Bin loader package and method

A bin loader package for shipping, storing and dispensing cut paper directly into the paper supply bin of equipment that uses the paper. The bin loader package comprises a box having opposite side walls, opposite end walls, a top and a bottom. The bottom includes foldable flaps that are foldable inwardly at least partially over the bottom of the box for supporting at least a marginal edge portion of sheets of paper placed in the box. The top includes foldable flaps that are foldable over the top of the box to close the top of the box, and the top wall flaps include structure to facilitate grasping of the top wall flaps to lift the box when it is desired to discharge the paper therefrom. The bottom wall flaps are unsecured to one another and are openable under the weight of paper in the box when the box is lifted, to enable the paper to drop through the open bottom for deposit onto a supporting surface, whereby the paper may be directly deposited from the box into a paper supply bin by simply lifting the box away from the paper. In one form of the invention, the bottom flaps are relatively narrow and do not close the bottom of the box. In another form of the invention, the bottom panels are dimensioned to close the bottom of the box when they are folded to their closed position. The Box may be treated to incorporate a moisture vapor barrier therein.

FIELD OF THE INVENTION 
This invention relates to packaging, and more particularly, to a package 
and method for rapidly loading cut paper into the bin of a photocopier, 
printer, or similar machine. The invention is especially adapted for 
rapidly loading large quantities of cut paper into the bin of high-speed 
photocopying machines, printers, and the like which typically use large 
quantities of paper over short periods of time. 
BACKGROUND OF THE INVENTION 
Photocopiers, printers and like equipment are in widespread use in 
commercial and office environments. Such equipment generally has a 
compartment or bin in which a stack of sheets of paper is placed for use 
by the machine during its operation. 
The paper for use in such machines has generally been packaged in 
individual reams covered with a ream wrap material to assist in 
maintaining the proper condition of the paper, and the wrapped reams are 
then placed in a cardboard or similar box for shipment and storage. When 
the need arises for loading paper into a photocopier, printer or the like, 
a box is opened and one or more reams of paper are removed from the box, 
the ream wrap removed, and the paper placed in the bin or other 
compartment of the machine for supplying paper to the machine during its 
operation. 
This manner of packaging paper for use in such machines has not posed a 
problem for relatively low volume, low speed machines, since such machines 
typically hold only one or two reams or even less paper, and use it 
relatively slowly. However, relatively high speed, high volume 
photocopiers, printers and similar machines have come into more widespread 
usage, and these machines generally have relatively large paper holding 
capacities in order to provide an adequate supply for the greater rate of 
use due to their higher speed of operation. In spite of the large paper 
holding capacity of such machines it may be necessary to frequently 
replenish the supply of paper in the bin. With conventional packaging, it 
can take considerable time to open the box and then remove and open 
individual reams of paper so that the paper can be stacked one ream at a 
time in the supply bin of the machine, which may typically hold five or 
more reams of paper. 
Efforts have been made to solve this problem, as exemplified by U.S. Pat. 
Nos. 4,556,210, 4,770,301, 4,802,586 and 4,830,186. These patents disclose 
various packaging concepts for loading large quantities of paper into the 
supply bin of a photocopy machine without the necessity of opening 
individual reams of paper. In these patents, the carton or package in 
which the paper is supplied is placed on the elevator platform of the 
supply bin in the photocopier or other machine and the carton is then 
manipulated so that it can be removed from the bin, leaving the paper 
stacked on the platform. All of these patents (except U.S. Pat. No. 
4,830,186) involve fairly complex box constructions, and require lateral 
movement of box components away from the bin of the machine. In other 
words, the packages described in these patents are essentially side 
discharge packages. Moreover, the complexity of their construction adds 
substantially to the cost of the package and the difficultly of use. Thus, 
while the prior art packages enable a large quantity of paper to be 
stacked in the supply bin of a photocopier or similar machine without 
requiring individual reams of paper to be opened, the prior art devices 
require substantial manipulation of the package itself, thereby at least 
partially offsetting the advantages gained by eliminating he need to open 
and handle individual reams of paper. 
Accordingly, there is need for a simple and inexpensive package which 
enables a large quantity of paper to be quickly and easily supplied to the 
paper supply bin of a photocopier or printer or other machine, without the 
necessity of handling individual reams of paper. 
