Corrugated container with bulge control

Wall panels for a corrugated paper board container have bulge control lines formed therein to control the bending of the wall panels as the container is loaded with contents, such as liquid containing contents. The bulge control lines are configured to control the bending of the wall panels to mitigate the possibility of undesirable spouting that makes the containers more difficult to store.

TECHNICAL FIELD

This disclosure relates to containers comprising corrugated paper board material, commonly known as combo bins or combos that are often used to hold flowable materials.

BACKGROUND

Combos or combo bins are large open topped containers with a bottom that typically have no flaps or other structure on the top edges. Combo bins are often used to hold flowable material. An example of a combo bin is an open top container that generally fits a conventional pallet of 48″×40″ (length by width) pallet.

Flowable material refers to material that may or may not have some liquid content, such as juice, brine or free water that oozes or drips from solid material. Examples include meat, such as ground beef, meat cuts and chicken all of which emit purge, a liquid substance. Pickles in brine would be another example. Other examples include plastic pellets and grains. Combo bins of such flowable materials that contain liquid are subjected to hydraulic pressures from the liquid content in the flowable material. The greater the liquid content, the more flowable the material and the greater the hydraulic forces on the combo bin when filled.

Combo bins often deform in shape due to the forces imposed by their contents being much greater than the bending stiffness of the bin material and relative panel sizes. This is further exacerbated when containers are elongated so that some of the panels are wider than others.

When paper board containers are elongated and exposed to hydraulic forces and/or time, the shape of the container changes. The open top of an empty container initially matches the shape and profile of the bottom of the container. However, as the container is filled, the shape deforms because the top of the container is unconstrained. Though an optimal shape under internal loading is round (the top would “like to become” a circle), the bottom structure adds additional constraints and forces to the wall panels that form the container. Essentially the top of the container has a tendency to become a 90 degree shifted image of the container footprint. When equilibrium is reached, the width of the container at the top may actually end up greater than the length of the container at the bottom due to spouting. The term spouting refers to the buckling of one or more side wall panels of the container along a top edge thereof. Typically, a spout is V-shaped and comprises or consists of a region of progressively decreasing triangular cross section moving downwardly away from the top edge of the buckled side panel. The resulting spout projects outwardly beyond the top edge of the panel that would be present if no spouting takes place. The hydraulic or other forces of the contained product can cause panel buckling or false scores (scores in the form of creases that form on their own due to force or defect), typically near the midpoint, left to right, of a container panel. The largest width panels buckle or break first and form spouts with subsequent buckling typically in the next largest panels. Often the largest panels only buckle at or near the middle of their width as such buckling creates a significant relief and the remaining sub-panels are too small (relative to the stiffness of the materials) to sub-divide or buckle into additional panels.

This singular buckling or break in the largest width panels can cause the top of the container to flare outward in an angular fashion. This spouting can cause the upper portion of the container to exceed the width of the transportation platform or pallet. This can pose significant challenges when pallets with containers thereon are placed in a confined space, such as on a racking system.

As a specific example, consider the prior art combo bin8shown inFIGS. 1-3. With reference to these figures, this combo bin is comprised of a plurality of upright corrugated paper board wall panels that have respective bottom forming panels that are interconnected to form the base or bottom of the bin. The wall panels include first and second end panels10,12. End panel10is positioned between a first set of diagonal corner panels14,16(panel16being formed from two sub-panels18and20that are glued together). Diagonal or corner panels22,24are formed at the opposite end of the container with wall panel12there between. The illustrated container includes opposed side panels30,32that are the widest panels of the combo bin8. The combo bin is shown on a pallet33that can be a conventional pallet that is 40 inches wide by 48 inches long.

The side panels30,32start out as vertical straight or planar side walls when the combo bin is empty. When empty, the illustrated combo bin8is an elongated octagonal shape. The end and corner wall panels10,14,16,12,22and24can be the same width. Alternatively, they can be of different widths; for example the end wall panels10and12can be wider than the corner panels. A liner, such as a large plastic bag40, can be placed in the combo bin for receiving contents deposited in the bag. As the combo bin is filled, the hydraulic pressures (if the contents contain liquid) become greater as the flowable material is added to the bag40. Eventually the hydraulic forces can reach a level that causes the widest panels, in this case side panels30,32, to buckle. This buckling is indicated at locations42,44. In effect the side walls30,32end up with an additional fold at these buckling locations. Consequently, the overall width of the combo bin is expanded between the buckling locations.

In effect, a break or crease42, located approximately in the center of the side panel, subdivides the side panel30into respective panels43and45. In addition, the buckle44in effect subdivides the side panel32into sub-panels47and49.

With reference toFIG. 2, the buckling at42thus forms an angular spout at this location in that the upper portion of the combo bin projects outwardly a greater extent at the location of buckle42. In addition, the buckle44causes the panel32to form a spout with the upper end of the panel extending outwardly at the location of buckle44. As a result, the overall width of the combo bin increases and can be greater in width at its widest location than the width of the pallet33. The width at the widest location can extend a significant distance beyond the adjacent side of the pallet. This creates problems, such as when the pallets are moved to storage locations, as the over width bins can interfere with the ability to place the pallets next to one another or in racks.

With reference toFIG. 3, a spout42is shown from a side elevation perspective. Respective dashed lines50,52are illustrated for purposes of explanation. In general, as the side wall30tends to fail, initial buckling appears to happen along respective lines50and52that are typically at respective angles A and B relative to the bottom edge53of the side panel30. Angles A and B typically range from about 30 to 45 degrees, but can vary depending upon the failure of the container due to hydrostatic hydraulic forces.

There have been various attempts to address the change in shape of these types of containers. The most historically common approach uses bands and/or internal tape built into the structure of the corrugated paper board. These materials do not control the shape of the container per se, but do attempt to constrain the growth in the circumference of the container and thus restrict some of the more severe deformations. However, because the stretch of many of these band materials is on the order of or greater than the stretch of the paper board forming the container, they typically do not effectively limit the spouting type behavior of combo bins.

FIG. 4illustrates a combo bin with two lower bands or straps60,62and one upper band or strap64. For convenience, the various wall panels in the embodiment ofFIG. 4have been assigned the same numbers as inFIG. 1. As can be seen inFIG. 4, the straps60,62and64did not prevent the buckling at42and44and the corresponding spouts at the upper ends of the combo bin at these buckling locations. One reason that bands do not help is that the overall perimeter of the upper portion of the combo bin does not dramatically increase as the combo bin is filled, but primarily changes shape.

Another approach does not attempt early control of the bulge. Instead, the combo bin is left to deform in an uncontrolled fashion until an upper parabolic score, extending from upper corner to upper corner of the widest panel, tries to impede the formation of the spout. This upper parabolic score is positioned above the horizontal center line of the combo bin. This presents several problems. The uncontrolled nature of the start reduces the reliability that the parabolic score will actually mitigate the spout formation and thus reduce the overall combo width. Secondly the size of the resulting panel lends itself to subsequent fracture from hydraulic forces and spouting even if it initially performs as desired. Thirdly the upper parabolic score is limited in elongation aspect ratio, which is exacerbated by increasing panel widths.

Therefore, a need exists for a combo bin with structures that control the deformation of side walls of a combo bin, particularly when they are filled with a flowable material that exerts hydraulic pressures on the side walls. These and other aspects of this disclosure will become apparent from the description below and accompanying drawings.

