GB2297915A

GB2297915A - Collapsible carrycot

Info

Publication number: GB2297915A
Application number: GB9512167A
Authority: GB
Inventors: Martyn Michael Charles
Original assignee: Individual
Current assignee: Individual
Priority date: 1995-06-15
Filing date: 1995-06-15
Publication date: 1996-08-21
Anticipated expiration: 2015-06-15
Also published as: GB9512167D0; GB2297915B

Abstract

A collapsible carry-cot comprising a base, a pair of oppositely opposed longitudinal walls, a pair of oppositely opposed lateral walls, flexible hinge portions connecting the base to each of the walls, flexible corner portions connecting each lateral wall to its adjacent longitudinal wall, fastening means for securing adjacent walls together and a pair of handles. At least one of the walls and the base comprise both relatively rigid laminate portions 21 and relatively flexible laminate portions. The rigid portions comprise an interior of cellular construction, which may be plastic or expanded sheet metal, at least on the inward side thereof, an interior layer of foam material 30 and may also have additional foam layers 25, 27.

Description

LIGHTWEIGHT COLLAPSIBLE CARRY-COT The present invention relates to lightweight collapsible carry-cots for babies, and more particularly, although not exclusively, to carry-cots suitable for stowage on aircraft.

Most large airlines provide necessities for infants and babies, including carry-cots. These cots need to be collapsible to a generally flat condition for convenient stowage, e.g. in overhead lockers, when out of use. They need to be of as light a weight as possible, since every item carried increases the cost of the flight in terms of fuel consumed. However they also need to be strong, since the airline may be liable in the case of accident. For this reason airlines normally require such cots to conform to a suitable standard, e.g. the appropriate British Standard Specification.

Collapsible carry-cots normally comprise a base, a pair of oppositely opposed longitudinal walls, a pair of oppositely opposed lateral walls, flexible hinge portions connecting the base to each of the walls, flexible corner portions connecting each lateral wall to its adjacent longitudinal wall, fastening means enabling the cot to stand rigidly in its operative state and a pair of handles.

An aircraft carry-cot in current use utilises panels of hardboard to provide rigid reinforcement for the base and each of the walls. These panels are covered with PVC sheeting which constitute the inward and outward surfaces and provide flexible hinge regions around the base and flaps at the corners, allowing the walls to collapse inwardly upon the base to a generally flat condition when out of use.

Flexible PVC covered handles are attached at the inward surfaces of the longitudinal walls.

The present invention is based on an appreciation that the known carrycot suffers from a number of disadvantages, which are reduced or overcome by an ingenious blend of material selection and design. The use of PVC covered hardboard, although providing the necessary strength leads to a heavy and uncomfortable article. Also the inwardly collapsing design, while protecting to an extent the inward surfaces during stowage precludes any padding of the base, which would interfere with the folding of the walls. It is often left to the ingenuity of the mother to devise some form of mattress from the few articles of clothing or other material she has with her in the aircraft.

The invention provides a carry-cot comprising the features set out above wherein at least one of (a) the walls and (b) the base is of laminated construction, including relatively rigid laminate portions and relatively flexible laminate portions, said rigid portions each comprising an interior rigid panel of cellular construction and, at least on the inward side thereof, an interior layer of foam material.

In general, throughout the specification, the expressions "inward" and "outward" refer to surfaces of the cot as a whole, while "interior" and "exterior" are used to denote layers of a laminate.

By "cellular construction" it is meant that the panels are constructed, generally of thin sheet material, so as to define compartments or cavities whereby the predominant part of the total volume of the panel consists of air space.

Preferably the panels include wall sections which (or at least parts of which) extend across the median plane of the panel so as to provide rigidity. The panels may be simply of expanded metal sheet, i.e. sheets of e.g. steel, aluminium or suitable light alloy which have been slit and stretched. Such material is particularly suitable where severe flame retardancy specifications must be met.

The expanded metal sheet may, but need not be attached to sandwich sheets on one or both sides.

