This is advantageous to protect the foldable sidewall against damage when the foldable container is not in use for transporting or holding objects.

[0082] In an embodiment the method comprises the additional step of detachably attaching the shelf to the first side panel of the foldable sidewall after folding the shelf against the first side panel of the foldable sidewall. The shelf can be detachably attached to the first side panel of the foldable sidewall using for instance a hook, a clamp, a snap button, magnetic means or another suitable means. Preferably the shelf is detachably attached using magnetic means. This embodiment is beneficial to improve the ease of folding the foldable container. After folding the shelf against the first side panel, the shelf will not drop while folding the foldable sidewall, forcing a user to restart folding the foldable container. It is also not required to hold the shelf manually against the first side panel. The user has his two hands available for folding the foldable sidewall.

[0083] In an embodiment the second side panel of the foldable sidewall comprises a door. The door is positioned above the shelf. The door extends to the open side of the loadable volume. The foldable container comprises locking means for holding the door in a closed position. The door is beneficial to lower the second side panel when unloading the foldable container in an unfolded state, especially when removing objects from a volume below the shelf. The method comprises the additional step before folding the foldable sidewall of closing and locking the door. This is beneficial to avoid that door is damaged during folding the foldable sidewall. This is additionally beneficial to reduce thickness of a parallel stack of the first side panel, second side panel, third side panel and fourth side panel of the foldable sidewall in folded state.

[0084] In a preferred embodiment the foldable container is loaded in a reverse order. The foldable container is unfolded from a folded state to an unfolded state. In a first step the folded foldable sidewall is removed from the pallet and put in an upwards position. The folded foldable sidewall is unfolded. Unfolding the folded foldable sidewall is preferably executed on the pallet, in order to have the unfolded foldable sidewall immediately in a correct position on the pallet. Objects are loaded on the loadable surface of the pallet. Thereafter the shelf is folded down and further unfolded around the first fold line. Objects are loaded on the shelf. The foldable container can be unfolded and loaded as simple and as fast as it can be unloaded and folded. The same embodiments and its advantages as described before are mutatis mutandis applicable for loading the foldable container.

[0085] In a third aspect, the invention relates to a kit.

[0086] In a preferred embodiment the kit comprises a pallet and a folded sidewall. The pallet forms a loading surface. The folded sidewall is in an unfolded state a rectangular tube with open ends formed by a first side panel, a second side panel, a third side panel and a fourth side panel. The first side panel and the second side panel of the foldable sidewall are opposite side panels. The third side panel and the fourth side panel of the foldable container are opposite side panels. The first side panel is attached to the third side panel and the fourth side panel. The second side panel is attached to the third side panel and the fourth side panel. The foldable sidewall is folded in each corner formed by two adjacent side panels of the foldable sidewall. Two adjacent side panels are the first side panel and the third side panel, the first side panel and the fourth side panel, the second side panel and the third side panel and the second side panel and the fourth side panel. The third side panel and the fourth side panel of the foldable sidewall are folded between the first side panel and the second side panel, resulting in a parallel stack of the first side panel, second side panel, third side panel and fourth side panel of the foldable sidewall. The third side panel and the fourth side panel are located in between the first side panel and the second side panel of the foldable sidewall in said stack. The foldable sidewall is detachable installable on the pallet in order to define a loadable volume.

[0087] A shelf is hinged to the first side panel. The shelf is hinged to the first side panel by the use of a hinge, preferably a living hinge. The shelf is attached to the first side panel by use of for instance screws, bolts and nuts, rivets or another suitable means. The shelf is folded along a first fold line parallel to the first side panel and folded against the first side panel of the foldable sidewall. The foldable sidewall comprises support means to support the shelf at the second side panel of the foldable sidewall. The support means can be for instance a bar attached inside the loadable volume to the second side panel of the foldable sidewall, hooks and eyes attached to the shelf and the second side panel of the foldable sidewall or another suitable means.

[0088] The kit as described herein provides an advantageous effect that a foldable container can be assembled which comprises a minimum number of structural elements and which is subdivided by a shelf in two separate volumes. The kit has a volume which is substantially smaller than a loadable volume defined by the pallet and the foldable sidewall after assembling the foldable container. No tools are required to assemble the foldable container. Due to the foldable sidewall and the shelf that is hinged to the first side panel of the foldable sidewall, the kit can be assembled in a very short time by a single person.