SUMMARY

In accordance with an aspect of this disclosure, bulge control scores, also called bulge control lines, are provided wall panels, such as the largest width panels, of a combo bin prior to any filling. These bulge control scores subdivide the side wall panels into a plurality of upright sub-panels that form as a container is filled and bulges out. The bulge control scores can be formed by weakening the side walls of the container (typically the largest width side walls, width meaning the distance in a horizontal direction when the wall panels are in an upright orientation) along which bulging is to be controlled. In one example, this weakening can be provided by forming score lines such as compression lines in a surface of a plurality of side wall panels of a container comprising corrugated paper board. One or more additional container walls in addition first and second side walls can be provided with bulge control lines. The bulge control lines are designed to mitigate the risk of spouting of the wall panels having the bulge control lines.

In accordance with another aspect of this disclosure, an embodiment of a container comprising corrugated paper board can comprise: first and second side wall panels opposed to one another, the container comprising a plurality of other wall panels other than the first and second side wall panels which other wall panels together with the first and second side wall panels are coupled together and form the walls of the container. A bottom or base portion is coupled to the first and second side wall panels and to the other wall panels of the container. In addition, the first and second side wall panels can each comprise a panel body including a bottom edge, a top edge, a center between the bottom edge and the top edge, and first and second side edges. Each panel body can comprise a plurality of bulge control lines that extend from a first location at or adjacent to the bottom edge of the panel body to a second location at or adjacent to the top edge of the panel body, the bulge control lines subdividing the panel body into at least three subpanels, the bulge control lines extending from the first location to a second location adjacent to the to the top edge of the panel body, and wherein the bulge control lines are further apart at the first location than at a third location that is above the first location. As alternative aspects of this embodiment, the third location is between the first location and the second location and can be about at a horizontal center line of the panel body, the horizontal center line extending through the center of the panel body; the third location comprises a region of the panel body that extends from below to above the center of each panel body and/or from below to above the horizontal centerline of the panel body; the subpanels comprise a subpanel with portions positioned on opposite sides of a vertical centerline through the center of the panel body; the first and second bulge control lines are spaced from the vertical centerline of the panel body; the first and second bulge control lines are about equally spaced from the vertical centerline of the panel body; and/or the first and second bulge control lines are symmetric about the vertical center line of the panel body.

As another aspect, container walls of a container comprising corrugated paper board, such as opposed first and second container side walls, can comprise a panel body comprise first and second bulge control lines, the first bulge control line comprising a first bulge control line section below the center of the panel body and the second bulge control line comprising a second bulge control line section below the center of the panel body, wherein the first and second bulge control line sections converge along a least a portion of the length of the respective first and second bulge control line sections moving away from the bottom edge and upwardly toward the center of the container. In addition, the first and second bulge control line sections can be arcuate. The first bulge control line comprises a third bulge control line section above the center of the panel body and the second bulge control line comprises a fourth bulge control line section above the center of the panel body. The third and fourth bulge control line sections can diverge along at least a portion of the length of the of the respective third and fourth bulge control line sections moving away from the center and toward the top edge. The third and fourth bulge control line sections can alternatively be straight, such as parallel to one another, or arcuate.

As yet another aspect, an embodiment of a container can have first and second walls, such as side walls comprising a panel body with respective first and second bulge control lines. More than two upright bulge control lines can also be included with the first and second bulge control lines in one or both of the side walls. The panel body can comprise first, second, third and fourth corners, the first corner being at the intersection of the of the first side edge and the bottom edge, the second corner being at the intersection of the second side edge and the bottom edge, the third corner being at the intersection of the first side edge and the top edge and the fourth corner being at the intersection of the second side edge and the top edge. In addition, the first bulge control line of each panel body can have a first section that extends upwardly and from the first corner and the second bulge control line of each panel body can have a second section extends upwardly from the second corner.

As a further aspect, a container comprising corrugated paper board can comprise the first and second bulge control lines in panel bodies of one or more wall panels that are arcuate, are spaced apart from one another at the center of the panel body and that extend from a location at or adjacent to a bottom edge of the panel body to a location at or adjacent to the top edge of the panel body.

As a still further aspect, a container comprising corrugated paper board comprises first and second wall panels each having a panel body, first and second side edges, a bottom edge and a top edge; wherein each panel body comprises first and second bulge control lines, the first bulge control line extending upwardly from a first bulge control line first location to a first bulge control line second location, the second bulge control line extending upwardly from a second bulge control line first location to a second bulge control line second location, each panel body further comprising first, second, third and fourth corners, the first corner being at the intersection of the of the first side edge and the bottom edge, the second corner being at the intersection of the second side edge and the bottom edge, the third corner being at the intersection of the first side edge and the top edge and the fourth corner being at the intersection of the second side edge and the top edge, wherein first bulge control line first location is at or adjacent to the first corner and the first bulge control line second location is at or adjacent to the top edge, and wherein the second bulge control line first location is at or adjacent to the second corner and the second bulge control line second location is at or adjacent to the top edge. The first bulge control line second location can be spaced inwardly along the top edge of the panel body from the third corner and the second bulge control line second location can be spaced inwardly along the top edge of the panel body from the fourth corner.

As a further aspect, containers comprising corrugated paper board can have first and second walls with respective first and second bulge control lines that are mirror images of one another.

As another aspect, the bulge control lines can be formed can be formed in the interior surfaces of respective wall panel bodies of containers comprising corrugated paper board.

In accordance with an exemplary embodiment, a container comprising corrugated paper board can comprise first and second side wall panels that are wider than the other wall panels of the container, the first and second side wall panels comprising respective first and second bulge control lines and the other panels can be provided without bulge control lines.

In accordance with another aspect of this disclosure, an embodiment of a container comprising corrugated paper board can comprise: first and second side wall panels opposed to one another, the container comprising a plurality of other wall panels other than the first and second side wall panels which other wall panels together with the first and second side wall panels are coupled together and form the walls of the container. A bottom or base portion is coupled to the first and second side wall panels and to the other wall panels of the container. In addition, the first and second side wall panels can each comprise a panel body including a bottom edge, a top edge, a center between the bottom edge and the top edge, and first and second side edges. Each panel body can comprise a plurality of bulge control lines that extend from a first location at or adjacent to the bottom edge of the panel body to a second location at or adjacent to the top edge of the panel body, the bulge control lines subdividing the panel body into at least three subpanels, the bulge control lines extending from the first location to a second location adjacent to the to the top edge of the panel body, and wherein the bulge control lines are further apart at the first location than at a location that is above the first location. The other wall panels can include four corner wall panels each with first and second corner wall panel side edges, and first and second end wall panels each with first and second end wall panel side edges, a first of the corner wall panels having its first corner panel side edge connected a the first side edge of the first side wall panel and its second corner panel side edge connected to the first side edge of the first end wall panel, a second of the corner wall panels having its first corner panel side edge connected to a second side edge of the first side wall panel and its second corner panel side edge connected to the first end wall side edge of the second end wall panel, a third of the corner panels having its first corner panel side edge connected to a first side edge of the second side wall panel and its second corner panel side edge connected to the second side edge of the first end wall panel, and a fourth of the corner panels having its first corner panel side edge connected a the second side edge of the second side wall panel and its second corner panel side edge connected to the second end wall side edge of the second end wall panel, wherein the first and second side wall panels have a greater width than the width of the first and second end wall panels. The first and second end wall panels can also have a greater width than each of the four corner wall panels. As a further aspect, the first and second bulge control lines can be spaced apart such that the width between the first and second bulge lines at the center of the wall panels is not greater than the width of the end wall panels. Alternatively, the width between the first and second bulge control lines at the center of the wall panels can also be not greater than the width of the corner wall panels. The width of the subpanel between the first and second of the bulge control lines at the center of the first and second wall panels can also be no greater than the width of the first and second end wall panels. Alternatively, the width of the subpanel between the first and second bulge control lines can be no greater than the width of each of the four corner panels.