Alternatively the rigid panels may be of hollow wall plastics material. e.g.

of hollow ply construction with interior separator walls defining tubular or discrete cellular cavities.

The inward surface(s) of the base and/or walls are preferably of plastics sheeting, normally adhered to the foam layer e.g. by flame bonding. A particularly useful and attractive inward surface layer may be provided by using decoratively perforated plastic sheeting. If an open cell foam is used underneath the inward layers will be air and liquid pervious. This has advantages and disadvantages and such construction will depend upon the circumstances of use and airline preference. The result is a softer interior in which the air is partly "squeezed out" by the baby's body where the construction is used in the base.

Spilled liquid and urine will tend to be trapped in the foam underlayer. This will maintain a dry interior e.g. for the duration of a flight, but will render the article difficult to wash and sterilise for re-use. However many airlines make a practice of donating the cot to the mother at the end of the flight for the journey home.

The outward surface(s) of the base and/or walls are preferably of fabric covered foam material.

Preferably the laminated construction described is used throughout, i.e.

the base and walls are of the said laminated construction, the foam layer of the base being thicker than the corresponding layers of the walls.

Thus the rigid panels of the walls and base are preferably separate, to allow folding, and adhered to outer layers of flexible material which extend continuously over the inward and outward surfaces of the cot. The layer or layers of the walls other than said rigid panels may be adhered together outside the area of said panels at hinge, corner and margin regions to constitute flexible laminate portions. In the region of the base the thin foam layer on the inward side may be bonded to a thicker layer of foam to provide the base "mattress". The underlayer of the mattress may but need not be bonded to the rigid panel used in the base.

A preferred feature lies in the construction of the hinge portions to permit the walls to fold outwards from their operative position to lie flat, i.e. generally in the plane of the base, and more preferably backwards from such flat position to a collapsed state in which the inward surfaces are exposed outwardly. This allows a thick foam padding to be used in the base without obstructing the folding operation. The edges of the padding in fact abut against the walls to prevent any tendency for them to collapse inwardly in use. Any suitable retaining means may be provided to retain the cot in the collapsed state. Since the inward surfaces will not be protected, it may be convenient to store the collapsed cot in a lightweight plastics envelope.

In the embodiments described hereafter, the handles are of flexible material, e.g. loosely covered elastic material, situated on the inward surfaces of the longitudinal walls with their ends extending through slots in said walls to connecting means on the outward sides of the walls. This has advantages associated with other features as will become apparent.

The outward surface layers of the cot are preferably of brushed fabric.

Not only does this provide a suitable soft finish, but such fabric is responsive to "hook" material used in "hook and eye" fastenings e.g. as sold under the Trademark VELCRO. Other "hook" responsive material may be substituted. The ends of the handles may be attached to anchoring portions of such "hook" material fastenable to the "hook" responsive fabric. This allows the handles to be removed if necessary, to be made at a different assembly point, and to be fitted at a late stage in assembly by non-experts, e.g. the purchaser. The anchoring portions may also be used as retaining means to hold the walls in the collapsed state. Thus they may be located so as to be fastenable to outward parts of the lateral walls in the collapsed state to hold the lateral walls together over the longitudinal walls.

In the upright or operative state of the cot, the flexible corner portions are preferably foldable against portions of the longitudinal or (more preferably) lateral walls and fastened to them e.g. by press studs to retain the walls upright. Other fastening means may be used such as "hook and eye" fastenings e.g. provided by portions of "hook" material attached to the flexible corner portions.

It is possible by means of the invention to manufacture cots weighing less than 2 kg, preferably less than 1.5 kg and with a mass per unit area of less than 2 kg/m2, preferably less than 1.5 kg/m2.

