US20070223842A1

US20070223842A1 - Collapsible container

Info

Publication number: US20070223842A1
Application number: US11/387,566
Authority: US
Inventors: Azad Sabounjian
Original assignee: Individual
Current assignee: Individual
Priority date: 2006-03-22
Filing date: 2006-03-22
Publication date: 2007-09-27
Also published as: WO2007111831A1

Abstract

A collapsible container has twist-and-fold panels in which a web of flexible material is held taut by a tension loop frame fastened to a periphery of the web. The container has a first and second panel each with a top and a bottom joined by sides, and with each side on the first panel being connected to a different one of the sides on the second panel. Either the web of material between the top and bottom on the first panel is shorter than the unrestrained distance between the top and bottom of the first frame or a strap connects the top and bottom of the first frame, so the top and bottom of the first panel are bowed out of a flat plane and extend away from the second panel when the container is in the expanded configuration. A bottom sheet fastened to the bottom of the first and second panels, and a top panel is optionally fastened to the top of the panels. When stacked into overlapping panels, the stacked panels assume a planar shape if the frames are not bowed during stacking, and assume a twisted, corkscrew-like shape if one of the frames is bowed during stacking.

Description

BACKGROUND

Collapsible containers exist that have flexible rectangular sides, a bottom and tops that are either open or closed, or that have a fabric top with an opening in the top. In these containers twist-and-fold frames are contained in pockets or edging extending around the periphery of each side panel. Opposing sides can be folded against each other to form a flat, planar assembly and then the stacked flexible frames are twisted into two or three overlapping loops or circles to form the collapsed container. These collapsible containers consistently use three, and typically use four or more flat side panels to form a single enclosed volume with a single opening, with the lower portion of each side panel's frame joined to a bottom panel. Such collapsible containers are shown and described in U.S. Pat. Nos. 5,971,188 and 5,964,533.
The use of three or four connected panels to form a single enclosed volume increases cost and increases the manufacturing difficulty. A need exists for a collapsible container of simpler construction. The use of the flat panels also results in containers with angular corners. There is a need for a more aesthetically pleasing shape that does not use these angular corners, or does not use as many angular corners.