As a further aspect, a container comprising corrugated paper board with wall panels comprising the first and second bulge lines can comprise a base of bottom portion that comprises a plurality of bottom flap panels extending from lower edges of the wall panels of the container, such as from lower edges of the side wall panels, end wall panels and the corner panels.

As a still further aspect, a container comprising corrugated paper board can comprise wall panels, such as side wall panels, the end wall panels, and the corner panels, first and second wall panels having the bulge control lines and wherein the wall panels form a tubular container wall structure, and further comprising a base or bottom portion that comprises a base coupled to the tubular wall structure.

As yet another aspect, a container comprising corrugated paper board with wall panels comprising the first and second bulge control lines can be formed from a one piece blank wherein the blank comprises first and second side wall panels with the bulge control lines together with the other wall panels of the container. The one piece blank can include bottom or base forming panel sections. As an alternative aspect, the one piece blank can form the wall panels of the container and a second one piece blank can be used to form the base or base portion of the container.

In accordance with a still further aspect, an embodiment of a container comprising corrugated paper board can comprise: first and second side wall panels opposed to one another and that are in respective first and second planes, the container comprising a plurality of other wall panels other than the first and second side wall panels which other wall panels together with the first and second side wall panels are coupled together and form the walls of the container; a bottom or base portion coupled to the first and second side wall panels and to the other wall panels; and wherein the first and second side wall panels each comprise means for subdividing the side wall panel into at least three upright subpanels that bulge out from the respective first and second planes and that extend from the bottom to the top of the container as the container is filled with contents.

As still further aspects, this disclosure encompasses individual wall panels with bulge control lines with all combinations and sub-combinations of the bulge control line aspects described above. In addition, this disclosure encompasses containers having all combinations and sub-combinations of the above described aspects.

In accordance with an aspect, one specific embodiment of a wall panel for a container comprising corrugated paper board comprises: a panel body comprising corrugated paper board including a bottom edge, a top edge, a center between the bottom edge and the top edge, and first and second side edges; the panel body comprising a plurality of bulge control lines that extend from a first location at or adjacent to the bottom edge of the panel body to a second location at or adjacent to the top edge of the panel body, the bulge control lines subdividing the panel body into at least three subpanels that extend from a location adjacent to the bottom edge of the panel body to a location adjacent to the to the top edge of the panel body; and wherein the bulge control lines comprise first and second bulge control lines, the first bulge control line comprising a first bulge control line section below the center of the panel body and the second bulge control line comprising a second bulge control line section below the center of the panel body, wherein the first and second bulge control line sections converge along a least a portion of the length of the respective first and second bulge control line sections moving away from the bottom edge and upwardly toward the center of the container. As another aspect, the bulge control lines comprise at least the first and second bulge control line sections are arcuate.

As additional aspects, the panel body can first, second, third and fourth corners, the first corner being at the intersection of the of the first side edge and the bottom edge, the second corner being at the intersection of the second side edge and the bottom edge, the third corner being at the intersection of the first side edge and the top edge and the fourth corner being at the intersection of the second side edge and the top edge, wherein the first bulge control line section extends upwardly from a first location at or adjacent to the first corner and the second bulge control line section extends upwardly from a second location at or adjacent to the second corner.

As a further aspect, the wall panel comprises an interior surface which faces the interior of a container with the wall panel, the first and second bulge control lines being formed in the interior surface of the wall panel.

These and other aspects of containers and wall panels with bulge control lines will become apparent with reference to the description below and the Figures.

DETAILED DESCRIPTION

In accordance with an aspect of this disclosure, bulge control scores, also called bulge control lines, are provided in the largest width panels of a combo bin prior to any filling. These bulge control scores subdivide the side wall panels into a plurality of upright sub-panels that form as a container is filled and bulges out. The bulge control scores are formed by weakening the side walls of the container (typically the largest width side walls, width meaning the distance in a horizontal direction when the wall panels are in an upright orientation) along which bulging is to be controlled. In one example, this weakening can be provided by forming compression lines in a surface of a plurality of side wall panels of a corrugated paper board container, such as in the two widest opposed side wall panels or side walls, such as in the interior surface of the wall panels to be subjected to controlled bulging. The extent of compression used to form the bulge control lines can be varied. In one example, the paper board is compressed from the surface sufficiently to deform the fluted material of the paper board. The paper board compression will rebound following compression, but the bulge line formations to guide the bulging of the side wall remain effective.

As a specific example, the paper board can be compressed to a depth of 25 percent from the interior surface with rebounding following compressing resulting in a bulge line that is 5 percent of the depth or thickness of the paper board. An exemplary range of initial compression would be from 15 percent to 35 percent. As mentioned above, if a large combo bin filled with flowable material has no features to prevent it from doing so, the panel or panels of the greatest width will likely fracture or buckle near the middle, in response to hydraulic forces, to relieve stress. This singular fracture creates a spouting condition (the worst situation) resulting in subdividing the spouted side wall panel into two sub-panels that are generally equal in width.

As another aspect of this disclosure, bulge control lines are provided to intentionally form, at a minimum, a plurality of at least three upright sub-panels as the bin is filled and that desirably extend from the bottom to the top of the combo bin, and/or from a location adjacent to the bottom of the bin to the top of the bin. Desirably a sub-panel spans or extends in an upright direction across the center of the widest side wall panels of the combo bin. In a desirable example, one of these sub-panels is centered or centrally positioned on each of the largest (width) panels (e.g., the two widest opposed side wall panels) to thereby extend across the area of the side wall that is prone to spouting in the absence of controlled buckling. These subdivided panel sections can be referred to as sub-panels because, while they are defined by lines of weakness (scores or bulge lines), the bottom flap associated with each of the overall widest panels, or the bottom of the container in an embodiment with a bottom formed separately from an upright tube formed from the side walls, desirably restrain the bulge lines from operating when the container is in an unfilled state. It is the bulge of the combo bin upon filling that actually forces the bulge lines to operate and form the upright sub-panels. The combo bin can also be provided with spaced apart encircling reinforcing straps in addition to bulge control lines.

In an embodiment wherein one of the sub-panels is centrally located in the widest panel, there will be at least two other sub-panels (e.g., at least one on each side of the centrally located sub-panel). The widths of the sub-panels do not have to be equal but the central width of the central or mid sub-panel is desirably equal to or less than (at its narrowest point) than the width of any vertical non-sub-paneled side wall panels of the combo bin (such as less than the width of the end and corner wall panels in the case of an elongated octagonal combo bin). This assures that any further buckling outside of the defined bulge lines, un-intended but naturally occurring, happens in those other non-widest panels, which are less critical.