- Embodiments of the invention is hereafter described with reference to the accompanying drawings, in which: Figure 1 is a perspective view from above of one form of carry-cot according to the invention in its operative state (position of use), Figure 2 is a view corresponding to Figure 1 showing an initial stage of collapse, Figure 3 is a plan view from above of the cot of Figures 1 and 2 in the collapsed state1 Figure 4 is a partial sectional view along the line IV-IV of Figure 1, Figure 5 shows the same section partly unfolded towards the collapsed state, Figure 6 is a view similar to part of Figure 4 of a modification, and Figure 7 is a view from above of an alternative form of rigid panel composed of expanded metal.

The drawings show a carry-cot 10 comprising a base 11, a pair of oppositely opposed longitudinal walls 12 and 13, a pair of oppositely opposed lateral walls 14 and 15, flexible hinge portions 16 connecting the base 11 to each wall, flexible corner portions 17 connecting each lateral wall to its adjacent longitudinal wall, fastening means in the form of co-operating pairs of press studs 19a and 19b enabling the cot to stand rigidly in its operative state, shown in Figure 1, where the flexible corner portions 17 are folded outwardly and attached by the press studs 19a and 19b to the lateral walls.

Handles 20 of flexible PVC covered elastic strip are situated at the inward surfaces of the longitudinal walls 12, 13 with their ends extending through slots 20a in such walls. The ends of the handles are attached to anchoring portions 20b of "hook" material fastenable to the "hook" responsive fabric.

The construction is best shown in Figures 4 and 5. Separate rigid panels 21 of hollow wall plastics provide the necessary reinforcement for each of the walls and the base. Suitable material is sold under the Trademark COREX and consists of hollow ply plastics material of about 5 mm thickness with parallel planar skins 22 separated by separator walls 23 defining square tubular cavities 24. A single thickness of this material has been found to provide sufficient strength in the present embodiment. The tubes are preferably arranged so as to extend longitudinally, i.e. horizontally in the walls in their operative state.

However if additional strength is needed, two thicknesses can be used e.g. for the base (preferably bonded together) with the tubular cavities at right angles.

When the cot is viewed in a planar unfolded state as partly seen in Figures 2 and 5, the rigid panels 21 of the walls are slightly separated from the edges of the base, as shown in Figure 5 to allow for the provision of the flexible hinge portions 16 which are defined by flexible parts of the laminate.

Bonded to the rigid panels 21 over the entire bottom area as viewed in Figure 5 is a composite layer of foam backed fabric composed of a thin layer of flame retardant, open cell polyurethane foam 25, e.g. 2-3 mm thick, and a layer 26 of brushed fabric which is "hook" responsive, i.e. it will adhere to "hook" type sheeting as used in fasteners sold under the Trademark VELCRO. The foam backed fabric extends also across the corner regions of the cross shaped area defined by the rigid panels 21 to form the flexible corner portions 17, where the margin of the fabric is preferably rounded off as illustrated e.g. at the right of Figure 1 so that attachment by the press studs 19a, 19b is conveniently provided towards the centre of the lateral walls 14, 15.

A composite layer of foam backed plastics sheeting composed of a thin layer 27, e.g. 2-3 mm thick, of flame retardant open cell polyurethane foam bonded to a layer 28 of flexible, perforated PVC sheet extends, correspondingly to the bottom layer, over the whole top (Figure 5) or inward surface of the cot in its planar state. In the marginal edge areas, indicated at 29 in Figure 5, and the corner portions 17 the two adjacent foam layers 25 and 27 are bonded together, e.g. by flame bonding to provide flexible laminate regions. The free edge of the cot is reinforced by a stitched hemming 31.

Extra padding is provided over the rigid panel of the base, as shown in Figures 4 and 5 by a relatively thick layer 30, e.g. 1.5 cm thick, of flame retardant polyurethane foam, which may be of somewhat lower density than the other foam layers. This is bonded, e.g. by flame bonding, to the foam layer 27 as shown in Figures 4 and 5 to provide a composite foam layer in the base region. While the thin foam layers are bonded to the rigid panels, e.g. by continuous adhesive layers (not shown) over the remainder of the article, such bonding may be omitted between the lower surface of the thick foam layer 30 and the base panel. This allows some slippage of the foam which facilitates the folding and unfolding operations and reduces wear caused by these operations.