BRIEF SUMMARY

A collapsible container is provided that uses two flexible panels each having a twist-and-fold frame with a top and bottom and with a web of material stretched over the frame fastened to the webbing (typically by placing the frame in pockets or edgings fastened to the webbing). At least one, and preferably both panel are constrained by the web of material or a strap so the top and bottom portions of the frame extend away from the center of the container. The top and bottom of the frames are bowed and typically form curves, preferably semi-circular curves, with two opposing curves on the top of the frames forming the container opening and two opposing curves on the bottom of the frames forming the bottom support. When viewed from the side, each frame comprises a generally U-shaped structure, and the fabric on each separate frame preferably takes a slightly saddle-shaped configuration curving outward at the top and bottom and also curving slightly inward toward the longitudinal axis of the container between the top and bottom, and curving around the longitudinal axis in a plane orthogonal to that axis. For simplicity each of these panels are referred to as the bowed panels. When the two bowed panels are fastened together along a vertical portion they form a generally cylindrical container, with each bowed panel forming half of the cylindrical container. Depending on whether the tops or bottoms of the bowed panels are larger, the bottom can have a larger dimension than the top, or vice versa. A larger dimension bottom provides more stability, while a smaller bowed top is believed to be more aesthetically pleasing. A handle can be fastened to one or both panels, fastened to one or both frames or fastened to the pockets containing one or both of the frames.
Containers of differing size can be formed by using more than two bowed panels with the side of one panel joined to the side of an adjacent panel. In this embodiment each bowed panel forms a smaller portion of the overall shape of the container.
In a further variation a flat, planar panel is provided between the two bowed panels. This center panel provides a divider for the interior of the container. The center panel is preferably, but optionally, rectangular in shape and has opposing generally parallel sides contained in pockets that are fastened to the pockets containing the sides of the bowed panels. The bottom of the center panel can abut the ground or be spaced apart from the ground. A handle can optionally be attached to this center panel.
In a still further embodiment one bowed panel is fastened to one flat panel to form a container resembling half a cylinder. This configuration is well suited for hanging over the back of a door with the flat panel aligned with the door and the bowed panel forming a semi-circular container, although the shape can vary depending on how the tops and bottoms of the panels are bowed by the web or strap(s) which bow the panel. A hanging strap is fastened to one or both frames, panels or to the pockets containing the frames with the strap adapted to fasten to the door. A door hanger or hood can be fastened to the strap.
In the above embodiments each panel preferably has a generally straight portion extending vertically when the bottom of the container rests on the ground, with the straight portions preferably being joined by fastening the pockets together or by using a common pocket or by other means now known or developed in the future.
The above containers are collapsed by pushing the panels forming the container so it abuts each adjacent panel to form a generally saddle-shaped stack of frames which is not flat or planar. If one of the panels is bowed when the panels are stacked, then the stack takes the, form of a twisted stack of frames which is further twisted and coiled into overlapping loops to form a compact configuration for shipping or storage. Expanding the containers involves the reverse sequence. For embodiments using a central panel, that center panel can be twisted to collapse and coil the panels, or can be untwisted to uncoil and separate the panels into the expanded container configuration. For embodiments in which straps bow the frames, if the straps are released the panels can be placed next to each other in a flat, planar stack, which is then twisted and coiled into overlapping loops to form the compact, collapsed configuration.
In more detail, the collapsible container has an expanded configuration and a collapsed configuration and uses a first panel substantially covered by a first web of flexible material with a first pocket extending around at least a portion of a periphery of the first web with a first, flexible, twist-and-fold frame located in the first pocket. The first panel and frame have a top and bottom connected by first and second opposing sides. The container has a second panel substantially covered by a second web of flexible material and a second pocket extending around at least a portion of a periphery of the second web with a second, flexible, twist-and-fold frame located in the second pocket. The second panel and frame also have a top and bottom connected by first and second opposing sides. The sides of the first panel are attached to the sides of the second panel. The panels are foldable at the sides to place the panels in abutting relationship, wherein the top on the first panel is bowed out of a flat plane and extends away from the corresponding top on the second panel in the expanded configuration. A bottom sheet of material is fastened to the bottoms of the first and second panels, and an optional removable or openable top sheet of material can be fastened to the top of the panels.
Advantageously, the tops on the first and second panels are each bowed out of a flat plane and each extends away from the other top, as are the bottoms of those panels. The sides of the panels are preferably sewn together. The second panel can be bowed like the first panel, or the second panel can have an expanded configuration comprising a substantially flat planar surface which is an advantageous shape for an over-the-door hamper. A door hook is fastened to one of the panels to hang the container from the door, with the hook preferably being connected to the flat panel directly or through a strap or flexible handle.
The two panels need not be aligned, and the second panel can be offset above or below the first panel, or it can be shorter or longer than the first panel. The second panel can thus have an expanded configuration comprising a substantially flat planar surface with the bottom of the second panel located at the bottom of the first panel or between the bottom and top of the first panel when the container is in the expanded configuration.
In further variations, the container can have a third panel with a web of material flexible fastened to a third pocket extending around at least a portion of a periphery of the third web with a third, flexible, twist-and-fold frame located in the pocket. The third panel and frame have a top and bottom connected by first and second opposing sides, with the third panel being located between the first and second panels and fastened to the sides of at least one of those panels. Advantageously, but optionally, the bottom sheet of material is connected to the bottom of the third panel. Preferably, but optionally, the third panel is substantially a flat plane in its expanded configuration. The third panel can be offset relative to the other panels, and advantageously the bottom of the third panel is located between the bottom and top of the first panel. The third panel can be shorter or longer than either the first or second panels, but preferably all frames are quadrilaterals with about the same length on each frame and about the same width on each frame. Advantageously the length is greater than the width. A flexible handle can be connected to the container, preferably to the top of one or ore panels, and more preferably to the middle panel when it is present. A zippered opening can be provided on the bottom sheet of material, or on a top sheet of material if present.
The panels can be bowed by connecting a strap to the top and bottom of the first frame where the strap has a length or is adjustable to a length that is shorter than the undeformed distance between the top and bottom of the first panel, in order to bow the top and bottom of the first panel out of a flat plane. The strap can be releasably connected to the top and bottom of the first panel, or permanently fastened to the panel. Alternatively, the web of material between the top and bottom can be sized to bow the panel.
