CONTAINER FOR BULK MATERIALS

Abstract: A container (10) includes upper (11) and lower (12) shells attached by a connector (39). Corner columns (40, 61) are formed between walls (26, 28, 30; 46, 63, 64). Spaced ribs (42, 70) extend inwardly from the walls (26, 28, 30; 46, 63, 64) to support an internal bottle (13). The bottle (13) has a valve (59) exposed through opening (58) in wall (46). A valve access door (143) is operable to close the opening (58). A lug (160) and notch (150) maintain the door (143) open. The bottom surface (74) of the container (10) is provided with drainage channels (78-81) sloped toward a drain hole (82). Foot assemblies (14) include crushable foot members (118) filled with a foam block (119) and have breakable tabs (104-108, 110-112, 114, 115) which can be attached to the bottom surface (74). When a load is applied to the container (10), the tabs (104-108, 110-112, 114, 115) will break and the foam will crush to absorb the energy and protect bottle (13). The top surface (15) of the container (10) has flat ledges (21) of the same profile as the foot members (118) so that the container (10) can be stacked on a like container.

Description: CONTAINER FOR BULK MATERIALS TECHNICAL FIELD This invention generally relates to a container of the type which iβ particularly suited to carry bulk liquid or solid materials. More particularly, this invention relates to such a container wherein a rigid plastic shell may safely hold a plastic bottle, bag or similar container therein which, in turn, holds the bulk material. BACKGROUND ART Traditionally, the transportation of extremely large quantities of bulk liquids or solids has been accomplished by tanker trucks or the like whereas smaller quantities thereof have been shipped or transported in the conventional 55-gallon drum. While such drums have for years been the benchmark for small quantity bulk material containers, such are not without their problems. Such is particularly the case where intermediate quantities of material, that is, more than 55 gallons and less than a tanker truck quantity, are desired to be stored and/or shipped. In addition to their weight and the tendency to leak, dent, and corrode, one of the primary concerns regarding the 55-gallon drum relates to the costs of handling, using, and disposing of the same. For example, if in excess of 300 gallons of bulk material is desired, six 55-gallon drums must be separately filled, shipped, and then handled by the user. Dispensing of the material is not easy in that the container must be tipped and/or inverted to do so or a suitable pumping apparatus must be employed. Upon emptying, such drums must then be cleaned for re-use and often, upon opening a drum believed to be empty, the user finds a small quantity of remaining material therein which not only becomes wasted but which also compounds the cleaning problem and increases the attendant costs. Then the drums must usually be shipped for refilling, and since they take up as much space empty as filled, and since their cylindrical configuration wastes space when positioned side by side, return shipping costs are amplified. Finally, the life of such drums is such that disposal is required oftentimes after one use and certainly after no more than four uses. Aβ such, unless the drums are cleaned, land fills will be loaded up with the remnants of possibly hazardous material, thereby incurring the potential for long-term, open-ended liability. In an effort to solve at least some of these problems, recently some bulk containers have been introduced which have become known in the trade as intermediate bulk containers because they are capable of holding more material than a 55-gallon drum, but much lesβ than a tanker truck. Typical of βuch containers are the types which include a plastic bottle-like tank which is received within a heavy metal cage or multi-walled corrugated box for structural support, carbon or stainless steel vessels, or containers having a high density polyethylene outer frame which supports a high density polyethylene bottle. While being capable of providing more volume than the 55-gallon drum, most of βuch containers are still heavy and difficult to clean and do not adequately protect the bottle in the event a container is dropped. Moreover, in most instances, there is no way for the user to be certain that the contents thereof have been completely depleted and as in the case of the 55- gallon drum, quite often when the container iβ opened, some remaining material is found therein. In addition, most of these containers are quite expensive and are not designed for easy access, disassembly, easy cleaning, and hence long-term reuse. The metallic prior art versions can easily become corroded due to paint chips and aggressive environments, thereby engendering high reconditioning and/or replacement costs. On the other hand, the plastic prior art versions tend to bulge under full conditions, giving at least the appearance of weakness. Finally, all of such containers are quite heavy