[0089] A person of ordinary skill in the art will appreciate that a foldable container according to the first aspect is suited for executing a method according to the second aspect and is preferably assembled with the use of a kit according to the third aspect and that a method according to the second aspect is preferably executed with the use of a foldable container according to the first aspect. Accordingly, any feature described in this document, above as well as below, may relate to any of the three aspects of the present invention.

[0090] The invention is further described by the following non-limiting figures which further illustrate the invention, and are not intended to, nor should they be interpreted to, limit the scope of the invention.

DESCRIPTION OF FIGURES

[0091] FIG. 1 shows a perspective view of a foldable container according to an embodiment of the present invention, with a shelf in a lowered position.

[0092] The foldable container (1) comprises a pallet (2) and a foldable sidewall (3). The pallet forms a loading surface (34). The loading surface (34) is hidden on FIG. 1 by a shelf (15). The foldable container (1) has a width, depth and height. The width is measured along an axis parallel to a width direction (8), the depth along an axis parallel to a depth direction (9) and the height along an axis parallel to a height direction (10). The foldable sidewall (3) has a first side panel (4), a second side panel (5), a third side panel (6) and a fourth side panel (7). The first side panel (4) and the second side panel (5) are opposite side panels of the foldable sidewall (3). The first side panel (4) and the second side panel (5) are parallel to the width direction (8). The third side panel (6) and the fourth side panel (7) are opposite sides. The third side panel (6) and the fourth side panel (7) are parallel to the depth direction (9). The foldable sidewall (3) is detachable installed on the pallet (2) in order to define a loadable volume (11). The pallet (2) comprises an upstanding edge (29) to retain the foldable sidewall (3) on the pallet (2). The foldable sidewall (3) is foldable in each corner (14) formed by two adjacent side panels. Adjacent side panels are the first side panel (4) and the third side panel (6), the first side panel (4) and the fourth side panel (7), the second side panel (5) and the third side panel (6) and finally the second side panel (5) and the fourth side panel (7). The second side panel (5) is attached to the third side panel (6) and to the fourth side panel (7) with a living hinge. The foldable sidewall (3) is foldable twice in a corner (14) formed by the first side panel (4) and the third side panel (6) and in a corner (14) formed by the first side panel (4) and the fourth side panel (7). The first side panel (4) is attached to the third side panel (6) and the fourth side panel (7) with a double hinge, being a first living hinge (39) and a second living hinge (40). A distance between the first living hinge (39) and the second living hinge (40) is at least 2 cm. The foldable sidewall (3) is foldable at a second fold line (12) comprised in the third side panel (6) and at a third fold line (13) comprised in the fourth side panel (7). The second fold line (12) and the third fold line (13) are parallel to the height direction (10). The second fold line (12) and the third fold line (13) are positioned at a distance of at most 10 cm from a middle of respectively the third side panel (6) and the fourth side panel (7). The second fold line (12) and the third fold (13) line are formed by a living hinge. The foldable container (1) comprises a shelf (15). The shelf (15) is hinged to the first side panel (4). The shelf (15) is hinged to the first side panel (4) by the use of a hinge (16). The hinge (16) is a living hinge. The shelf (15) comprises a first fold line (17). The first fold line (17) is parallel to the width direction (8). The foldable container (1) comprises support means to support the shelf (15) at the second side panel (5). Because the shelf (15) is in a lowered position, the actual support means are not visible on FIG. 1. The support means exists of hooks (19) attached to the shelf (15) and eyes (20) attached to the second side panel (5). The hooks (19) and the eyes (20) are not visible on FIG. 1), but protection plates (24) on the first side panel (4) to protect the first side panel (4) against damage by the hooks (19) when the shelf (15) is folded against the first side panel (4). The shelf (15) comprises a bar (25) that is next to the first fold line (17). The actual bar (25) is not visible on FIG. 1, although the screws (26) holding the bar (25) to the shelf (15) are. The foldable container (1) comprises further support means to support the bar (25) at the third side panel (6) and the fourth side panel (7). The further support means exists of hooks (21) at opposite ends of the bar (25) and eyes (22) at the third side panel (6) and the fourth side panel (7). The further support means are not visible on FIG. 1, but a reinforcement plate (18) is. The reinforcement plates (18) are mounted opposite the eyes (22) and avoid that the third side panel (6) and the fourth side panel (7) are damaged when the shelf (15) is loaded with objects, due to tension on the eyes (22). The foldable container (1) comprises magnets (23) on the first side panel (4) for holding the shelf (15) folded against the first side panel (4). The shelf (15) comprises ferromagnetic plates (33). When the shelf (15) is folded against the first side panel (4), the ferromagnetic plates (33) are attracted by the magnets (23). The ferromagnetic plates are not visible on FIG. 1. The second side panel (5) comprises a door (27). The door (27) is positioned above the shelf (15). The foldable container (1) comprises locking means (28) for holding the door (27) in a closed position. The door (27) is in FIG. 1 in the closed position. The locking means (28) are slidable U-shaped profiles at an edge of the second side panel (5) at an open side of the loadable volume (11).