SUMMARY OF THE INVENTION 
The present invention provides an exceptionally simple and economical 
package for shipping, storing and dispensing paper into the paper supply 
bin of photocopiers, printers and the like. 
The basic concept of the invention is to provide a single stack of loose 
sheets of paper in a box sized roughly for the capacity of the supply bin 
of a photocopier, printer, or similar machine. The box includes an 
unsecured bottom wall that is supported during shipping and handling by 
temporary support means applied to the box. When it is desired to transfer 
the paper from the box to the supply bin of a photocopier or the like, the 
package is set in the bin and the temporary supports removed, after which 
the box is simply lifted out of the bin, with the unsecured bottom opening 
to deposit the paper onto the elevator platform of the bin of the machine. 
The unsecured bottom comprises inwardly folded flaps on the bottom edges 
of the side and end walls of the box, with the paper being supported on 
these flaps prior to lifting of the box to discharge the paper from it. 
In a preferred form of the invention, the flaps forming the bottom wall are 
relatively narrow so that they support the paper only at a peripheral 
margin thereof. In this form of the invention, when the box is lifted to 
deposit the paper onto the platform of the supply bin of the photocopier 
or other machine, the paper drops only a very short distance as the flaps 
are moved to their unfolded or open position by the weight of paper 
contained in the box. In order to protect the paper during shipping and 
handling and to prevent premature discharge of the paper from the package, 
shrink wrap is applied to the box and at least one support strap is placed 
around the box to hold the flaps closed and to keep the paper in place in 
the box. 
In another form of the invention, a false bottom or panel is placed in the 
bottom of the box and is supported on the inwardly folded narrow marginal 
flaps, with the paper being supported, in turn, on this panel. In use, the 
temporary supports are removed from the box and when the box is lifted the 
narrow flaps unfold or open up and the bottom panel and paper supported 
thereon are deposited on the platform of the supply bin of the machine. 
This panel may then be slid out from under the paper, if desired. Further, 
in this form of the invention the box and false bottom or panel may be 
treated with a moisture vapor barrier material to maintain proper moisture 
content in the paper stored within the box. In this embodiment, a shrink 
wrap or other means of maintaining proper moisture content in the paper, 
such as ream wrap on individual reams of paper, is not necessary. 
In another form of the invention disclosed herein, the flaps forming the 
unsecured bottom are relatively wide and essentially close the bottom of 
the box when they are folded to their closed position. Since the bottom of 
the box in this form of the invention is completely closed by the flaps, 
there is no need for a false bottom or interior panel. The box may be 
treated with a moisture vapor barrier material, or other means may be 
provided to maintain proper moisture content in the paper stored within 
the box. 
In all forms of the invention, dispensing of the paper into the supply bin 
of a photocopier or other machine is easily accomplished simply by lifting 
the package into the supply bin, removing the temporary supports which 
maintain the package closed, and then lifting the carton or box out of the 
bin, depositing the paper onto the platform of the bin. 
The box of the invention may be made of any suitable material, including 
cardboard, paperboard, plastic, or other material, as desired. Moreover, 
the package of the invention may be made in any desirable size for holding 
an appropriate quantity of paper to fill the bin capacities on various 
photocopiers, printers and other machines that may be used. It is 
contemplated, however, that the paper capacity of the package according to 
the invention will range from about 1,500 sheets up to about 2,500 sheets.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
Referring more specifically to the drawings, a first form of bin loader 
package according to the invention is indicated generally at 10 in FIGS. 
1-9. The package according to this form of the invention comprises a 
rectangularly shaped box 11 having opposite side walls 12 and 13 and 
opposite end walls 14 and 15. 
The upper end of the box is closed by a bellows-folded top wall 16 defined 
by flaps 17, 18, 19 and 20 integrally formed on the upper ends of the side 
and end walls, respectively. As seen best in FIGS. 3-5 and 7-9, 
bellows-folded end flap 19 is defined by a pair of diagonally extending 
fold lines 21 and 22 extending from the opposite corners of the upper end 
of the end wall 14 to approximately the center of the upper free edge of 
the flap 19, defining three triangularly shaped contiguous panels 19a, 19b 
and 19c. 