As shown in Figures 4 and 5, the thick foam layer 30 does not extend fully to the edges of the base rigid panel 21. When the cot is in the operative state shown in Figure 4 it can be seen that the bottom edge of the wall panel 21 rests on the surface of the base panel 21 and the loose foam backed plastics sheeting between the walls and the base is tightly folded against the thick edge of the foam padding layer 30. This assists in preventing inward collapse of the walls in use and provides a firm support for the bottom edges of the walls. With the upper edges of the walls firmly secured by the press studs 19a and 19b the cot is rigid in use.

When the cot is out of use for stowage1 the press studs 19a and 19b are unclipped and the walls folded down as shown in Figure 2, firstly to the planar state, i.e. where the walls and base are generally in the same plane as in Figure 5. The cots may be stacked in this state where storage of sufficient area (vertical or horizontal) is available. More generally, e.g. to fit overhead storage lockers of aircraft, further folding may be necessary. This can be accomplished by folding the walls further backwards to the state shown in Figure 3 in which preferably the longitudinal walls 12, 13 are first folded and the lateral walls then folded over them. The inward surfaces of the walls are exposed outwardly in this state, but that of the base is covered.

The cot may be secured in this state by any suitable means. It may be convenient to slip the collapsed cot into a light plastics envelope, which will keep it flat and protected without adding much to its weight and expense. However the "hook" portions 20b at the ends of the handles may also be utilised. Two of these can be stretched out from their slots as indicated by the broken lines in Figure 3 under the overlap normally present in the longitudinal walls 12, 13 and secured to the underside of the adjacent folded lateral walls to hold them down.

Wherever possible, all materials used are flame retardant. A cot manufactured as described with reference to Figures 1 to 5 typically weighs from 1.0 to 1.2 kg and has a mass per unit area of from 1.2 to 1.6 kglm2.

Many modifications are possible within the invention to the embodiment of Figure 1 to 5. One such is illustrated in Figure 6, where parts corresponding to those of Figures 4 and 5 are referenced similarly, preceded by the numeral 1. In this embodiment a stiffening bar 100 of suitable stiff cross-section, such as the hollow square cross-section plastics illustrated, is incorporated in the margin areas of the walls to assist in preventing inward collapse during use.

An alternative form of rigid panel is shown in Figure 7. This is composed of expanded steel sheet 200 in which the original sheet has been discontinuously slit and then stretched so that the strips 201 defining the walls of compartments 202 are twisted and extend across the median plane of the panel, providing rigidity. In common with the COREX construction described earlier, rigidity is greater in one dimension than the other. If greater rigidity is needed, two such sheets may be arranged at right angles (and bonded or welded if desired).

Alternatively a flat sheet may be used as a sandwich layer on one or both sides, or a stiffening bar utilised as described with reference to Figure 6.

In another embodiment (not illustrated) stretch fabric material may be used to replace the brushed fabric at least in the hinge regions to provide additional freedom for the bending of the cot walls to the positions of use and stowage. Thus material such as that sold under the Trademark LYCRA may be used in place of the brushed fabric on one or both surfaces. Areas of "hook" sensitive material may be attached where needed.

In another embodiment (not illustrated) the foam padding layer 30 is omitted to allow the walls to fold inwardly. In this case a separate "mattress" of matching size is provided, which is suitably of PVC covered flame retardant polyurethane foam, which can be fitted in place after the cot is set up in its operative state. Such a mattress can be stowed in a plastic envelope with the cot or the mattresses can be stacked separately. The embodiment also allows for a thicker and possibly more comfortable foam padding and the thin foam layer adjacent the PVC sheeting (which would otherwise be immediately over the rigid panel of the base) could be omitted. The use of perforated PVC (or equivalent plastics) and open cell foam is more suitable in this embodiment, since the mattress can be washed and sterilised after use.

The storage envelopes referred to above and elsewhere in the specification may be sealed e.g. following sterilisation of the cots when new.