Viewed another way, the collapsible container has twist-and-fold panels in which a web of flexible material is held taut by a tension loop frame fastened to a periphery of the web. The container has a first and second panel each with a top and a bottom joined by sides. The sides on the first panel are connected to a different one of the sides on the second panel. Ether the web of material between the top and bottom on the first panel are shorter than the unrestrained distance between the top and bottom of the first frame or a strap connecting the top and bottom of the first frame is shorter than that distance, so the top and bottom of the first panel are bowed out of a flat plane and extend away from the second panel when the container is in the expanded configuration. A bottom sheet is fastened to the bottom of the first and second panels.
This embodiment has similar variations as discussed in the above embodiments, including sides joined along a substantially straight line, with both the top and bottom of the first panel bowed to extend away from the second panel and with the bottom panel extending a greater distance than the top. Alternatively, the top panel can extend a greater distance than the bottom. The second panel can be bowed, or it can be substantially flat and thus more suitable for an over-the door hamper. A third, planar panel can be interposed between the first and second panels with the third panel having its two sides each joined to a different one of the sides of both the first and second panels.
Whether two or three panels are used, the panels can have a partially collapsed configuration in which the immediately adjacent panels abut each other to form a stack of panels having a twisted configuration having a corkscrew-like configuration resembling a portion of a corkscrew. This stable configuration is achieved when the web causes the panels to bow, or when a strap causes the bow and the panels are stacked without releasing the strap to un-bow the panels to a flat position. If the panels are not bowed, then when they are stacked the panels have a partially collapsed configuration in which the panels abut another panel to form a stack of panels having a planar configuration. In either configuration, the panels' frames are optionally configured so the panels can be twisted and folded into a collapsed configuration having a plurality of overlapping coils.
A method is also provided for making a collapsible container. The method includes providing a first twist-and-fold panel having a top, a bottom and two sides joining the top and bottom on the first panel with a web of flexible material covering the first panel. A flexible frame extends around a periphery of the first panel. A similarly constructed second panel is provided. The method further includes fastening each side of the first panel to a different side of the second panel along a substantially straight portion and fastening a bottom sheet to the bottoms of the first and second panel. Finally, the method includes bowing the top and bottom of the first panel toward each other and out of a flat planar configuration and at least temporarily fixing the first panel in that configuration. Optionally, the method also includes bowing the top and bottom of the second panel toward each other and out of a flat planar configuration and at least temporarily fixing the second panel in that configuration.
The method optionally includes having the web of material bow the first panel out of a flat planar configuration. Alternatively, the method can include fastening a strap to the top and bottom of the first panel to bow the first panel out of a flat planar configuration. The method can further optionally include placing a releasably closable opening in the bottom sheet of material, or fastening a handle to one of the panels. The step of fastening the side panels preferably comprises sewing sides of the panels together.
In further embodiments, the method includes providing a third twist-and-fold panel and fastening the sides of the third panel to the sides of at least one of the first and second panels. In this further embodiment the third panel is preferably-planar in the expanded configuration, and interposed between the first and second panels.
There is also provided an advantageous method of collapsing a container where the container has first and second twist-and-fold panels with spring-loop frames each fastened to a web of material and with the two panels being joined together along sides of the two panels. A bottom sheet is connected to bottoms of the first and second panels so the bottom sheet and the two joined panels form an enclosed space when the panels are in an expanded configuration in which the top and bottom of the first panel are spaced apart from the respective top and bottom of the second panel. The method includes moving the top of the first panel from the spaced apart position to a position adjacent the top of the second panel and forming a stack of two panels having a stable, twisted configuration comprising a portion of a corkscrew.
The method can also optionally include twisting the stacked panels further in the direction of the twist to coil the frames into overlapping loops. The panels are preferably rectangular with four corners and two diagonal corners are in a different plane the remaining two diagonal corners when the two panels are stacked adjacent each other. Further, the second panel can have a flat, planar shape in the expanded configuration, or alternatively, the second panel can have an expanded configuration in which the top and bottom are spaced apart from a plane through the joined sides to form a bowed configuration. In a still further variation, the method includes fastening a third panel between the first and second panels, with the third panel having an expanded configuration comprising a flat, planar shape in the plane of the joined sides. Other aspects and variations are discussed in more detail below.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features and advantages of the various embodiments disclosed herein will be better understood with respect to the following description and drawings, in which like numbers refer to like parts throughout, and in which:
FIG. 1 is a perspective view of a collapsible container having a center divider between and two bowed panels;
FIG. 2 is a side plan view of the container of FIG. 1;
FIG. 3 is a bottom plan view of the container of FIG. 2;
FIG. 4 is a front perspective view of the container of FIG. 1 with the three panels stacked in a twisted, corkscrew-like configuration resembling a portion of a corkscrew;
FIG. 5 is a side perspective view of FIG. 4, showing the container of FIG. 1 with the three panels stacked in a twisted, corkscrew-like configuration resembling a portion of a corkscrew;
FIG. 6 is an upper perspective view showing the container of FIG. 1 in a collapsed configuration with the panels coiled into overlapping loops;
FIG. 7 is an upper perspective view of the container of FIG. 1 without a center panel;
FIG. 8 is a front plan view of the container of FIG. 1 without a second bowed panel;
FIG. 9 is a side perspective view of the container of FIG. 8;
FIG. 10 is a bottom perspective view of the container of FIGS. 8-9, showing a zippered opening in the bottom of the container;
FIG. 11 is a partial section view taken along section 11-11 of FIG. 1, showing three frames, each in a separate pocket, joined together by stitching;
FIG. 12 is a partial sectional view taken along section 11-11 of FIG. 1, showing an alternative embodiment with three frames in a single pocket;
FIG. 13 is a partial perspective view of a handle with a door hook;
FIG. 14 is a partial sectional view of a hook fastened to a frame of a panel and/or fastened to a panel;
FIG. 15 is a side plan view of a further embodiment with three planar panels in a stacked configuration and also in an expanded configuration with two bowed panels held by straps;
FIG. 16 is a perspective view of two planar panels bowed by straps to form a container;
FIG. 17 is a partial view of the embodiment of FIG. 15 in a closed configuration with items inside the enclosed space defined by the panels;
FIG. 18 is a perspective view showing a strap fastened to a frame by encircling the frame;
FIG. 19 is a perspective view of an over-the-door hamper with a frame bowed by a strap;
FIG. 20 is a perspective view of a variation of the container of FIG. 1 with a frameless divider panel;
FIG. 21 is a perspective view of a variation of the container of FIGS. 9 and 19, but with a frameless panel;
FIG. 23 is a plan view of an oval panel;
FIG. 24 is a side view of a container formed using two oval panels.

