Foldable Enclosure

This application claims the benefit of U.S. Provisional Application No. 63/657,284, filed Jun. 7, 2024, the entire contents of which is incorporated herein by reference in its entirety.

The present disclosure relates to an enclosure. More particularly, the present disclosure relates to a foldable enclosure.

Enclosures or containers may be used to store or contain a variety of components in different application. For example, an enclosure may be an electrical enclosure that may contain energized components.

In a global economy, goods, like enclosures, are typically manufactured in one location and then transported (e.g., via ship, plane, truck, etc.) to a separate location where they may be used by an end user or resold to an end user. Regardless of the method used to transport the enclosure, the medium used to transport the enclosures has a finite area. Designing containers that can maximize the number shipped at one time, while also remaining large enough to meet customer requirements, may be an important factor in reducing costs.

One current solution is using an enclosure that is foldable and is capable of taking up a smaller volume while in transit and can expand to a larger volume in use to meet customer requirements. While current solutions are effective at reducing each enclosures shipping footprint and creating more space for shipping, they also introduce safety concerns. For example, current solutions may create pinch points, or places where installers' appendages (e.g., fingers, arms, etc.) could become caught as the enclosure is being unfolded. There is a need to develop an enclosure that similarly reduces its shipping footprint, while also minimizing safety risks to technicians.

Various embodiments of the present disclosure can overcome various of the aforementioned and other disadvantages associated with known enclosures and offer new advantages as well.

According to one aspect of various embodiments of the present disclosure there is provided a foldable enclosure.

According to one aspect of various examples of the present disclosure, there is provided a collapsible enclosure.

According to one aspect of various examples of the present disclosure, there is provided an enclosure constructed from a light-weight material.

According to one aspect of various examples of the present disclosure, there is provided an enclosure with a first side and a second side. The first side is pivotable relative to the second side.

According to another aspect of various embodiments of the present disclosure, there is provided a collapsible enclosure that includes an anchor structure, a pair of side walls, and a pair of end walls. The anchor structure includes a plurality of corner pieces, and a plurality of rods. Each rod is connected between two adjacent corner pieces to form an enclosed perimeter. Each side wall is movably connected to a rod of the plurality of rods. Each end wall is movably connected to a rod of the plurality of rods between the pair of side walls. The pair of side walls and the pair of end walls move between an expanded position where each side wall of the pair of side walls is perpendicular to each end wall of the pair of end walls, to a collapsed position where the pair of side walls and the pair of end walls are stacked on top of one another.

According to another aspect of various embodiments of the present disclosure, there is provided a collapsible enclosure that includes an anchor structure, a side wall, and an end wall. The anchor structure includes a corner piece, a first rod extending from the corner piece in a first direction, and second rod extending from corner piece in a second direction perpendicular to the first direction. The side wall is movably connected to the first rod. The end wall movably connected to the second rod. The side wall and the end wall move between an expanded position where a corner of the side wall engages a corner of the end wall, and a collapsed position where the side wall is parallel to the end wall.

According to another aspect of various embodiments of the present disclosure, there is provided an anchor structure for a collapsible enclosure that includes a first corner support, a second corner support, a third corner support, and a fourth corner support. The first corner support has a first upper end and a first lower end. A first opening is disposed more proximate to the first upper end and a second opening is disposed more proximate to the first lower end. The second corner support has a second upper end and a second lower end. A third opening is disposed more proximate to the second upper end and a fourth opening is disposed more proximate to the second lower end. The third corner support has a third upper end and a third lower end. A fifth opening is disposed more proximate to the third upper end and a sixth opening is disposed more proximate to the third lower end. The fourth corner support has a fourth upper end and a fourth lower end. A seventh opening is disposed more proximate to the fourth upper end and an eighth opening is disposed more proximate to the fourth lower end. The anchor structure also includes a first rod, a second rod, a third rod, and a fourth rod. The first rod is connected to the first corner support and the second corner support and extending between the first opening and the third opening. The second rod is connected to the first corner support and the third corner support and extending between the second opening and the sixth opening. The third rod is connected to the fourth corner support and the second corner support and extending between the eighth opening and the fourth opening. The fourth rod is connected to the third corner support and the fourth corner support and extending between the fifth opening and the seventh opening.

According to another aspect of various embodiments of the present disclosure, there is provided a method of collapsing an enclosure. The method includes rotating a first side wall in a first rotational direction away from a first end wall and a second end wall and rotating a second side wall in a second rotational direction away from the first end wall and the second end wall. The first rotational direction is opposite to the second rotational direction. The method also includes rotating the first end wall about 90 degrees in a third rotational direction perpendicular to the first rotational direction and rotating the second end wall about 90 degrees in a fourth rotational direction opposite to the third rotational direction so that the first end wall and the second end wall is on top of the first end wall. The method also includes continuing to rotate the first side wall in the first rotational direction to contact a surface of the second end wall and continuing to rotate the second side wall in the second rotational direction to contact a surface of the first side wall.