As another aspect of this disclosure, it is desirable to control the starting point of bulging that takes place along the bulge control scores. Encouraging the container to start bulging to create sub-panels in the intended path is highly desirable in order to obtain highly repeatable results. Because the bottom flaps of the container or a separately attached base or bottom normally preclude the operation or bending along these scores or bulge control lines, one can utilize a secondary mechanism to actuate the bulging. Containers traditionally bulge and fail with panel buckling radiating out of the corners of the bin in a 30-45 degree angle (seeFIG. 3). By starting the predetermined bulge scores at or adjacent to the lower corners of the wall panels to be bulge controlled, and at the same or a similar angle, such as within plus or minus ten degrees of one another, the bulge will start to shape and form along the predetermined lines, and ultimately follow them throughout.

It is possible to start one or both of the lines away from the associated lowest corner (either upwardly above the corner, inwardly from the corner, or both). However, this does increase the possibility that the bulge controlled panel will break in an unintended area first. The most desirable embodiment is to start the bulge lines at the lower corners of the panel to be bulge controlled and to have the bulge lines extend upwardly to the upper edge of such bulge control panel. However, starting each bulge line adjacent to the nearest lower corner, such as within two to four inches of the lower corner, constitute additional embodiments. The bulge lines can also terminate short of the upper edge of the bulge controlled wall panel, such as adjacent to the upper edge, such as within two to four inches of the upper edge. Also, the score lines can terminate at locations at or spaced inwardly from the upper corners of the bulge controlled wall panel.

As yet another aspect of this disclosure, the shape of the bulge line pathways are controlled to result in a desired number of upright sub-panels. Again, in desirable embodiments, at least three sub-panels extend from the bottom to the top, and/or adjacent to the top of the bulge controlled side panels, when formed. As explained below, the bulge control pathways can take a number of shapes.

One particularly desirable set of bulge pathways is formed as follows and utilizes upwardly extending spaced apart curved bulge line pathways. These bulge pathways can be mirror images of one another and can converge moving upwardly from the respective lower corners of the bulge controlled side wall and can also diverge at a location above the horizontal center line of (and above the center of) the combo bin as they extend toward the upper edge of the side wall. A pair of bulge lines in an upright hour glass configuration is one specific example that results in three upright sub-panels. The narrowest distance or width between the pathways can vary.

As a specific desirable example, each such curved bulge line can start at a respective lower corner of the side wall and emanate out at a 30-45 degree angle and can arc in an upward manner. One third to one-half of the vertical distance up the side wall, the arc starts to sweep back. This arc and the associated generally-mirror-image of it creates the paths for the container to bulge as the container is filled with contents. The wall panels, including those with bulge lines, are desirably planar until the container is filled with contents and the bulge lines control the bulging of the container walls having the bulge lines. The bulge lines of weakness or scores create a “path” almost encouraging it to bulge in the lower middle section of the side wall, which results in additional bulge control. The curvature of the bulge lines in this specific example creates at least three interrelated and interfitting convex/concave sub-panels that give the sub-panels additional rigidity beyond the material bending stiffness alone. In addition the curvature naturally bends the upper most portion of the container back into itself, further reducing the overall width of the filled container. As mentioned before, in elongated containers this area typically splays outwardly creating the greatest external dimension (the largest challenge to material handling in racking systems). With the two opposing curving scores, an upright edge is defined between them, reducing the external width dimension between the opposing sub-panels with a defined structure; resulting in a mitigation of the spouting behavior of a combo bin that does not have the bulge control features.

The creation of a plurality of upright sub-panels in the largest width panel is an important aspect of this disclosure as it eliminates or mitigates the propensity of unintended panel buckling. Desirably, the sub-panels, when formed as a result of filling the container, extend from the bottom, or a location adjacent to the bottom, to the top of the bulge controlled widest side walls of the combo bin even if the bulge control lines do not extend from the bottom to the top of the side walls. This also enables the combo bin structure to form something closer to a rounded shape at the top; a shape that is closest to equilibrium given a uniform loading force from the contents inside the container. By starting the scores at or adjacent to the lower corner regions of the panel to be subdivided, additional assurance is gained that the scores (predetermined buckling lines) will be followed and the panel will bulge in the intended way. Adding controlled upwardly extending bulge paths, such as of convex/concave shape, allows the container to bulge in response to hydraulic forces, but doing so by giving the combo bin a predefined shape and rigidity. This greatly increases the likelihood that no further unintended panel breaks will happen in the widest width panels as well as minimizing the upper flaring or spouting of the container.

FIG. 5illustrates a corrugated paper board blank70for use in making an exemplary embodiment of a combo bin with bulge control lines or weakened areas in the widest panels of the blank. With reference toFIG. 5, a corrugated paper board blank comprises or consists of a body72of a plurality of layers comprising paper, including interior and exterior layers and a corrugated fluted core, forming the blank. The corrugated paper board blank can have additional layers. A corrugated paper board container is one formed from such a blank. The blank need not be in one unitary piece, although in form ofFIG. 5the container blank is an integrated one piece blank. In the form shown inFIGS. 17 and 18, a first integrated one piece blank is used to form the walls of the container ofFIG. 16and a separate integrated one piece blank is used to form the base portion of the container. The direction of the corrugations is desirably upright, vertically when the combo bin is erected, as indicated by arrow74. The illustrated body is comprised of a plurality of side wall forming panels. The number of side wall panels can be varied. An octagon shaped combo bin is one desirable example. However, the bin typically is not of an equilateral octagon configuration, as it can have a pair of side walls that are wider than the other walls. End walls and corner forming walls can be of the same width or, as illustrated in theFIG. 5embodiment, of different widths.

More specifically, the body72of the embodiment inFIG. 5has first and second end forming walls76,78and side wall forming panels or walls80,82. The illustrated combo bin blank has a first corner panel84positioned between end wall panel76and side wall panel80; a second corner panel86positioned between side wall panel80and end wall panel72; a third corner panel88positioned between end wall panel72and side wall panel82; and a fourth corner forming panel comprised of panel sections90A and90B. Panel sections90A and90B are glued together when the container is manufactured. Panel section90A is positioned alongside end wall panel76and panel90B is positioned alongside side wall panel82. The side edges of the respective wall panels are joined together along respective fold lines100,102,104,106,108,110,112, and114. These fold lines are upright, such as vertical, when the combo bin is erected. A respective bottom forming panel is joined to each of the wall panels in this illustrated example ofFIG. 5. In the embodiment ofFIGS. 16-18, these bottom panels are eliminated and the bottom is formed by a separate bottom or base structure. The bottom panels are indicated at120A,122,124,126,128,130,132,134, and120B. The respective bottom panels are joined to associated wall panels and are foldable about a fold line140that extends horizontally (inFIG. 5) from side to side of the blank72. Thus, bottom panel section120A is foldable about fold line140relative to panel section90A; panel section122is foldable about the fold line relative to end wall panel section76; bottom panel section124is foldable about the fold line140relative to corner wall panel84; bottom panel section126is foldable about the fold line relative to side wall panel section80; bottom panel section128is foldable about the fold line relative to corner wall panel86; bottom panel section130is foldable about the fold line relative to end wall panel78; bottom panel section132is foldable about the fold line relative to corner wall panel88; bottom panel section134is foldable about the fold line relative to side wall panel82; and bottom panel section120B is foldable about the fold line140relative to corner wall panel90B. Respective cuts150,152,154,156,158,160,162, and164separate the respective adjacent bottom panels from one another. The cuts150,152,158and160can have a curved or angled cut at their upper ends, one of which is indicated at170to facilitate folding of the respective bottom panel sections. Portions of the bottom panels, such as portions of the bottom panels attached to respective corner panels, can be crushed or otherwise densified to strengthen the bottom. The respective bottom panels126and130include slots180,182,184, and186that receive tabs of the end wall panels (e.g., tabs192,194,196, and198) when the combo bin is assembled. The respective tabs are separated from adjoining portions of the bottom panels122,130by V-shaped notches with side edges that, in this example, diverge at the same angle from one another. The bottom panels may be modified and interconnected using different interconnecting structures, adhesive or fasteners.