DETAILED DESCRIPTION

Referring to FIGS. 1-3 and 11-12, a collapsible container 10 is shown having a first and second bowed panel 11, 12 on opposite sides of a generally flat panel 14. The frames 16 are flexible, and thus the panel 14 can twist slightly and may not be completely flat. Each panel 11, 12, 14 has a frame 16 (FIG. 11) located in a pocket or edging 18 formed around the periphery of a web of material 20. The pocket 18 is typically sewn to the periphery of the web 20 and the frame 16 is then inserted through a slit in the pocket which is later sewn shut or covered. As shown in FIG. 11, the three pockets 18 are preferably fastened together, as by stitches 23, but more than one frame could be in the same pocket as reflected by FIG. 12.
The frame 16 is typically of spring steel and rectangular cross section, although it may be of other materials that allow the frame to repeatably coil into overlapping loops, including plastic, and may be of other cross-sections shapes, including round, oval, square, triangular or other geometric shapes and materials that allow the frame to repeatably coil into overlapping loops. The pocket is typically made of durable material such as nylon and the web 20 is made of various flexible materials such as fabric, cloth or canvas depending on the use. An open mesh Nylon material is commonly used for web 20 when the container 10 is used as a hamper, with a solid Nylon material used on containers intended for more demanding uses. The construction of flat panels is described in more detail in U.S. Pat. Nos. 5,971,188 and 5,964,533, the complete contents of which are incorporated herein by reference
Each panel 11, 12, 14 has a top 11 a, 12 a, 14 a, an opposing bottom 11 b, 12 b, 14 b, and two opposing sides 11 c & 11 d, 12 c & 12 d, and 14 c and 14 d. In the depicted container 10 the sides 11 c, 12 c, 14 c are fastened together as are the opposing sides I id, 12 d and 14 d. The sides are typically fastened together by sewing the pockets as illustrated in FIGS. 11-12 but the pockets or panels could also be glued, melted together, mechanically fastened by rivets or loops of material encircling a plurality of the frames 16, or fastened by other mechanisms. The sides of the container of FIG. 1 are shown as fastened together along a straight, generally vertical side, but the sides could take other shapes, including convex and concave shapes and including circular shapes. But preferably the sides include a straight portion which is fastened together and which is longer than either the top or the bottom of the panel
The web 20 on panels 11 and 12 is preferably, but optionally shaped and sized so the tops 1 la, 12 a bend or bow out of a flat plane and extend away from the center panel 14 which extends through a longitudinal axis 17 of the container 10 when the panels 11, 12 are in the expanded configuration. Likewise, the web 20 on panels 11 and 12 is preferably sized and shaped so the bottoms 11 b and 14 b bow and extend away from the center panel 14. Thus, the tops 11 a, 12 b of panels 11, 12 extend out of a flat plane away from each other and form an opening 19. Bottoms 11 b, 12 b of panels 11, 12 extend away from each other to form an enlarged, spread apart base. The distance between bowed top 11 a and bowed bottom 11 b is preferably, but optionally, smaller than the distance between the top 14 a and bottom 14 b on flat panel 14. Likewise, the distance between bowed top 12 a and bowed bottom 12 b is preferably, but optionally smaller than the distance between the top 14 a and bottom 14 b on flat panel 14.
These bowed panels 11, 12 can be achieved by shaping the web 20 so the distance between the top and bottom of the frame 16 in those panels is shorter than the unrestrained distance of those respective panel frames so as to bend and bow the frames and accompanying panels. The shorter length of web material causes the tops and bottoms of panels 11, 12 to bend out of a flat plane as found in planar panel 14. The way the web 20 is shaped also affects the shape of the tops 11 a, 12 a and bottoms 11 b, 12 b as well as affecting the distance the tops and bottoms extend away from the longitudinal axis 17 (FIG. 1) and/or panel 14 (when present). Tops and bottoms having a uniform curvature when viewed along the longitudinal axis 17 are shown, but the tops and bottoms could have various shapes including generally triangular shaped tops and bottoms. The various shapes are achieved by appropriate shaping of the web 20 which restrains the expansion of the frame 16, or by using one or more straps (discussed later) to achieve the desired panel and frame configuration, or both.
A bottom 21 is fastened to the bottoms 11 b, 12 b of bowed panels 11, 12, and preferably (but optionally) also fastened to the bottom 14 b of center panel 14. Typically the bottom 21 is sewn to the pockets 18, but other fastening mechanisms could be used as described herein. As used herein, the terms top and bottom, above and below have the relative orientation as depicted in FIG. 1. In use the orientation of the container 10 may change.
The precise shape is difficult to put into words, but when viewed from the side (FIG. 2) each bowed panel 11, 12 forms a generally U-shaped structure, and the flexible web 20 on each separate frame preferably takes a generally saddle-shaped configuration curving outward from a flat plane and away from the center panel 14 at the top and bottom, curving inward toward the center panel between the top and bottom, and curving around the longitudinal axis 17 in a plane orthogonal to that axis. The curved top portions 11 a, 12 a of bowed panels 11, 12 preferably, but optionally have the same general shape as the curved bottom portions 11 b, 12 b as seen in FIG. 3, but could be larger than or smaller than to bottom portions. For simplicity each of these panels 11, 12 are referred to as bowed panels.
In the depicted embodiment the tops 11 a, 12 a extend further away from the center panel 14 than do the bottoms 11 b, 12 b and provide a top opening 19 larger than the base of the container. That is not as stable compared to having bowed bottoms 11 b, 12 b larger than the top 11 a, 11 b, but the larger top/smaller bottom is believed to be more aesthetically pleasing. However, the distance of the tops and bottoms from the central, preferably flat panel 14 can be set as desired. If the base is larger than the opening 19 formed by the tops 11 a, 12 a, then the broader base may provide more stability to the container 10 and that is thus preferred for functional reasons.
The web 20 on panels 11 and 12 is preferably shaped so the tops 11 a, 12 a and bottoms 11 b, 12 b are curved and preferably are semicircular when viewed along longitudinal axis 17. Moreover, the web 20 on panels 11 and 12 is preferably shaped to deform or bend the tops 11 a, 12 a and bottoms 11 b, 12 b to have a substantial portion that is planar to and perpendicular to the generally flat center panel 14. That also makes a portion of tops 11 a, 12 a lie in a plane that is generally orthogonal to the longitudinal axis 17. Preferably, each panel 11, 12 (and optionally panel 14) is oval with a flat top and bottom, or a quadrilateral, and in both cases has four corners 22 a, 22 b, 22 c and 22 d, although that need not be the case. The sharper the corners 22 located between the tops 11 a, 11 b and sides 11 c and 11 d of the panels, the larger is the flat, planar portion of the panels. Thus, the tops 11 a, 12 a and bottoms 11 b, 12 b are generally flat and parallel to the ground to provide a more stable support and a wide opening 19 to the container 10. But the tops and bottoms of the panels 11, 12 need not be flat, and likely will not remain flat during use as the frames 16 in panels 11, 12 can deform when items or materials are placed inside the container 10.
The bottom 14 b of the center panel 14 is preferably at or above the bottoms 11 b, 12 b of panels 11, 12 relative to the floor on which the container 10 sets and as shown in the figures. Preferably the bottom 14 b is slightly offset from the plane containing bottoms 11 b, 12 b, and offset toward the tops 11 a, 12 a of the panels. The bottom 14 b of the center panel 14 is preferably at or above the plane of the bottoms 11 b, 12 b of panels 11, 12 relative to the floor on which the container 10 sets and as shown in the figures. Preferably the top 14 a of the center panel 14 extends above the plane containing tops 11 a, 12 a of bowed panels 11, 12, but it could be below the top 11 a and thus located between the top 11 a and bottom 11 b. Preferably the panel 14 extends a distance sufficient so that the frame in panel 14 can overlap the frame 16 in one, and preferably overlap the frame in both panels 11, 12 when the panels 11 and 12 are placed in abutting relationship with center panel 14.