when in the empty condition and cannot be readily stacked when in the full condition, thus making their shipment, either full or empty (for refilling) a costly procedure. DISCLOSURE OF THE INVENTION It is thus an object of the present invention to provide a light-weight, lower cost, reusable bulk container of an intermediate size, being capable of holding a quantity of material of several 55-gallon drums. It is another object of the present invention to provide a container, as above, in which a plastic shell can hold a plastic bottle, bag or the like which holds the bulk material. It is a further object of the present invention to provide a container, aβ above, in which the bottle iβ safely held even if the container is dropped. It is an additional object of the present invention to provide a container, as above, which utilizes rib structures for strength as well as to confine the bottle, while at the same time allowing for bottle expansion between the ribs during dropping or high temperature conditions. It is yet another object of the present invention to provide a container, as above, in which the housing is of a modular or split design for ease of manufacture and versatility, and yet the split frames can be readily attached together by a mechanism which also adds hoop strength to the container. It is a still further object of the present invention to provide a container, as above, in which the housing provides acceββ to a drain valve at the bottom of the bottle and yet the valve iβ protected from damage. It iβ another object of the present invention to provide a container, as above, which has corner columns and energy-absorbing, systematically crushable feet to absorb the energy of a drop or fall. It iβ a further object of the preβent invention to provide a container, aβ above, in which the housing has a drainage passage should the bottle overflow or leak a fluid that it might be carrying. It is an additional object of the present invention to provide a container, as above, which can be stacked, up to at leaβt three high, even when filled with a bulk material. It iβ still another object of the present invention to provide a container, aβ above, which iβ easy to clean, able to withstand high temperatures, and can resist most aggressive chemical compositions. These and other objects of the preβent invention, as well as the advantages thereof over existing prior art forms, which will become apparent from the description to follow, are accomplished by the improvements hereinafter described and claimed. In general, a container made in accordance with the concepts of the present invention has several unique features. In accordance with one aspect of the present invention, the container includes a bottom βurface and walls extending upwardly therefrom. A plurality of foot assemblies support the bottom surface, each foot assembly including a hollow foot having a plurality of breakable tab members extending upwardly therefrom. A crushable foam block iβ positioned in the hollow foot and selected of the tab members are connected to the bottom βurface so that when a load is applied to the container, the tab members will break and the foam will crush to absorb the energy of the load and protect the contents of the container. Those contents can include a flexible internal bottle to hold a liquid material. The bottle includes a valve assembly, access to which is gained through an opening in one of the walls. A door may be provided to selectively open and close the openings, and means are provided to hold the door in an open position. In accordance with another aspect of the preβent invention, a top βurface connecte the top of the walls and corner columns extend from the top to the bottom of the container between each of the walls to provide extraordinary structural strength to the container. Strength iβ alβo provided to the container by rib structures provided throughout. For example, spaced ribs extend inwardly from the wallβ not only to provide strength, but alβo to support the flexible bottle. The bottle is also thereby able to expand into βpaceβ between the ribs should it be overfilled or expand due to high temperatures or a shock to the container. The bottom βurface of the container may be provided with a plurality of drainage channels formed on the inside thereof. All of the channels are sloped toward a drain hole βo that any liquid in the container may pass through the drain hole, as desired. The top surface of the container, while otherwise irregularly shaped, may be provided with flat ledges of a predetermined profile formed at the corners thereof. The foot members of the container are of the same profile so that the container can be readily stacked on a like container. Finally, in accordance with another important aβpect of the invention, the container may be made in two parts. That is, it includes a firβt βection having the top βurface, downwardly directed wallβ and an open bottom, and a section having the bottom βurface, upwardly directed wallβ, and an open top. The