In the above example, the side wall panels80and82are the widest panels in the resulting combo bin structure. Although the corner panels and end wall panels can be of the same width, making the structure an equilateral octagon, in this example the corner panels are of narrower width than the end wall panels. For example, the corner panels can end up being 15 inches wide, the end wall panels 17 inches wide, and the side wall panels being 25¾ inches wide. These dimensions can be varied.

InFIG. 5, each of the widest panels, namely opposed side wall panels80,82, are provided with bulge formation lines on their interior surfaces. Bulge control lines as describe herein can be included in one or more other wall panels in addition to the side wall panels80,82. The wall panels with the bulge control lines comprise a panel body with first and second side edges, a bottom edge and a top edge. The panel body has a center and a horizontal centerline (when the wall panel is upright) that passes through the center of the wall panel body. In addition, the panel body has a vertical centerline passing through the center of the panel body. The wall panels with bulge control lines desirably have a plurality of bulge control lines, such as first and second bulge control lines, that desirably extend from a first location at or adjacent to the bottom edge of the panel body to a second location at or adjacent to the top edge of the panel body, the bulge control lines subdivide the panel body into at least three subpanels. The bulge control lines are desirably spaced at the first location at or adjacent to the bottom edge than at a third location that is above the first location. As alternative aspects of this embodiment, the third location is between the first location and the second location and can be about at a horizontal center line of the panel body; the third location comprises a region of a subpanel body, desirably the middle subpanel body if there are three subpanels, that extends from below to above the center of each panel body and/or from below to above the horizontal centerline of the panel body; the subpanels comprise a subpanel with portions positioned on opposite sides of the vertical centerline of the panel; the first and second bulge control lines are spaced from the vertical centerline of the panel body; the first and second bulge control lines are about equally spaced from the vertical centerline of the panel body; and/or the first and second bulge control lines are symmetric about the vertical center line of the panel body.

InFIG. 5, panel80is provided with two such bulge formation lines200,202. In addition, panel82is provided with two such bulge formation lines204and206. Bulge formation lines subdivide side wall panel80into the respective sub-panels210,212and214. In addition, bulge formation lines204,206subdivide side wall panel82into respective sub-panels216,218, and220. When the box is empty, the sub-panels210,212and214do not bulge out from one another in the illustrated embodiment but instead are planar. Similarly, when the container is empty, the sub-panels216,218and220are also planar in this example.

Although they can be different, inFIG. 5, the bulge control lines of each of the side wall panels80,82are the same. For this reason, only the bulge control lines of side wall panel80will be described. Bulge control line200starts at a location230at the lower right hand corner of the side wall panel80inFIG. 5. The control line200extends upwardly along a first path portion232that is angled at an angle typically from 30 to 45 degrees from the fold line140. At a location that can be 20-30 percent of the way up toward the top edge241of the blank, the bulge line232curves upwardly to a greater extent from the starting angle and continues to extend upwardly. At a location above the horizontal center line of the side wall panel, the curve200bends to extend in a direction toward the upper right hand corner236of the side wall panel80. The bulge control line200in this example terminates at a location238along the upper edge241of the side wall80. The location238is spaced inwardly from the corner236. In this example, bulge control line202is the mirror image of bulge control line200, although it can have a different shape. The bulge control line202inFIG. 5starts at the lower left hand corner250of side wall panel80, extends upwardly along a first portion of a path252, at the same angle in this example as the path232, and then bends backwardly toward the upper left hand corner of the side wall panel254after reaching a location above the horizontal center line of the container. The fold line202terminates at a location256spaced inwardly from the corner254. The distance d between the fold lines200,202at their narrowest location is, in this example, less than or equal to the width of the corner panels76,78. Consequently, once the sub-panels210,212and214are formed by bulging of the side wall80in response to hydraulic forces of contents of the erected bin, the side wall80, along with side wall82, will bulge outwardly as guided by the respective sets of bulge lines200,202and204,206; without unintended buckling. If further stresses are encountered, the end panels76,78will tend to buckle before there is further buckling of the side wall panel because the narrowest width of the sub-panel212is narrower than the width of the end panels76,78.

FIG. 6illustrates an alternative form of side wall panel structure in which the distance dl is narrower than the distance d in theFIG. 5embodiment. In theFIG. 6embodiment, the side wall80is shown. In addition, corresponding components are given the same numbers inFIG. 6as inFIG. 5for convenience and will not be discussed further. The same numbers for corresponding components have been used in theFIGS. 7-15embodiments. In theFIG. 6example, a perforation191and a perforation193can be provided in a portion of the bottom panels124,128for folding purposes. Portions of the corner panels124,128can be densified, but typically none of the bottom panels connected to the end walls are densified.

FIG. 7illustrates a combo bin formed from a blank like that shown inFIG. 5at two-thirds scale. InFIG. 7, the panel82is shown in a forward most position in this figure. As one can see, the bulge lines204,206caused the container side wall82to subdivide into three upright sub-panels216,218and220. The bend or bulge lines204,206are indicated generally in this figure. The actual bulge of the boxes may not precisely follow the bulge lines but tend to be close to the location of the bulge lines. As the bulging sub-panels are formed and bulging approaches the upper edge241of the container, the bulging may deviate from the bulge line and head vertically upwardly up from some point. As is apparent, in this example, a relatively flat center sub-panel218is formed rather than an outwardly projecting angular spout located roughly in the center of panel82. Consequently, the overall width of the combo bin between the side panels80and82is reduced.

FIGS. 8 through 15illustrate examples of side walls or side wall panels with alternative constructions of bulge control lines. These bulge control lines are desirably included in a plurality of the side wall panels of a container. Most desirably, the bulge control lines of these FIGS. are included in side wall panels of the greatest width, such as in the two opposed side wall panels of an octagon container having two side wall panels of the greatest width and other side wall panels (e.g., end wall panels and corner wall panels of a smaller width. In these FIGS., the widest side wall panel80is indicated along with the adjacent corner panels84and86. The bottom panel section126, if included, is also indicated. Side wall82can have bulge lines like those shown for side wall80. The remaining portions of the combo bin blank can be as previously described. Again, different bulge lines can be used in different panels. Otherwise, the focus of the description below is on the respective bulge forming lines in the side wall80.