A handle 24 is preferably, but optionally attached to one or more of panels 11, 12 or 14. The handle 24 could comprise a flexible strap having a free loop handle at one end with the other end fastened to a panel. Preferably the handle 24 takes the form of a flexible strap of material, such as nylon, which is fastened to the container 10 at both ends of the strap, preferably by fastening to the pocket 18 and/or fastening to the web 20 or fastening to the frame 16 by encircling the frame. A strap with one end encircling the frame is shown in FIG. 18. The handle 24 can be fastened by sewing, gluing, melting, riveting, crimping, removable snaps, buttons or other permanent and/or removable fastening mechanisms. The strap 24 is preferably fastened to the top 14 a of the center panel 14, preferably by having each end encircle the frame 16 through a different hole in the pocket 18.
Preferably, but optionally, supporting material 26 is used to strengthen the joints where the corners 22 on bowed panels 11, 12 diverge from the straight sides of the center panel 14 at the tops 11 a, 12 a and at the bottoms 11 b, 12 b. The supporting material 26 typically takes the form of triangular shaped pieces of material, but the shape will depend on the configuration of container 10 and the way the tops 11 a, 12 a and bottoms 11 b, 12 b diverge from each other and diverge from panel 14 (if panel 14 is used).
Referring to FIGS. 2-6, to collapse the container 10 the tops and bottoms of panels 11, 12 and 14 are placed together to form a stack of panels. Opposing panels are moved toward each other so they abut each other. In doing so one the tops of the bowed panels 11, 12 become straighter when viewed along the longitudinal axis 17, and the resulting deformation of both bowed panels 11, 12 are lessened. The previously flat, planar center panel 14 is twisted between the two panels. The resulting stack of panels 11, 12, 14 is not a flat planar assembly, but is twisted by the constrained frames 16 into a spiral so it looks like a portion of a corkscrew as seen in FIGS. 4 and 5. The tops 11 a, 12 a, 14 a of the panels 11, 12, 14 are aligned and lie in a first plane, while the bottoms 11 b, 12 b, 14 b are also alighed by in a plane that intersects the plane containing the tops. The shape is difficult to put into words. The two diagonally opposing corners 22 a, 22 c in the expanded configuration remain diagonally opposite each other in this partially folded configuration but are in a different plane than the other two corners 22 b, 22 d which are also diagonally opposite each.
This twisted configuration is stable as the frames 16 maintain that configuration until they are manually moved into a different configuration. This partially collapsed configuration is a stable shipping configuration, because the three-dimensional curvature allows stacking of the stacked panels, while the shape prevents the panels from sliding off each other. To further collapse the stack of panels, two diagonally opposing corners 22 a, 22 c, or 22 b, 22 d are then grabbed by hand, rotated and moved toward each other in order to cause the frames 16 to coil into overlapping loops as shown in FIG. 6. In the coiled configuration the collapsed container 10 wants to spring apart, so it is preferably restrained in the collapsed configuration by an encircling strap, an enclosing bag or another device. But if the coiled configuration is released it springs into the twisted, corkscrew-like configuration rather than springing into a planar configuration as in the prior art, thus the tension-loop frames 16 do not release all the energy stored from being coiled into overlapping loops. In short, releasing the coiled container 10 of this invention does not cause it to pop-open with as large a force as occurs with prior art, tension-loop containers.
The steps are reversed to expand the collapsed container 10 to its expanded configuration. First, the coiled loops are expanded into the corkscrew-like configuration of FIGS. 4-5. For further expanding the container 10, it is useful to grab the top 14 a and bottom 14 b of the center panel 14 and twist it into a flat, planer configuration, whereupon the bowed panels 11, 12 will usually pop into their bowed configuration.
A further variation is seen by comparing FIGS. 1 and 7. In the container of FIG. 7 the center panel 14 is omitted, leaving a single, larger opening 19 to the container 10. In this embodiment the bowed side panel 11 has its sides 11 c, 11 d fastened to the adjacent side of the opposing panel 12 c, 12 d. As there is no center panel the bottom 21 is fastened to the bottoms 11 b, 12 b of the bowed panels 11, 12. Supports 26 can be used at the bottom 21 as desired to completely enclose the volume enclosed by bowed panels 11, 12.
As desired a handle 24 can be fastened to one or both panels 11, 12. This container is collapsed like the prior one, with the panels 11, 12 which are now directly opposite each other being placed together in an abutting relationship to form a twisted shape resembling a portion of a corkscrew. The corners are further twisted and brought toward each other to twist the frames 16 into overlapping coils. The container is expanded into its expanded configuration by reversing the steps and spreading the panels 11, 12 apart to form the container 10.
A further variation on the container of FIG. 1 is shown in FIG. 8 in which one of the second bowed panels 11, 12 is omitted, and here it is panel 12. The sides of bowed panel 11 c, 11 d are fastened to the adjacent sides of the flat, planar panel 14 c, 14 d, preferably by sewing the pockets 18 together, or by placing the sides of the frames 16 in a common pocket. The bottom 21 is fastened to the bottom 11 b of the bowed panel and the bottom 14 b of the panel 14. Corner supports 26 are used with the bottom 21 as desired to strengthen and completely enclose the lower portion of the space enclosed by the panels 11, 14. The top 14 a of flat panel 14 extends beyond the top 11 a. Preferably, but optionally the bottom 14 b is located at about the same plane as the bottom 11 b so the container 10 can sit flat on a floor, but the bottom 14 b could be above or below the bottom 11 b, especially if the container 10 is designed to be used as an over-the-door hamper. Preferably, the web 20 on panel 11 is such that the distance between top 11 a and bottom 11 b is preferably, but optionally, smaller than the distance between the top 14 a and bottom 14 b and the panel 11 takes a bowed configuration in its expanded configuration.
A handle 24 is preferably fastened to one of the panels 11, 14, and preferably fastened to the top 14 a of flat panel 14. The handle 24 in FIG. 1 is shown as comprising a flexible strap having two ends fastened to the panel 14, and with an adjustable length strap, and that handle is suitable for t his variation of the container. Advantageously the handle 24 comprises a strap that can be looped over a hook on the back of a door. More preferably, a hook 28 (FIG. ______) is fastened to the handle 24, with the hook being configured to fit over the top of a door and being flat enough so allow the door to close with the hood over the door. A hook make of plastic or thin metal is believed suitable.
Referring to FIGS. 3 and 10, the bottom 21 is fastened to the bottom of the panel 11 and 14, preferably by sewing the web 20 to the pocket 18 along the bottoms of the panels 11, 14. But other fastening mechanisms could be used and the bottom sheet 21 could be fastened to the web 20 adjacent the pockets along the bottoms 11 b, 14 b of the panels. A zipper 30 can is optionally provided din the bottom to make it easier to remove items from the container 10. The zipper 30 is preferably, but optionally located along the bottom 11 b or 14 b of one of the panels 11, 14, with the zipper being shown along the bottom 11 b of bowed panel 11. By opening the zipper 30 gravity urges any items or clothing in the container 10 out the second opening formed by the unzipped bottom 21.
To collapse this embodiment of the container 10 the top and bottoms of panels 11 and 14 of the directly opposing panels 11, 14 are placed together to form a stack of two panels. The bowed panel 11 is restrained by the flat, planar panel 14 and the previously planar panel 14 bows to conform more to the bowed panel 11. The resulting stack of two panels 11, 14 is not a flat planar assembly, but is twisted into a spiral so it looks like a portion of a corkscrew. Depending on the relative sizes of the frames 16 in each of the panels 11, 14, and depending on whether the panels are offset along the longitudinal axis relative to each other, the stacked panels may be slightly offset. The two diagonally opposing corners 22 a, 22 c are diagonally opposite each other and in a different plane than the other two corners 22 b, 22 d which are also diagonally opposite each other (FIGS. 4-5). The corners 22 a, 22 b are then grabbed by hand, rotated in the direction which further twists the panel and moved toward each other in order to cause the frames 16 to coil into overlapping loops as shown in FIGS. 6. In the coiled configuration the collapsed container 10 wants to spring apart, so it is preferably restrained in the collapsed configuration by an encircling strap, an enclosing bag or another device. Again though, the partially collapsed configuration of FIGS. 4-5 is stable so the coiled container does not spring apart with the same force as the prior art coiled containers.