According to another aspect of various embodiments of the present disclosure, there is provided a method of collapsing an enclosure. The method includes moving a first side wall in a first rotational direction from a first position in engagement with a first end wall and a second end wall to a second position at least partially spaced apart from the first end wall and the second end wall. The method also includes moving a second side wall in a second rotational direction from a first position in engagement with a first end wall and a second end wall to a second position at least partially spaced apart from the first end wall and the second end wall. The second rotational direction is opposite to the first direction. The method also includes rotating the first end wall in a third rotational direction perpendicular to the first rotational direction and rotating the second end wall in a fourth rotational direction opposite to the third rotational direction to be in contact with the first end wall. The method further includes continuing to rotate the first side wall in the first rotational direction to be oriented parallel to the first end wall and the second end wall and continuing to rotate the second side wall in the second rotational direction to contact a surface of the first side wall.

The disclosure herein should become evident to a person of ordinary skill in the art given the following enabling description and drawings. The drawings are for illustration purposes only and are not drawn to scale unless otherwise indicated. The drawings are not intended to limit the scope of the invention. The following enabling disclosure is directed to one of ordinary skill in the art and presupposes that those aspects within the ability of the ordinarily skilled artisan are understood and appreciated.

illustrates an enclosurewith an internal volume. In some forms, the enclosuremay have a substantially rectangular cross-section, and the internal volume may be at least partially formed by a pair of side wallsand a pair of end walls. In other examples, the enclosuremay have a different cross-sectional shape and may have a different number of walls.

In some forms, a corner anchormay be disposed between adjacent walls,. For example, a corner anchormay be disposed between an adjacent side walland end wall. The illustrated example may include four corner anchors, although any number may be used.

illustrates an exploded view of the enclosure. In addition to the walls,and the corner anchors, the enclosureincludes a number of rods. For example, the enclosure includes four rods, although any number of rodsmay be used. As described in more detail below, the rodsmay assist in connecting and anchoring the walls,.

shows the rodsconnected between the corner anchors. The rodsmay be substantially straight, cylindrical members (see e.g.,). The resulting connection between the corner anchorsand the rodsmay form a substantially rectangular base.

As shown in, each rodmay be substantially hollow with a channel openingat either end. In other examples, one or more of the rodsmay have an openingat only one end and/or may not be hollow along the entire length. The hollow channel through each rodmay have substantially the same width along the respective rod's length.

In some forms, each rodmay include at least one connection passage(e.g., two shown). Each illustrated connection passageis disposed proximate to an end of the respective rodand may be oriented substantially perpendicularly with respect to the channel openings. However, the connection passage(s)may be disposed at any length along the respective rodand/or may be oriented at any angle with respect to the channel and channel openings.

As shown in, each corner anchormay include an outer surfacewith a substantially curved shape that extends between a pair of planar faces. In some forms, the outer surfacemay extend about 90 degrees, although other examples of the outer surfacemay extend any angular distance.

In some forms, the outer surfacemay include apertures, which may be spread out around the outer surface. The illustrated outer surfacemay include a pair of upper aperturesand a pair of lower apertures. Each pair of aperturesmay be grouped together in the respective region of the outer surface. The upper pair of aperturesmay also be offset from the lower pair of apertures.

In some forms, the inner surface of each corner anchormay include an anchor lip. The illustrated anchor lipmay extend continuously between the planar faces. In other examples, there may be a discontinuity along at least a portion of the anchor lip.

In some forms, each planar surfacemay include a holethat may extend into the body of the corner anchor. In the illustrated example, the holeon one planar surfaceis more inferior (e.g., lower as viewed in) than the holeon the other planar surface. The holesmay be circular in shape and have substantially the same diameter, although in other examples, the shape and/or size of one holemay be different.

As shown in, the lower holemay be oriented proximate to the lower pair of apertures. In the illustrated example, the pair of aperturesmay be oriented substantially perpendicularly so that one lower apertureis substantially concentric with the holeand the other lower aperture is perpendicular to an axis that extends through the center of the hole. Although not show, the upper holeand the upper pair of aperturesmay be oriented in substantially the same configuration.

In some forms, the rodsmay be inserted into the holes. Some rodsmay extend between the upper holesof adjacent corner anchorsand other rodsmay extend between lower holesof adjacent corner anchors. As shown in, two rods(e.g., the rodsthat extend along a length of the enclosure) may be oriented in the upper holes, and two rods(e.g., the rodsthat extend along the width of the enclosure) may be oriented in the lower holes.

Fasteners may be used to retain each rodwithin the respective corner anchor. Specifically, the fasteners may be inserted through the aperturesafter the rodsare inserted through the respective holes.