Claims

WHAT WE CLAIM IS:

1. - A collapsible carry-cot comprising a base, a pair of oppositely opposed longitudinal walls, a pair of oppositely opposed lateral walls1 flexible hinge portions connecting the base to each of the walls, flexible corner portions connecting each lateral wall to its adjacent longitudinal wall, fastening means enabling the cot to stand rigidly in its operative state and a pair of handles, wherein: at least one of (a) the walls and (b) the base is of laminated construction, including relatively rigid laminate portions and relatively flexible laminate portions, said rigid portions each comprising an interior rigid panel of cellular construction and, at least on the inward side thereof, an interior layer of foam material.

2. A carry-cot according to claim 1 wherein the inward surface(s) of the base and/or walls are of plastics sheeting.

3. A carry-cot according to claim 1 or claim 2 wherein the outward surface(s) of the base and/or walls are of fabric covered foam material.

4. A carry-cot according to any preceding claim wherein the base and walls are of the said laminated construction, the foam layer of the base being thicker than the corresponding layers of the walls.

5. A carry-cot according to any preceding claim wherein the rigid panels of the walls and base are separate and adhered to outer layers of flexible material which extend continuously over the inward and outward surfaces of the cot.

6. A carry-cot according to any preceding claim wherein the layer or layers of the walls other than said rigid panels are adhered together outside the area of said panels at hinge regions and margin regions to constitute flexible laminate portions.

7. A carry-cot according to any preceding claim wherein said hinge portions permit the walls to fold outwards from their operative position to lie flat, i.e.

generally in the plane of the base.

8. A carry-cot according to claim 7 wherein said hinge portions further permit the walls to fold backwards from said flat position to a collapsed state in which the inward surfaces are exposed.

9. A carry-cot according to claim 8 including retaining means to retain the cot in said collapsed state.

10. A carry-cot according to any preceding claim wherein the handles are of flexible material situated on the inward surfaces of the longitunial walls with their ends extending through slots in said walls to connecting means on the outward sides of the walls.

11. A carry-cot according to claim 10 wherein said handles are of loosely covered elastic material.

12. A carry-cot according to any preceding claim wherein the outward surface layers of the cot are of brushed fabric or other "hook" responsive fabric.

13. A carry-cot according to claim 12 as dependent on claim 10 or 11 wherein the ends of the handles are attached to anchoring portions of "hook" material fastenable to said "hook" responsive fabric.

14. A carry-cot according to claim 13 wherein said anchoring portions are fastenable to outward parts of the lateral walls in the collapsed state of the cot to constitute retaining means as defined in claim 9.

15. A carry-cot according to any preceding claim wherein said hinge portions are foldable against portions of the longitudinal or lateral walls in the operative state of the cot and provided with fastening means to such walls to retain the walls upright.

16. A carry-cot according to claim 15 wherein said fastening means are constituted by "hook and eye" fastenings.

17. A carry-cot according to any preceding claim wherein the cot has a mass per unit area of less than 2 kg/m2, preferably less than 1.5 kg/m2.

18. A carry-cot according to any preceding claim wherein the cot has a mass per unit area of less than 2 kg, preferably less than 1.5 kg.

19. - A carry-cot according to any preceding claim wherein said rigid panels are of hollow ply plastics material with interior separator walls defining tubular cavities.

20. A carry-cot according to any of claims 1 to 18 wherein said rigid panels are composed at least partly of metal.

21. A carry-cot according to claim 20 wherein said rigid panels each comprise a sheet of expanded metal.

22. A carry-cot according to any preceding claim wherein said foam material is of open cell and/or said plastics sheeting is perforated.

23. A carry-cot according to any preceding claim wherein margin areas of the cot are stiffened.

24. A carry-cot according to any preceding claim comprising a foam layer in the base of not less than 5 mm thickness.

25. A carry-cot according to any of claims 1 to 21 wherein essentially the same laminate structure is employed in the base and walls and a separate fitting mattress of plastics sheet covered foam is provided.