The panels are fastened together various ways. In each of the above embodiments the web 20 can be sized and configured to shape the curvature or shape of the top 11 a, 12 a and of the bottom 11 b, 12 b. As the top or bottoms of panels 11, 12 extend further from the plane of panel 14, the more twisting will occur as the panels are stacked prior to twisting and coiling into overlapping loops. A difference in the length of the frames 16 in panel 11 compared to panel 14, or panel 12 compared to panel 14, will cause the frames 16 to be offset as they are stacked prior to twisting into overlapping coils. If the panels 11, 12 are offset along axis 17 relative to panel 14, the frames 16 are also offset as they are stacked together. If the offset becomes too great it is difficult to coil the frames and their associated panels into overlapping loops for storage.
In the embodiment of FIG. 11, the pocket 18 extends around a substantial portion of the frame 16, and preferably extends around the entire frame 16, and each frame has a separate pocket for the entire panel. In the embodiment of FIG. 12, two or more frames share the same pocket 18 along the sides 11 c, 11 d, 12 c, 12 d, 14 c, 14 d of the panels, with each frame having its own, separate pocket 18 for the tops and bottoms 11 a, 11 b, 12 a, 12 b, 14 a, 14 b. The frames 16 in panels 11, 12 and 14 are preferably about the same length, but could be different lengths. When the middle frame 14 is present, it can be shifted vertically along longitudinal axis 17 relative to frames 11 and/or 12. The center frame 14 is not shifted enough to prevent the panels 11, 12, 14 from being coiled into overlapping loops as in FIG. 6.
Referring to FIGS. 14-17 and 19, in a further variation, it is believed that the panels 11, 12 can also be flat, planar panels that are bowed by fastening a strap 34 between the top and bottom ends 11 a, 11 b where the strap is shorter than the undeformed distance between those ends. The strap 34 is removably fastened to one of the panels 11, 12, as by a connector 34 such as a snap hook, or by button-snaps on a portion of the strap that encircles the frame, or by hook and loop fasteners, by an adjustable and releasable buckle located along the length of the strap, or by other releasable connection mechanisms. The strap 34 is connected to the opposing top and bottom of a panel, such as top 11 a and bottom 11 b in order to bow the panel. The corner support 26 has to be shaped to accommodate the desired amount of bowing or to shape the bowing, and the length of the fastened sides 11 c, 11 d is sized to accommodate the desired bowing. One strap 34 for each panel 11, 12 is believed suitable, but two or more straps could be used on one panel to alter the shape of the opening 19. If the strap 34 is removed, the previously deformed panel 11, 12 will be resiliently urged by frame 16 to resume its unbowed, planar configuration, and thus tend to enclose anything placed in the container 10 as reflected in FIG. 16.
When the flat panels are bowed by strap 34 the web of material effectively closes off easy access to the interior of the container formed by the bowed panels. Moving opposing sides 11 c, 11 d towards each other provides an enlarged interior. Thus, a second strap 38 is preferably fastened between opposing sides 11 c, 11 d and 12 c, 12 d of each bowed panel. Alternatively, the bottom panel 21 could be sized so the panels 11, 12 have the opposing sides at the desired spaced-together position. Preferably though, the panel 14 is provided with a lateral width that is smaller than the undeformed width of panels 11, 12. Alternatively, the web 20 of penal 14 could extend between and be fastened to opposing sides 11 c, 11 d and/or 12 c, 12 d in order to pull the sides of panels 11, 12 closer together an open up the interior space of the container defined by the panels. In this later case, the frame 16 and pocket of panel 14 could be omitted as only the web, or a sheet of flexible material is needed to fasten to opposing sides of the frames 11, 12. Such a central web 20 on frame-less panel 14′ is shown in FIG. 20.
As reflected by FIG. 15, in this embodiment the stacked panels 11, 12, 14 are planar as each panel is planar—the straps 34, 38 being removed or disconnected. These stacked panels can be twisted and coiled into overlapping loops to achieve the configuration of FIG. 6. When stacked into overlapping panels, the stacked panels 11, 12, 14 assume a planar shape if the panels are not bowed during stacking, and assume the twisted, corkscrew-like shape if one of the panels is bowed during stacking. The intermediate, stable configuration of FIGS. 4-5 does not exist as long as the panels 11, 12 are not restrained into a bowed configuration when the panels 11, 12, 14 are stacked. The strap 34 could be permanently fastened to the tops and bottoms of selected panel(s) 11, 12, but then the stacked configuration would be twisted as in FIGS. 4-5. Likewise the lateral strap 38 could be permanently fastened between opposing sides of the panels 11, 12 or the panels otherwise held in the desired spaced-together relationship, but then the stacked configuration would be curved about the longitudinal axis 17.
The strap 34 could be used as a carrying handle 24. If removable, the strap 34 could be reconnected to another portion of the container 10 for carrying. Encircling the sides 11 b, 12 c (if present) and 14 c with a common connector 34, at two spaced apart locations, would provide a secure connection of the frames 16 to a strap 34 or handle 24. The tops 11 a, 12 b, 14 b (or bottoms) could also be encircled by a connector 34 if the frames 11, 12, 14 were sized so the tops could be placed adjacent each other when the container 10 had items inside the panels forming the container.
The above embodiments have an open top 19. As desired, a top sheet of material could be fastened to the tops 11 a, 12 a, 14 a which are present in a particular embodiment in order to provide a top panel and a closed or closable top. A zippered top like the zippered bottom of FIG. 10 could also be provided. If a top is provided, it should be removable, or have an opening that can be closed as by a zipper, snaps, etc. Alternatively, the top 19 could be covered permanently by a sheet of material, with an access opening formed in the web 20 of one or more of the panels 11, 12, 14. A zippered opening using zipper 30 is one such suitable opening, as are openings using mechanisms described relative to the opening in bottom sheet 21.
Referring to FIGS. 20-21, in the above embodiments using a middle panel, the panel could comprise only the web of material 20 extending between opposing sides 11 c, 11 d or 12 c, 12 d of the container. The frame 16 and pocket 18 could be omitted. The bottom portion of this un-framed panel 14′ could be fastened to the bottoms sheet 21 by sewing, gluing, rivets, or other mechanisms, it could be unattached to the bottom sheet and fastened only to the sides of the container 10. The frameless panel 14′ could be used to form a two panel container 10 using panels 11, 12 as in FIG. 20 where the web 20 on the panels 11, 12 causes the bowing of panels 11, 12. Or the web 20 on frameless panel 14′ could urge the sides of panels 11, 12 towards each other and contribute to the bowing of the panels 11, 12.
Likewise, in FIG. 21, the frameless panel 14′ is fastened to opposing sides 11 c, 11 d of bowed panel 11, where the web 20 of panel 11 causes the bowing. Alternatively, the frameless panel 14′ could contribute to the bowing in combination with the web 20 of panel 11, or in combination with a strap as shown in FIG. 19. In the container 10 of FIG. 21, the width of the container is preferably less than the length along longitudinal axis 17, and preferably at least 1.5 times greater in length than in width. As shown in FIG. 21, the frameless panel 14′ has no frame, but an edging or pocket is provided to prevent raveling of the web 20.
Referring to FIGS. 22 and 23, the frames 11, 12 14 need not be rectangular. An oval frame is shown, with the sides of panels 11, 12 joined along a very short vertical length measured along axis 17, and with larger supports 26 to accommodate the greater curvature of the panels.
The above description is given by way of example, and not limitation. Given the above disclosure, one skilled in the art could devise variations that are within the scope and spirit of the invention disclosed herein, including various ways of fastening the sides of the panels 11, 12, 14 and of attaching handles to the container 10. Further, the various features of the embodiments disclosed herein can be used alone, or in varying combinations with each other and are not intended to be limited to the specific combination described herein. Thus, the scope of the claims is not to be limited by the illustrated embodiments.