InFIG. 8, the bulge line200is curved, much like the bulge line200shown inFIG. 5. However, the bulge line200ofFIG. 8terminates at its upper end at the upper right hand corner236of the panel80. In addition, the bulge line202ofFIG. 8terminates at the upper left hand corner254of the panel80. In theFIG. 8example, the closest distance d between the arcuate bulge lines200,202is greater than the distance d inFIG. 5. The center portion of the sub-panel212spans the center of the side wall panel80where the panel would tend to buckle in the absence of the bulge lines. As a result, bulging is shifted outwardly from the center of this panel toward the bulge lines. It should be noted that the respective bulge lines on opposite sides of the center of the side wall80need not be mirror images of one another as they can be of a different configuration.

In the embodiment ofFIG. 9, the respective bulge lines are such that the distance d is narrower than the distance d inFIG. 7. Again, the respective bulge lines200,202inFIG. 8, like those ofFIG. 7, terminate at the upper right hand corner236of side wall80in the case of bulge line200, and at the upper left hand corner254of side wall panel80in the case of bulge line202. The bulge lines200,202inFIG. 8can be mirror images of one another or they can be different from one another.

InFIG. 10, an example is illustrated in which there more than three upright sub-panels are formed by bulge lines in side wall80when the container is filled. That is, inFIG. 9, bulge lines200,202are provided along with an additional bulge line207. Bulge line207, in this example, curves in an opposite direction to the bulge line200and is positioned between bulge line200and fold line104. As a result, an additional sub-panel215is provided in side wall80when the container is filled, in addition to sub-panels210,212and214. In theFIG. 9example, bulge line200starts at a location231, spaced inwardly from the lower right hand corner230of side wall80. In addition, bulge line202starts at a location233spaced inwardly from the lower left hand corner232of the side wall80. When the container is filled, the lower portion of the container tends to collapse or bulge with the bulge traveling from the corners toward the respective bulge lines200,202at which point the buckling is guided to follow the bulge lines200,202to define the sub-panels. In addition, the bulge line207provides yet another bulge line for the container to bulge along as the container is filled. The bulge line207, in this example, starts at a location253spaced inwardly from the right hand corner230of side wall80and terminates at a location255spaced inwardly from the upper right hand corner236of the side wall80. Another bulge line like bulge line207can be added between the bulge line202and the fold line106. Bulge lines200and202are spaced from the center of the side wall80where the side wall would tend to buckle if no bulge lines were present.

FIG. 11illustrates an embodiment with bulge lines200,202that are not of a curved construction. InFIG. 11, bulge line200starts at the lower right hand corner230of side wall80and extends upwardly at an angle slightly greater than 45 degrees. In addition, bulge line202starts at the lower left hand corner232of the side wall80and extends upwardly at a similar angle to the initial portion of bulge line200. Although schematically shown as being different from one another, desirably the lower portions of the respective bulge lines extend upwardly and inwardly at the same angle and the bulge lines are mirror images of one another. At location281, which is typically 10 to 20 percent above the fold line140, the bulge line200extends vertically upwardly to terminate at a location238along the upper edge241of the side wall80. Similarly, bulge line202angles upwardly to a location283and then extends vertically upwardly to a location256along upper edge241. The construction ofFIG. 11can mitigate the formation of spouts because the center panel212of the sub-panels210,212and214spans the center of the side wall where a spout would tend to form, thereby encouraging bulging at locations spaced from this center. However, the vertical components of the bulge lines200,202do not provide the additional structure achieved by curved bulge lines200,202in the form previously discussed.

The embodiment ofFIG. 12is like the embodiment ofFIG. 11except that the bulge lines200,202are curved at their lower ends instead of the inclined angular construction of the bulge lines200and202ofFIG. 11.

In the embodiment ofFIG. 13, the bulge line200at the lower end is like the bulge line200ofFIG. 10and the bulge202at its lower end is like the bulge line202ofFIG. 10. After reaching respective locations281,283the bulge lines202and204extend vertically upwardly (when the bin is erected) to respective locations285,287. At location285, bulge line200angles to the upper right hand corner236of the side wall panel80. In addition, at a location287, the bulge line202angles upwardly to the upper left hand corner254of the side wall panel80.

FIG. 14illustrates an example where the respective bulge lines200,202start and end at locations spaced from the respective corners of the side wall panel80. Thus, in this embodiment, the bulge line200starts at a location231spaced inwardly and upwardly from the lower right hand corner230of the side wall80and terminates at a location235spaced inwardly and below the upper right hand corner236of the side wall panel80. Similarly, the bulge line202starts at a location233spaced upwardly and inwardly from the lower left hand corner232of the side wall80and terminates at a location237spaced inwardly and below the upper left hand corner254of the side wall80. When the bin ofFIG. 14is loaded, respective sub-panels210,212and214would be formed rather than a centrally located spout.

FIG. 15illustrates an example that includes a lower transverse bulge line203of an arcuate shape extending across side wall80from corner230to corner250. In this example, a sub-panel47is also formed in side wall80as the container is filled. In addition, the sub-panel212is separated from the bottom of the container (fold line140) by the sub-panel217. In this example, three upright sub-panels210,212and214are formed with the center sub-panel212spanning the center of the side wall80. Each of these upright sub-panels extend from a location below the horizontal center line of the combo bin to a location above this horizontal center line.

The examples ofFIGS. 8 through 15are for purposes of illustration as not all of them have been tested and only some of them have even been tested in less than full scale tests.

Turning now toFIG. 16, a container assembly310according to another embodiment is shown. The container assembly310is also adapted to hold contents, such as flowable contents, being transported from a first location to a second location. The container assembly310has a tube portion312and a base portion314. The tube portion312and the base portion314may be made of or comprise corrugated paper board. The tube portion312has bulge control score lines such as described below. The tube portion comprises side walls of the container and can have bulge control score lines of the side walls of any of the above described container side walls. One specific exemplary form of tube312with score lines is described below.

In the illustrated embodiment ofFIG. 16the tube portion312and the base portion314each have an octagonal shape (i.e., eight sides). It is contemplated, however, that the tube portion312and the base portion314can have any suitable shape such as rectangular, square, hexagonal, other polygonal shapes. It is also contemplated that the width W of the side walls can vary, such as set forth above for the side walls (e.g., side wall panels, corner panels and end wall panels) of the in the described containers.

Turning now toFIGS. 17 and 18, plan views of a base blank313and a tube blank315, respectively, for the formation of the container assembly310ofFIG. 16are shown.

Referring first toFIG. 17, a top side345of the base blank313is shown according to one embodiment. The base blank313includes a bottom panel316having a generally octagonal shape (e.g., eight sides318a-h). The eight sides318a-hinclude first and second side wall sides318a,318e, end wall sides318c,318g, and corner wall sides318b,318d,318f, and318h. The bottom panel316includes eight side wall flaps320a-hextending from and integrated with each of the eight sides318a-h. These flaps include side wall forming flaps320a,320e; end wall forming flaps320c,320g; and corner wall forming flaps320b,320d,320fand320h. The corner wall forming flaps320a-hare separated from the bottom panel316by respective fold lines322a-h. The flaps320b,320d,320f,320hextend from the generally diagonal sides318b,318d,318f,318hof the bottom panel316and include opposing tabs324extending therefrom. The opposing tabs324are separated from the remaining portion of the flaps320b,320d,320f,320gby fold lines326. The width W1and height H1of the overall base blank can vary. One specific example is 50½ wide by 58 7/1″ high.