[0093] FIG. 2 shows a perspective view of a foldable container according to an embodiment of the present invention, with a shelf folded against a first side panel of a foldable sidewall.

[0094] The foldable container (1) is the foldable container (1) of FIG. 1, with the shelf (15) folded against the first side panel (4) of the foldable sidewall (3). The shelf (15) is folded in two parts along the first fold line (17). The two parts are approximately equal, as the first fold line (17) is at a distance of at most 10 cm from a middle of the shelf (15), seen along the depth direction (9). Because the shelf (15) is folded against the first side panel (4), the loading surface (34) of the pallet (2) is visible. Also visible is the bar (25) mounted at a bottom side of the shelf (15). At opposite ends of the bar (25) one can see the hooks (21) of the further support means. The bar (25) has a handle (30) to lower the shelf (15). The shelf (15) is folded over twice at the first side panel (4) to form a reinforcement (31) of the shelf (15). The reinforcement (31) is attached to the first side panel (4) using bolts (32).

[0095] FIG. 3 shows a perspective view of a shelf according to an embodiment of the present invention.

[0096] The shelf (15) corresponds to the shelfs (15) of FIGS. 1 and 2, but in a lowered position, meaning an unfolded state. Clearly visible now are the hooks (19) of the support means and the ferromagnetic plates (33). The shelf (15) comprises four handles (30). A first pair of handles (30) is at a top side of the shelf (15), orientated towards an open side of the loadable volume (11) when the shelf (15) is in unfolded state. The first pair of handles (30) is used to fold the shelf (15) in two parts. A second handle (30) is at a bottom side of the shelf (15), orientated towards the pallet (2) when the shelf (15) is in unfolded state. The second handle is used to unfold the shelf (15) when the shelf (15) is folded in two parts, but not any longer folded against the first side panel (4). As described before, the shelf (15) comprises a third handle (30) on the bar (25). The third handle (30) is used to unfold the shelf (15) when folded against the first side panel (4) of the foldable sidewall (3).

[0097] FIG. 4 shows a cross-section of a foldable container according to an embodiment of the present invention, with a shelf in a lowered position.

[0098] The foldable container (1) corresponds to the foldable containers (1) in FIGS. 1 and 2. The shelf (15) is supported at the second side panel (5) with eyes (20). Hooks (19) attached to the shelf (15) hook in the eyes (20). The shelf (15) is additionally supported near the first fold line (17) with eyes (22) at the third side panel (6) and the fourth side panel (7). The fourth side panel (7) is not visible on FIG. 4. Hooks (21) at opposite ends of the bar (25) hook in the eyes (22). Clearly visible is how the upstanding edges (29) retain the foldable sidewall (3) on the pallet (2).

[0099] FIG. 5 shows a cross-section of a foldable container according to an embodiment of the present invention, with a shelf folded against a first side panel of a foldable sidewall.

[0100] The foldable container (1) corresponds to the foldable containers (1) in FIGS. 1, 2 and 4. The shelf (15) is folded along the first fold line (17) in two parts and folded against the first side panel (4). The ferromagnetic plates (33) are attracted by the magnets (23), holding the shelf (15) against the first side panel (4).

[0101] FIG. 6 shows a perspective view of a foldable container according to an embodiment of the present invention, with a partly folded foldable sidewall.

[0102] The foldable container (1) corresponds to the foldable containers (1) in FIGS. 1, 2, 4 and 5. The shelf (15) is folded along the first fold line (17) in two parts and folded against the first side panel (4). The foldable sidewall (3) is partly folded in corners (14) formed by adjacent side panels and along the second fold line (12) and the third fold line (13).

[0103] FIG. 7 shows a perspective view of a foldable container according to an embodiment of the present invention, in a completely folded state.