Claims

1. A collapsible container having an expanded configuration and having a collapsed configuration, comprising:

a first panel substantially covered by a first web of flexible material and a first pocket extending around at least a portion of a periphery of the first web with a first, flexible, twist-and-fold frame located in the first pocket, the first panel having a top and bottom connected by first and second opposing sides;

a second panel substantially covered by a second web of flexible material and a second pocket extending around at least a portion of a periphery of the second web with a second, flexible, twist-and-fold frame located in the second pocket, the second panel having a top and bottom connected by first and second opposing sides, the sides of the first panel being attached to the sides of the second panel, the panels being foldable at the sides to place the panels in abutting relationship, wherein the top on the first panel is bowed out of a flat plane and extends away from the corresponding top on the second panel in the expanded configuration; and

a bottom sheet of material fastened to the bottoms of the first and second panels.

2. The collapsible container of claim 1, wherein the bottom on the first panel is bowed out of a flat plane and extends away from the corresponding bottom on the second panel.

3. The collapsible container of claim 1, wherein the tops on the first and second panels are each bowed out of a flat plane and each extends away from the other top.

4. The collapsible container of claim 2, wherein the top on the second panel is bowed out of a flat plane and extends away from the first top and the bottoms on the first and second panels each extend away from the other bottom.

5. The collapsible container of claim 2, wherein the sides of the panels are sewn together.

6. The collapsible container of claim 4, wherein the sides of the panels are sewn together.

7. The collapsible container of claim 1, wherein the second panel has an expanded configuration comprising a substantially flat planar surface.

8. The collapsible container of claim 2, wherein the second panel has an expanded configuration comprising a substantially flat planar surface.

9. The collapsible container of claim 1, wherein the second panel has an expanded configuration comprising a substantially flat planar surface and the bottom of the second panel is located between the bottom and top of the first panel when the container is in the expanded configuration.

10. The collapsible container of claim 1, further comprising a third panel substantially covered by a third web of material flexible fastened to a third pocket extending around at least a portion of a periphery of the third web with a third, flexible, twist-and-fold frame located in the pocket, the third panel having a top and bottom connected by first and second opposing sides, the third panel being located between the first and second panels and fastened to the sides of at least one of those panels, and wherein the bottom sheet of material is connected to the bottom of the third panel.

11. The collapsible container of claim 1, wherein the third panel is substantially a flat plane in its expanded configuration.

12. The collapsible container of claim 11, wherein the bottom of the third panel is located between the bottom and top of the first panel.

13. The collapsible container of claim 12, wherein the top of the third panel is not located between the top and bottom of the first panel.

14. The collapsible container of claim 1, further comprising a third panel substantially covered by a third web of flexible material fastened to a third, flexible, twist-and-fold frame, the third panel having a top and bottom connected by first and second opposing sides, the third panel being interposed between the first and second panels and the third panel sides being connected to at least one of the first and second sides of the first and second panels, and wherein the bottom′ sheet of material is connected to the bottom of the third panel.

15. The collapsible container of claim 1, further comprising a flexible handle connected to the container.

16. The collapsible container of claim 1, further comprising a door hook connected to the second panel.

17. The collapsible container of claim 7, further comprising a zippered opening on the bottom sheet of material.

18. The collapsible container of claim 1, further comprising a strap connected to the top and bottom of the first panel and having a length or being adjustable to a length that is shorter than the undeformed distance between the top and bottom of the first panel to bow the top and bottom of the first panel out of a flat plane.