Similarly, bellows-folded end panel 20 is defined by a pair of diagonally 
extending fold lines 23 and 24, defining three triangularly shaped 
contiguous panels 20a, 20b and 20c. 
The panels 17, 18, 19, and 20 forming the bellows-folded top wall 16 are 
joined to the upper edges of the box side walls 12, 13, 14 and 15, 
respectively, along a fold line 26 extending the entire length of the 
blank B from which the box is made (see FIG. 9). The top wall panel flap 
18 comprises two half panels 18a and 18b that are joined together at 
approximately their midpoint along a manufacturers seam 27 that joins the 
two ends of the blank together in the erected box and comprises the only 
glue joint in the box. Similarly, and with reference to FIG. 9, it will be 
observed that the side wall 13 also comprises two half panels 13a and 13b 
that are joined along the manufacturers seam 27 to form the side wall 13 
in the erected box. 
With further reference to FIG. 9, it will be noted that the panels 17-20 
which form the top wall 16 extend upwardly beyond the fold line 26 a 
distance "d.sub.1 " that is approximately one half as great as the width 
"w" of the end panels 14 and 15. Thus, when the panels forming the top 
wall are folded inwardly over the upper end of the box, the free edges of 
opposite side panels 17 and 18 come into close proximity or contiguous 
relationship with one another, effectively closing the upper end of the 
box. See FIG. 1. 
A plurality of holes or openings are formed at predetermined locations in 
the panels that define the top wall 16, for a purpose to be described 
hereinafter. These holes or openings include an opening 28 adjacent the 
inner upper corner of half panel 18a, and a corresponding opening 29 
adjacent the free upper edge of panel 17 near one end thereof. These 
openings are positioned such that in the erected box the openings 28 and 
29 are disposed near opposite ends of the box, respectively, and on 
opposite sides of the longitudinal centerline thereof. See FIGS. 1 and 3. 
A pair of openings are also formed in each top end flap 19 and 20, 
respectively, including an opening 30 in panel 19a and an opening 31 in 
panel 19b, as well as corresponding openings 32 and 33 in panels 20a and 
20b, respectively. 
The bottom of the box is defined by four relatively narrow marginal flaps 
or flanges 35, 36, 37 and 38, joined to the side wall panels along a fold 
line 39 which extends the entire length of the blank B forming the box 
(see FIG. 9). 
As seen in FIG. 9, these bottom flaps extend beyond the fold line 39 a 
distance "d.sub.2 " that is substantially less than the distance "d.sub.1 
" at the top flaps forming the top wall of the box. 
Thus, and with reference to FIG. 2, it will be observed that the bottom 
flaps 35-38 extend inwardly over only a marginal edge portion of the 
bottom of the box. 
Since the bottom of the box is not closed in this form of the invention, 
and does not include interlocking bottom panels to form a load bearing 
bottom wall, the package is held closed by one or more tie straps 40, 41 
wrapped around the box in a lateral and/or longitudinal direction. As 
illustrated herein, one specific form of the invention includes a pair of 
tie straps 40 and 41 wrapped laterally around the box, spaced 
approximately equidistantly along its length. These tie straps serve to 
hold the bottom of the box closed and retain the sheets of paper "S" in 
the box until ready for use. 
Because of the relatively large opening left in the bottom of the box in 
this form of the invention, a shrink wrap 42 is applied around the box to 
protect the paper therein from ambient conditions. 
In use of this form of the invention, the package is prepared by placing a 
quantity of sheets of paper "S" in the box 11 and securing the box closed 
with one or more straps 40, 41, after which the box is shrink-wrapped with 
a suitable material to protect the paper from the environment. For 
example, a polyethylene film may be used to shrink wrap the box. The box 
may then be shipped and stored until it is ready for use. When it is 
desired to supply paper from the box to the bin of a photocopier or other 
machine, the shrink wrap 42 is removed and the box is carried to the 
machine. If desired, the box may be lifted by grasping the straps 40 and 
41. Insertion of the fingers under the straps may be facilitated by the 
openings 28 and 29, which are disposed in at least partially underlying 
relationship to the straps 40 and 41. 