In some forms, an end of each rodmay be retained by a first fastenerand a second fastener. The first fastenermay be inserted through an apertureand the aligned connection passage. The second fastenermay be inserted through the other apertureand the aligned channel opening. The second fastenermay be received within the first fastener(e.g., by a threaded connection). The engagement of the first and second fasteners,within the tubemay limit the respective end of the tubefrom being removed from the respective corner anchor.

illustrates the side wallof the enclosure. The side wallincludes an upper endand a pair of side portions. The upper endincludes a passagethat extends along a length of the side wall. The passagemay have a width that is approximately the same as a width of the tubes. As described in more detail below, a tubemay be inserted into the passage.

The upper endmay also include a ledge, which may be positioned on an inner surface of the side wall. As described in more detail below, the ledgemay be at least partially aligned with the anchor lipwhen the enclosureis assembled.

Each side portionmay be at least partially curved (e.g., toward the inner surface of the side wall). An end of each side portionmay include a groove. The illustrated grooveincludes a central channel and extends along the entire length of the side portion. Other examples may include a groovethat extends only part of the length.

illustrates the end wallof the enclosure. The end wallincludes an upper endand a pair of side edges. The upper endincludes a passagethat extends along a length of the end wall. The passagemay have a width that is approximately the same as a width of the tubes. As described in more detail below, a tubemay be inserted into the passage.

The upper endmay also include a ledge, which may be positioned on an inner surface of the end wall. As described in more detail below, the ledgemay be at least partially aligned with the anchor lipwhen the enclosureis assembled.

Each side edgemay include a groove. The illustrated grooveincludes a central channel and extends along the entire length of the side edge. Other examples may include a groovethat extends only part of the length.

In some forms, the side wallsand the end wallsmay include a series of protrusions and recesses formed in the respective inner and outer surfaces. The protrusions and recesses may be arranged in a series of equally spaced rows, although any pattern may be used.

As shown in, the enclosuremay be assembled by passing a tubethough one of the passages,. Specifically, the longer tubesmay be inserted through a passageof the side walland the shorter tubesmay be inserted through a passageof the end wall. Each tubemay be centered in its respective passage,so that a portion of each tubeextends out of the respective passage,on either end.

As shown in, the portion of each tubeextending from the respective passage,may be received within the holesof the corner anchors, as described above. Once received within the corner anchors, the first and second fasteners,may be inserted through the aperturesto secure each wall,.

Returning to, once all four walls,are connected to the respective corner anchorsin this manner, the enclosuremay include a complete perimeter. This this position, the anchor lipand the ledges,may be aligned on a common plain. The anchor lipand the ledges,may also be recessed from an upper edge of the enclosure. In some examples, a cover (not shown) may be positioned at least partially within the internal volumeand rest against the anchor lipand the ledges,. The cover may be used to enclose the internal volume.

As shown in, the walls,of some forms of the enclosuremay be movable. For example, each wall,may be able to pivot about the respective tube. As a wall,, the respective corner anchorsmay remain stationary.

In some forms, the walls,may be movable to reduce the footprint of the enclosure, which may assist with shipping and transportation. From an assembled position, the enclosuremay be disassembled by first pivoting the side wallsradially outwardly. When connected, the grooveof a side wallmay interface with a grooveof an adjacent end wall. The direction of interface may limit movement of the end wallsbut may not substantially limit movement of the side walls(see e.g., example in). The side wallscan therefore move outwardly away from the end walls.

Once the side wallsare free from the end walls, the end wallsmay be free to pivot. Specifically, the end wallsmay pivot toward a center of the enclosure(e.g., toward one another). The end wallsmay pivot so that one end wallrests on top of the other end walland both end wallsare substantially parallel to one another (e.g., both rotated about 90 degrees).

The side wallsmay then be similarly rotated toward a center of the enclosure. Each side wallmay continue to be rotated in the same direction. For example, each side wallmay be rotated about 270 degrees and stacked on top of the end walls. Each side wallmay be substantially parallel to the other side walland to the end walls.

When the walls,are rotated and stacked, the outer perimeter of the collapsed enclosuremay be substantially the same as the expanded enclosure. As shown in, the corner anchorsmay remain in substantially the same position after the walls,are pivoted.

In some forms, the walls,may latch together when they are connected (e.g., a mechanical latch, a snap fit, a press fit, a magnetic engagement, etc.). In other examples, the walls,may remain freely pivotable and may be secured in position by an additional connector (e.g., a cable, a strap, etc.).

The enclosurein the collapsed position may be more easily transported than the expanded enclosurebecause it takes up less space. For example, a greater number of enclosuresmay be transported and/or stored in a given location than expanded enclosures.

When the enclosurereaches its desired location, it can be unfolded and returned to its expanded position. For example, the side wallsmay be pivoted away from the center to expose the end walls. The end wallscan then be pivoted back to their initial portion. Then, the side wallscan be pivoted toward the end walls.

In some forms, the side wallsmay engage with the end wallsto secure the walls,together. For example, the grooves,may engage with one another (e.g., in a snap fit).

illustrate another example of an enclosure. The enclosuremay be similar to the enclosure. Similar features may include similar reference numbers plus “400”. Only some similarities and differences may be described.