In the embodiment ofFIG. 17, the bottom panel316can further include a collapsible feature327comprising a plurality of perforations and cut-outs. The perforations and cut-outs assist a user in collapsing and disposing of the container assembly310. In the illustrated embodiment, the bottom panel316includes two perforated lines328a,328bthat intersect at or near the center of the bottom panel316. A cut-out “X”330is formed at the intersection point of the perforated lines328a,328b. The bottom panel316further includes tear-out panels331a-dpositioned near the diagonal sides318b,318d,318f, and318hof the bottom panel316. The tear-out panels331a-dare generally bound by a pair of converging perforated lines332a,b,334a,b,336a,b,338a,bgenerally extending from points near opposing ends of each of the diagonal sides318b,318d,318f,318h. Each of the converging perforated lines332a,b,334a,b,336a,b,338a,bterminates in a cut-out line340a,340b. The cut-out lines340a,340bof each pair of converging perforated lines332a,b,334a,b,336a,b,338a,bare joined by a fold line342at one end and by a perforated line344at the opposite end.

When a user desires to collapse the container assembly310(seeFIG. 16), the user may break the perforated lines34(e.g., with his or her fingertips), grasp the tear-out panel such that the fold line342generally contacts the palm of the user's hand, and pull the tear-out panels331aalong the perforated lines332a,b,334a,b,336a,b,338a,b. The user may then push or punch in the center of the bottom panel316at the cut-out “X”330. The bottom panel316and, therefore, the container assembly310, will then be easily collapsed for easy and compact disposal of the container assembly310.

It is contemplated that a collapsible feature other than the collapsible feature327illustrated inFIG. 17can be incorporated into the base blank (e.g. base blank313). It is also contemplated that the base blanks of the embodiments of the present disclosure can also be solid (i.e., not including a collapsible feature, perforations, or cut-outs).

Referring now toFIG. 18, the tube blank315for forming the container assembly310is shown according to one embodiment. The tube blank315includes nine side panels346a-i. These side panels include opposed major side wall panels346a,346eof the greatest width W8, W12, which can desirably be equal; opposed end wall panels346cand346gof respective widths W10and W14, which can desirably be equal and are smaller in with than W8and W12in this example, and corner wall panels346b,346d,346fand are formed by corner wall forming sub-panels346hand346i; the formed corner walls have widths W9, W11, W13and W15+W15less the overlap that are desirably equal and smaller than the width of both the side wall panels and the end wall panels. The side panels346a-iare separated by respective fold lines348a-h. The widths of the side wall panels346a-grespectively correspond to the width of the side walls320a-hof the bottom panel316ofFIG. 17. That is, the side wall panels346a, have widths that allow the assembled tube312to fit within the assembled base310when the container310is assembled with the exterior surfaces of the side walls346a-iabutting the interior surfaces of the adjacent side walls of the base314. That is, the side walls346a,346edesirably abut the interior surfaces of side wall forming flaps320a,320e; the end walls346c,346gdesirably abut the interior surfaces of end wall forming flaps320c,320g; and the corner walls346b,346d,346fand formed by overlapping lower wall forming sections346h,346idesirably abut the interior surfaces of corner wall forming flaps320b,320d,320fand320h. The combined width of the endmost side panels346hand346iin the illustrated embodiment is slightly greater than the width of the side318hof the bottom panel316. Thus, when the container assembly310(FIG. 16) is assembled, the side panels346h,346ioverlap such that they may be readily adhered to one another, such as by using adhesive, fasteners and/or a combination thereof.

As can be seen inFIGS. 16 and 18, the major opposed side wall panels346a,346eare each provided with a respective pair of bulge control lines360b,366bfor side wall panel346aand360a,366afor side wall panel346e. These bulge control lines are like those shown inFIG. 5. However, they can alternatively be like the bulge control lines discussed herein that mitigate or eliminate spouting; such as, for example, as shown and described in connection withFIGS. 6-15 and 22-24.

In the embodiment ofFIG. 18, the tube blank315can be made of a single-wall corrugated fiberboard and can include internal reinforcement in the form of a plurality of internal straps350a-dpositioned between one of the liner boards and the fluted or corrugated material. The internal straps350a-dmay be formed of sesame tape or any other suitable material. It is also contemplated that a different number (i.e., none, one, two, three, or more than four) of internal straps may be used for the tube blank315. Alternatively, external straps can be used.

The tube blank315ofFIG. 18, as well as the container blank ofFIG. 5can comprise a plurality of bag holding structures for retaining the upper ends of a liner bag in place in the container. An example of one form of bag holding structure is indicated at376ainFIG. 18. This structure is formed by a diamond shaped pattern of intersecting fold lines378,380,382and384with cuts extending between the intersecting corners of the fold lines to form a cross-shaped cut within the fold lines. An upper portion of the liner can be inserted into the cut and is retained therein by the cut edges. Other alternative forms of bag retaining structures can also be used.

The container assembly310ofFIG. 16can be assembled using the base blank313ofFIG. 17and the tube blank315ofFIG. 18. To do so, the tube blank315can be formed into an octagonal shape such that the endmost side panels346h,346iare aligned and at least partly overlap with one another with enough of the side panels346h,346inot overlapping so as to form a wall of the tube312. The overlapping portions of the endmost side panels346h,346imay then be attached to one another using any suitable means such as adhesive. The resulting tube portion312is shown inFIGS. 16 and 19.

To form the container assembly310ofFIG. 16, the assembled tube portion312is placed over the bottom panel16of the base blank313(FIG. 17) such that each of the side panels346a-gof the tube portion312is adjacent to each of the respective flaps320a-gof the base blank313. The overlapping side panels346h,346iare adjacent to the flap320hin this example. In one embodiment, adhesive can be placed on the top sides345of the flaps320a-hand the tabs324. Each flap320a-his then folded toward the tube portion312along its respective fold line320a-hsuch that the adhesive top sides345of the flaps320a-hcontact and adhere to the respective side panels36a-i. The tabs324are then folded along their respective fold lines326and adhered to the adjacent side panels346of the tube portion312. As shown inFIG. 19, for example, the tabs324of the flap320bare adhered to the side panels346a,346c. The flaps320a-hcan alternatively be folded prior to placing the tube portion312over the base portion310and adhesive can be applied to the outer surfaces of the tube portion so that the base portion and tube portions are fastened together after the tube portion is inserted into the base portion and the adhesive dries.

The resulting double thickness of the base reinforces the corners and vertical scores of the container assembly310. The integrity of the lower portion of the container assembly310is, thus, significantly reinforced.

Reduced Scale Test Results

The term combo or combo bin refers to large-scale bins or containers, such as that can fit a standard palette. The features disclosed herein are not limited to large-scale bin applications. However, the features provide greater benefits in applications where the contents of the bin apply substantial hydraulic forces side walls of the bin.

The contents of meat combining combos are generally flowable. The level of flowability is determined by the leanness of the product. The leaner meat (less fat) tends to be more flowable. The flowability does not appear to be a linear progression as meat greater than 70% lean (beef) tends to hold a significant quantity of purge, making the contents more flowable and subject to significant hydraulic forces. Other products in addition to meat have a liquid content that in effect make them flowable.

Testing Approach

Most of the examples below were explored at half scale (some in ⅔rds or repeated in ⅔rds scale). In half scale the total water weight was 235 lbs roughly a factor of 8 less than typical combo container content weights. The paper board used in the examples varied from 44ECT C-flute to 32ECT (33-26-33) B-flute. The 32ECT B-flute has a bending factor of roughly 10 less than corrugated paper board used in a typical combo container (e.g. 31 SP4+) When ⅔rds scale was used the content weight was a factor of 4 less (500 pounds) than typical full size combo container content weights.