The box is lifted onto the elevator platform "P" in the paper supply bin of 
a photocopier or other machine, and the support straps 40 and 41 are cut 
and removed, as depicted in FIG. 3. The top wall panels 17 and 18 are then 
pivoted upwardly to an open position and the index and middle fingers of 
each hand may be inserted into the respective openings 30-31, 32-33 in the 
opposite top end wall panels 19 and 20, respectively, to lift the box from 
the stack of paper "S", depositing the paper onto the platform "P" as 
depicted in FIGS. 4, 5 and 6. 
It will be seen that manipulation of the box of the invention is relatively 
simple, and a minimal number of steps and minimum effort are required to 
remove the box to deposit the entire contents thereof in the paper supply 
bin of a photocopier or other machine. The relatively narrow width of the 
bottom wall flaps 35-38 ensures that the box may be relatively easily 
removed, and the paper will drop only a short distance as the box is 
lifted away from the paper. For instance, in a preferred embodiment of the 
invention the bottom wall flaps 35-38 have a dimension "d.sub.2 " from the 
fold line 39 to their free edges of only one and one half inches, as 
compared with a width "d.sub.1 " of approximately 45/16 inches at the top 
wall flaps 17-20. The box may have any suitable height, width and length 
dimensions, h, w, and l, respectively, as suitable or desired for a 
particular quantity of paper or paper size to be packaged in the box. 
The box may be made of a corrugated material, such as B, E or F-flute, for 
example, with Kraft paper liners having a basis-weight ranging from 33 
pounds to 42 pounds, and 26 pound mediums. The burst strength of the box, 
in a preferred embodiment, may range from 150 pounds to 200 pounds, and 
the box may be sized for any capacity, e.g., 1500-2500 sheets. Further, 
the box may be provided with a suitable moisture vapor barrier, e.g., a 
laminated liner, a coated liner, a plastic wrap, or an insert at the top 
and/or bottom sheets. The moisture vapor barrier material may be any 
suitable material, including a film-forming emulsified material that forms 
a close-grained crystal structure which is hydrophobic upon curing. A 
repulpable coating with water vapor barrier properties may also be formed 
from available dispersions such as acrylates and the like. Further, the 
moisture barrier may comprise a layer of polyethylene extruded onto or 
otherwise applied to paper. A specific construction comprises a lamination 
of low density polyethylene (LDPE) and Kraft paper applied as the inner or 
outer lining of the box. Although polyethylene forms an effective moisture 
barrier, it is not readily recyclable. 
First Modification 
A first modification of the invention is indicated generally at 50 in FIGS. 
10-14. This form of the invention is substantially identical to that 
described in relation to FIGS. 1-9, except that a bottom wall panel 51 is 
provided in the bottom of the box 11 to close the opening left by the 
relatively narrow marginal bottom flaps 35-38. Bottom panel 51 has a small 
pull tab 52 formed on one edge thereof in a position to lie within the 
space 53 defined between the edge of the stack of paper "S" and the side 
wall 13 of the box caused by the overlapping manufacturers seam 27 in the 
side wall 13. 
In all other respects, this form of the invention is identical to that 
previously described, and the same comments apply with respect to box 
dimensions and the manner of use, with the exception of the elimination of 
the use of shrink wrap and the use, instead, of a bottom panel to close 
the bottom of the box. 
Thus, when the box is lifted from the stack of paper in the manner as 
described in relation to that from of the invention illustrated in FIGS. 
1-9, the bottom panel 51 remains in place beneath the stack of paper "S" 
after the paper has been deposited onto the platform "P" in the supply bin 
of the photocopier or other machine, and the tab 52 is exposed at one 
side, whereby it may be grasped and pulled to remove the panel 51 from 
beneath the stack of paper, as depicted in FIGS. 13 and 14. 
It should be noted that the provision of the bottom panel 51 eliminates the 
necessity of utilizing shrink wrap as is done in the previously described 
form of the invention, if a moisture vapor barrier material is 
incorporated in the walls of the box itself, including the panel 51. 
Further, one or more support straps 40, 41 may be placed in encircling 
relationship to the box, either in a lateral or longitudinal direction, or 
both, to maintain the box closed until it is desired to dispense the paper 
therefrom. 