19. The collapsible container of claim 18, wherein the strap is releasably connected to the top and bottom of the first panel.

20. The collapsible container of claim 18, wherein the strap is releasably connected to the frame at the top and bottom of the first panel.

21. A collapsible container having twist-and-fold panels in which a web of flexible material is held taut by a tension loop frame fastened to a periphery of the web, comprising:

a first and second panel each having a top and a bottom joined by sides, with each side on the first panel being connected to a different one of the sides on the second panel, with either the web of material between the top and bottom on the first panel being shorter than the unrestrained distance between the top and bottom of the first frame or a strap connects the top and bottom of the first panel so the top and bottom of the first panel are bowed out of a flat plane and extend away from the second panel when the container is in the expanded configuration; and

a bottom sheet fastened to the bottom of the first and second panels.

22. The collapsible container of claim 21, wherein the sides are joined along a substantially straight line and the first panel is bowed by a strap.

23. The collapsible container of claim 21, wherein the sides are joined along a substantially straight line and the first panel is bowed by the web of material.

24. The collapsible container of claim 21, wherein the sides are joined along a substantially straight line and both the top and bottom of the first panel are bowed to extend away from the second panel, with the bottom panel extending a greater distance than the top.

25. The collapsible container of claim 21, wherein the sides are joined along a substantially straight line and both the top and bottom of the first panel are bowed to extend away from the second panel, with the top panel extending a greater distance than the bottom.

26. The collapsible container of claim 21, wherein the second panel is substantially flat and the sides are joined along substantially straight lines.

27. The collapsible container of claim 25, wherein a door hook is connected to the second panel directly or through an intermediate member.

28. The collapsible container of claim 21, wherein the web of material between the top and bottom on the second panel is shorter than the unrestrained distance between the top and bottom of the second frame so the top and bottom of the second panel are bowed and extend away from the first panel.

29. The collapsible container of claim 21, further comprising a third panel interposed between the first and second panels and having its two sides each joined to a different one of the sides of both the first and second panels.

30. The collapsible container of claim 28, wherein the top of the second panel is bowed and extends away from the third panel when the container is in the expanded configuration.

31. The collapsible container of claim 22, wherein the first and second panels have a partially collapsed configuration in which the first and second panels abut each other to form a stack of panels resembling a portion of a corkscrew.

32. The collapsible container of claim 23, wherein the first and second panels have a partially collapsed configuration in which the first and second panels abut each other to form a stack of panels resembling a portion of a corkscrew.

33. The collapsible container of claim 28, wherein the panels are twisted and folded into a collapsed configuration having a plurality of overlapping coils.

34. A method of making a collapsible container, comprising:

providing a first twist-and-fold panel having a top, a bottom and two sides joining the top and bottom on the first panel with a web of flexible material covering the first panel and a flexible frame around a periphery of the first panel;

providing a second twist-and-fold panel having a top, a bottom and two sides joining the top and bottom on the second panel with a web of flexible material covering the second panel and a flexible frame around a periphery of the second panel,

fastening each side of the first panel to a different side of the second panel along a substantially straight portion;

fastening a bottom sheet to the bottoms of the first and second panel; and

bowing the top and bottom of the first panel toward each other and out of a flat planar configuration and at least temporarily fixing the first panel in that configuration.

35. The method of claim 34, wherein the web of material bows the first panel out of a flat planar configuration.

36. The method of claim 34, wherein a strap fastened to the top and bottom of the first panel bows the first panel out of a flat planar configuration.

37. The method of claim 34, further comprising placing a releasably closable opening in the bottom sheet of material.

38. The method of claim 34, further comprising fastening a handle to one of the panels.

39. The method of claim 34, wherein the step of fastening the side panels comprises sewing sides of the panels together.

40. The method of claim 34, further comprising:

providing a third twist-and-fold panel having a top, a bottom and two sides joining the top and bottom on the third panel with a web of flexible material covering the third panel and a flexible frame around a periphery of the first panel; and

fastening the sides of the third panel to the sides of at least one of the first and second panels.

41. The method of claim 40, further comprising bowing the top and bottom of the second panel toward each other and out of a flat planar configuration and at least temporarily fixing the second panel in that configuration.

42. The method of claim 34, further comprising bowing the top and bottom of the second panel toward each other and out of a flat planar configuration and at least temporarily fixing the second panel in that configuration.

43. A method of collapsing a container having a first and second twist-and-fold panels having spring-loop frames each fastened to a web of material with the two panels being joined together along sides of the two panels with a bottom sheet connected to bottoms of the first and second panels so the bottom sheet and the two joined panels form an enclosed space when the panels are in an expanded configuration in which the top and bottom of the first panel are spaced apart from the respective top and bottom of the second panel, comprising:

moving the top of the first panel from the spaced apart position to a position adjacent the top of the second panel and forming a stack of two panels having a stable, twisted configuration comprising a portion of a corkscrew.

44. The method of claim 43, further comprising twisting the stacked panels further in the direction of the twist to coil the frames into overlapping loops.

45. The method of claim 43, wherein the panels are rectangular with four corners and two diagonal corners are in a different plane the remaining two diagonal corners when the two panels are stacked adjacent each other.

46. The method of claim 43, wherein the second panel has a flat, planar shape in the expanded configuration.

47. The method of claim 43, wherein the second panel has an expanded configuration in which the top and bottom are spaced apart from a plane through the joined sides to form a bowed configuration.

48. The method of claim 43, further comprising fastening a third panel between the first and second panels, with the third panel having an expanded configuration comprising a flat, planar shape in the plane of the joined sides, the panel having a twist-and fold frame within a pocket.

49. The method of claim 43, further comprising fastening a third, frameless panel between the first and second panels and extending laterally across a width of the container.

50. The collapsible container of claim 1, further comprising a sheet of material fastened to opposing sides of at least one of the first and second panels and extending laterally across a width of the container.

51. The collapsible container of claim 21, further comprising a sheet of material fastened to opposing sides of at least one of the first and second panels and extending laterally across a width of the container.