[0104] The foldable container (1) corresponds to the foldable containers (1) in FIGS. 1, 2, 4, 5 and 6. The foldable sidewall (3) is completely folded. A parallel stack of the first side panel (4), second side panel (5), third side panel (6) and fourth side panel (7) is formed. The folded foldable sidewall (3) is placed in a lying position on the loading surface (34) of the pallet (2). The foldable sidewall (3) is not sticking out of the loading surface (34) of the pallet (2). The upstanding edges (29) retain the folded foldable sidewall (3) on the pallet (2).

[0105] FIG. 8 shows a perspective view of a foldable container according to an embodiment of the present invention, in a completely folded state with a lid.

[0106] The foldable container (1) corresponds to the foldable containers (1) in FIGS. 1, 2, 4, 5, 6 and 7. The folded foldable sidewall (3) is placed in a lying position on the loading surface (34) of the pallet (2). An additional element has been added to the foldable container (1), being a lid (35). The lid (35) comprises locking means (36). The lid (35) is attached to the pallet (2) with use of the locking means (36). The locking means (36) are a type of latches. The actual latch is internal to the lid (35). Only the external part to manipulate the latch is visible. The folded foldable sidewall (3) is contained in a volume formed by the pallet (2) and the lid (35).

[0107] FIG. 9 shows a detail of an eye at a third side panel of a foldable sidewall according to an embodiment of the present invention.

[0108] The eye (21) corresponds to the eye (21) used in the foldable container (1) in FIGS. 1, 2, 4, 5, 6, 7 and 8. The eye (21) is an opening suited for receiving the hooks (22) at the opposing ends of the bar (25). The openings are lying in a plane. The eye (21) comprises a longitudinal plate (37) with mounting holes. The eye (21) is attached to the third side panel (6) using screws (38). The longitudinal plate (37) is transverse to the plane in which the openings lie. The eye (21) does not hamper folding the third side panel (6) towards the inside of the loadable volume (11), because it is only attached at one side of the second fold line (12) to the third side panel (6). The longitudinal plate (37) is L-shaped to avoid damage to the third side panel (6) by the hooks (22). It is clear that this description is mutatis mutandis valid for the fourth side panel (7) as well.

[0109] FIG. 10 shows a detail of a corner formed by a first side panel and a third side panel of a foldable sidewall according to an embodiment of the present invention.

[0110] This detail corresponds with the foldable container (1) in FIGS. 1, 2, 4, 5, 6, 7 and 8. It is clearly visible that the foldable sidewall (3) is foldable twice in the corner (14) formed by the first side panel (4) and the third side panel (6), allowing to fold the third side panel (6) around the shelf (15), while the shelf (15) is folded against the first side panel (4) and while folding the third side panel (6) between the first side panel (4) and the second side panel (5). The first side panel (4) and the third side panel (6) are attached by two parallel hinges, being the first hinge (39) and the second hinge (40). The first hinge (39) and the second hinge (40) are living hinges. The first hinge (39) and the second hinge (40) are parallel to the height direction (10). It is clear that this description is mutatis mutandis valid for the fourth side panel (7) as well.

[0111] The numbers in the figures refer to: [0112] 1. Foldable container [0113] 2. Pallet [0114] 3. Foldable sidewall [0115] 4. First side panel of foldable sidewall [0116] 5. Second side panel of foldable sidewall [0117] 6. Third side panel of foldable sidewall [0118] 7. Fourth side panel of foldable sidewall [0119] 8. Width direction [0120] 9. Depth direction [0121] 10. Height direction [0122] 11. Loadable volume [0123] 12. Second fold line [0124] 13. Third fold line [0125] 14. Corner [0126] 15. Shelf [0127] 16. Hinge [0128] 17. First fold line [0129] 18. Reinforcement plate [0130] 19. Hook of support means [0131] 20. Eye of support means [0132] 21. Hook of further support means [0133] 22. Eye of further support means [0134] 23. Magnet [0135] 24. Protection plate [0136] 25. Bar [0137] 26. Screws for bar [0138] 27. Door [0139] 28. Locking mechanism door [0140] 29. Upstanding edge [0141] 30. Handle [0142] 31. Reinforced part of shelf [0143] 32. Bolts for reinforced part of shelf [0144] 33. Ferromagnetic plate [0145] 34. Loading surface [0146] 35. Lid [0147] 36. Locking means of lid [0148] 37. Longitudinal plate of eye of further support means [0149] 38. Screws for eye of further support means [0150] 39. First hinge [0151] 40. Second hinge