Second Modification 
A second modification of the invention is indicated generally at 60 in 
FIGS. 15-18. This form of the invention is substantially identical to that 
described in relation to FIGS. 10-14, and includes a bottom panel 61 which 
fits closely within the side walls of the box 11 and lies on top of the 
bottom wall flanges 35-38. However, unlike the previously described form 
of the invention, there is no pull tab on the bottom wall panel 61. 
Instead, after the box 11 has been removed from the stack of the paper "S" 
to deposit the paper onto the platform "P" of the supply bin of a 
photocopier or other machine, the bottom panel 61 simply remains in place 
beneath the stack of paper. 
In all other respects, this form of the invention is identical to that 
described immediately above. 
Third Modification 
A third modification of the invention is indicated generally at 70 in FIGS. 
19-26. This form of the invention functions similarly to the previously 
described forms of the invention, but differs essentially in that the 
bottom wall 71 completely closes the bottom end of the box and is defined 
by a bellows-folded set of flaps substantially identical to those used in 
forming the top wall 16. Thus, a pair of bottom wall side panels or flaps 
72 and 73 are formed at the bottom edges of side walls 12 and 13, 
substantially identical in size and shape to the top wall flaps or panels 
17 and 18, respectively, except that the openings 28 and 29 that appear in 
the top wall panels are omitted in the bottom wall panels. Similarly, 
bottom end wall panels or flaps 74 and 75 are formed at the bottom edges 
of end walls 14 and 15, respectively, substantially identical in size and 
shape to the top wall panels or flaps 19 and 20 at the tops of the end 
wall panels, respectively, except that the openings 30-31 and 32-33 that 
appear in the top end wall panels are omitted from the bottom end wall 
panels. 
Flap 74 includes a first triangularly shaped panel 74a at the center of the 
flap and second and third triangularly shaped panels 74b and 74c, 
respectively, on opposite sides of the center panel. The center panel has 
its base edge joined to the end panel 14 along fold line 76, and the side 
panels are joined to the center panel along diagonal fold lines 77 and 78, 
respectively. 
Similarly, bottom end flap 75 comprises a center triangularly shaped panel 
75a with its relatively wide base end lying on the fold line 76, and a 
pair of triangularly shaped side panels 75b and 75c joined to the center 
panel along diagonal fold lines 79 and 80. 
Further, a vertically extending glue tab 81 is formed along one end edge of 
the blank B1, at the free edges of side panel 12 and top and bottom side 
panels 17 and 72. 
With reference to FIGS. 20-25, the bottom wall 71 is folded similarly to 
the way in which the top wall 16 is folded, whereby the opposite bottom 
side wall flaps 72 and 73 are folded over the bellows-folded end panels 74 
and 75, with the free edges of panels 72 and 73 lying in contiguous 
relationship to one another when in the fully closed position, and with 
the triangularly shaped panels 74a and 75a disposed internally of the 
bottom of the box. Thus, when the support straps are removed, the weight 
of the paper acts primarily upon panels 74a and 75a to move those panels 
downwardly and outwardly relative to the bottom of the box, causing the 
side panels 72 and 73 to also unfold as the box is lifted, so that the 
weight of the paper will cause the bottom wall to unfold and open up to 
discharge the paper onto the platform "P" of the photocopier or the like. 
As with those forms of the invention described above which utilize a bottom 
panel in the box, this form of the invention does not require the use of 
shrink wrap, but a moisture vapor barrier material may be incorporated 
into the box itself to provide protection to the paper from ambient 
conditions. Of course, shrink wrap could be used instead, if desired. 
It will be seen from the above that the present invention provides a very 
simple and economical package for shipping, storing and dispensing cut 
paper into the supply bin of a photocopier or printer or other machine. 
Further, the use of a single glue seam in the manufacture of the box 
greatly simplifies the manufacturing process and contributes to the ease 
of recycling. 
While particular embodiments of the invention have been illustrated and 
described in detail herein, it should be understood that various changes 
and modifications may be made to the invention without departing from the 
spirit and intent of the invention as defined by the scope of the appended 
claims.