The testing process was the following:

1. CAD cut, erect and palletize the sample container

2. Fill one-eighth to one-fourth full and measure top profile

3. Fill to 250/500 pounds depending on scale

4. Measure top profile without moving

5. Transition to outside and set down (move the pallet with the loaded container)

6. Measure top profile

7. If the results were favorable, commence hydraulic sequencea. Up and down movements on fork truck

8. Measure final upper profile

This was the basic procedure used in the reduced small scale testing.

Development Work and Results

In the sketches below (with a few exceptions) the black outline or border represents the basic outline of the widest side panel of a combo bin (or in one case a cutline) while the interior lines (inside the border) indicate a scoreline or bulge control line. The term scoreline or bulge control line refers to a compression line formed in the container side wall panel along which the combo bin is encouraged to fold under pressure, such as hydraulic pressure. If there are no interior lines then the illustrated combo bin side wall panel has no bulge guiding lines or control lines. In the sketches below, the top of the side wall is at the upper end of the sketch and the bottom of the side wall is at the lower end of the sketch. The corrugations extended vertically in these examples. The term spouted indicates a failure of the test to contain bulging of the side wall to desired levels (the formation of a spout). The two opposed major (largest width) side wall panels of the test combo bins were provided with the same bulge control lines (if bulge control lines were present). The other side wall panels of the combo bins had no bulge control lines.

In the test embodiments ofFIGS. 19 and 20, no bulge control lines were included in the major side wall panels. InFIG. 19, the aspect ratio is twelve units wide by nine units high. InFIG. 20, the aspect ratio was ten units wide by twelve units high. The aspect ratios in the major side wall panels of the test embodiments ofFIGS. 21 through 30was also ten units wide by twelve units high. The side wall panels inFIGS. 19 and 20test embodiments both spouted.

In the test embodiment ofFIG. 21, no bulge control lines were provided in the major side wall panels. However, two sets of three straps were positioned along a lower portion of the container and one set of three straps was positioned along an upper portion of the container. This test embodiment also spouted, although spouting was delayed.

In the test embodiment ofFIG. 22, two arcuate bulge control lines were placed in the major side wall panels. These bulge control lines were symmetric about the center of the side wall panels and were each convex relative the closest side edge of the side wall panel. The bulge control lines of this test embodiment extended from the bottom edge to the top edge of the major side wall panels. The result was no spouting.

In the test embodiment ofFIG. 23, bulge control lines like those in the test embodiment ofFIG. 24were used. In addition, short bulge control lines extending vertically upward (about two and one-half units) from the bottom of each of the centrally positioned bulge control lines were added. This embodiment also did not exhibit spouting. However, the vertical bulge control lines were not observed in this test to provide any observable benefit. However, during testing bulge control lines that had vertical sections were found to be less beneficial than those that were entirely curved.

In the test embodiment ofFIG. 24, the major side wall panels included two arcuate bulge control lines that each were convex relative to the closest side edge of the panel. The bulge control lines each started at a respective lower corner of the side wall panel and converged until the middle section of the panel and then diverged. The distance between the upper ends of the bulge control lines at the upper end of the side wall panel was less than the distance between the bulge control lines at the upper ends of theFIG. 22test embodiment. The result of this test was no spouting. It was observed that having a bulge control line originating at the lower corners provided a greater resistance to spouting.

In theFIG. 25test embodiment, the bulge control line was trapezoidal and extended from the upper edge of the container to a location above the center of the container. This test embodiment also resulted in spouting.

In theFIG. 26test embodiment, the bulge control line was V shaped and positioned above the center of the container. This embodiment resulted in spouting.

In theFIG. 27test embodiment, the bulge control line was parabolic (an upward smile shape) and positioned above the center of the container. This test embodiment resulted in spouting.

In theFIG. 28test embodiment, the bulge control line was horizontal and positioned above the center of the container. This design also resulted in spouting.

In theFIG. 29test embodiment, the container also spouted. However, it nearly worked to eliminate spouting. By extending one or more of the vertical bulge control lines to the upper end of the container, or to a location adjacent to the upper end of the container, this test embodiment is expected to eliminate spouting.

The test embodiment ofFIG. 30used a small parabolic bulge control line positioned above the center of the major side wall panels. This embodiment

The test embodiment ofFIG. 31used a u-shaped rectangular bulge control line with vertical legs extending downwardly from the upper edge of the major side wall panels and a horizontal bulge control line extending between the legs at a location one unit from the upper side wall edge. This test embodiment also resulted in spouting of one of the major side wall panels, while the other broke to the ends of the side wall flap defined by the bulge control line.

Observations

The break in the side wall panel that results in a spout happens very abruptly. Therefore, any likely solution needs to cause the panel to break or crease in its intended location early on.If the panel hasn't broken along a bulge control line by half fill; any break will likely find its own path rather than proceed along a defined bulge line.Even with a score located in a side wall panel, if a break occurs after the container is half filled, it seems that the break is so abrupt and violent that the break often will not find a bulge line.The break, while almost instantaneous, seems to originate at the top and shoot down a container side wall panel. This inherently makes sense as the top of the container has no structure to restrain it in the test examples.TheFIGS. 22, 23 and 24combo bin examples seem to work because they never really have a stress build up as the side walls start to bulge early on and along the pre-defined path. It appears that if you can get the panel to start to bulge in an intended way early as the combo bin is filled, the bending along the bulge control lines is controllable (handling forces not included).

Throughout this disclosure, when a reference is made to a first element being coupled to a second element, the term “coupled” is to be construed to mean both direct connection of the elements as well as indirect connection of the elements by way of one or more additional intervening elements. Also, the singular terms “a”, “and”, and “first”, mean both the singular and the plural unless the term is qualified to expressly indicate that it only refers to a singular element, such as by using the phase “only one”. Thus, for example, if two of a particular element are present, there is also “a” or “an” of such element that is present. In addition, the term “and/or” when used in this document is to be construed to include the conjunctive “and”, the disjunctive “or”, and both “and” and “or”. Unless otherwise expressly indicated, the term “or” shall have the same meaning as “and/or”. Examples are described with reference to directions indicated as “above,” “below,” “upper,” “lower,” “top”, “bottom”, and/or the like. These terms are used for convenient description, but do not imply or require any particular spatial orientation. For example, a wall panel described as having an upper and lower edge would be oriented in use with the upper edge of the panel above the lower edge. If the orientation is changed (e.g. a box blank is rotated) such that the lower panel edge is above the upper panel edge, the panel still has the upper edge, even though it is then oriented in a lower position. A location or component is adjacent to a top or bottom edge of a wall panel if it is within ten percent of the greatest distance between the top and bottom edges of the wall panel. The term “about” with reference to a value or characteristic shall mean within plus or minus ten percent of the value, unless otherwise expressly stated. Also, the terms “includes” and “has” have the same meaning as “comprises” and the terms “including” and “having” have the same meaning as “comprising”.

Having illustrated and described the principles of this invention with reference to exemplary embodiments, it should be apparent to those of ordinary skill in the art that the embodiments may be modified in arrangement and detail without departing from the principles of this invention. All such modifications are encompassed in this disclosure.