wallβ of the firβt section mate with the walls of the second section and a connection mechanism iβ provided to attach the wallβ of the firβt and βecond βections. A preferred exemplary container for bulk materials incorporating the concepts of the preβent invention iβ shown by way of example in the accompanying drawings without attempting to show all the various forms and modifications in which the invention might be embodied, the invention being measured by the appended claims and not by the details of the specification. BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 is a perspective view of a container for bulk materials made in accordance with the concepts of the present invention. Fig. 2 iβ a top plan view of the container of Fig. 1. Fig. 3 iβ a side elevational view of the upper βection of the container taken substantially along line 3- 3 of Fig. 2. Fig. 4 is a rear elevational view of the upper section of the container taken substantially along line 4- 4 of Fig. 2. Fig. 5 is a sectional view taken βubβtantially along line 5-5 of Fig. 3. Fig. 6 iβ a sectional view taken βubβtantially along line 6-6 of Fig. 3 and βhowing the internal bottle in place. Fig. 7 is a fragmented sectional view of the upper section of the container taken βubβtantially along line 7- 7 of Fig. 2. Fig. 8 iβ a fragmented sectional view of the upper βection of the container taken βubβtantially along line 8- 8 of Fig. 2. Fig. 9 is a bottom plan view of the container of Fig. 1. Fig. 10 is a side elevational view of the lower section of the container taken substantially along line 10-10 of Fig. 9 and βhowing two feet of the container in phantom. Fig. 11 iβ a front elevational view of the lower section of the container taken substantially along line 11-11 of Fig. 9 and showing two feet of the container in phantom. Fig. 12 is a sectional view of the lower βection of the container taken βubβtantially along line 12-12 of Fig. 9 and βhowing two feet of the container in phantom. Fig. 13 iβ a sectional view of the lower section of the container taken substantially along line 13-13 of Fig. 9 and showing two feet of the container in phantom. Fig. 14 is a sectional view of the lower section of the container taken substantially along line 14-14 of Fig. 9. Fig. 15 iβ a sectional view of the lower βection of the container taken βubβtantially along line 15-15 of Fig. 9. Fig. 16 iβ a sectional view taken substantially along line 16-16 of Fig. 10 and βhowing the internal bottle in place. Fig. 17 iβ a fragmented sectional view taken substantially along line 17-17 of Fig. 9. Fig. 18 iβ a fragmented sectional view of a corner of the lower section and a foot of the container taken βubβtantially along line 18-18 of Fig. 9. Fig. 19 is a top plan view of the mechanism which assists in fastening the upper βection of the container to the lower βection of the container. Fig. 20 iβ a fragmented, partially βectional view, showing the first βtep in the application of the mechaniβm βhown in Fig. 19 to the upper and lower sections of the container. Fig. 21 iβ a fragmented, partially βectional view, βhowing the βtep sequentially following Fig. 20 in the application of the mechanism shown in Fig. 19 to the upper and lower sections of the container to lock the sections together. Fig. 22 iβ an enlarged, fragmented, βectional view taken βubβtantially along line 22-22 of Fig. 21. Fig. 23 is a top plan view of a foot for the container. Fig. 24 is a side elevational view of a foot for the container taken substantially along line 24-24 of Fig. 23. Fig. 25 is a side elevational view of a foot for the container taken substantially along line 25-25 of Fig. 23. Fig. 26 is a bottom plan view of a foot for the container. Fig. 27 is a somewhat schematic graph plotting load in pounds versus time demonstrating how the feet of the container absorb the energy in the event the container is dropped. Fig. 28 iβ a front elevational view of the internal bottle for the container. Fig. 29 iβ a top plan view of the bottle of Fig. 28. Fig. 30 is a aide elevational view of the bottle of Fig. 28. Fig. 31 is a side βectional view of the container with the bottle of Fig. 28 in place. Fig. 32 iβ a fragmented perspective view of the lower, central, front portion of the lower section of the container showing a closure mechaniβm for the valve of the bottle. Fig. 33 iβ a perspective view of the door of the closure mechaniβm shown in Fig. 32. Fig. 34 iβ a fragmented βectional view taken substantially along line 34-34 of Fig. 1. PREFERRED EMBODIMENT FOR CARRYING OUT THE INVENTION A container for bulk materials is indicated generally by the numeral 10 in Fig. 1 and it preferably includes an upper shell or βection generally indicated by the numeral 11, a lower shell or βection generally indicated by the numeral 12, an internal container bottle carried within sections 11 and 12 and generally indicated by the numeral 13, and foot assemblies generally indicated by the numeral 14. The two sections 11 and 12 are preferably made of a reaction injectable plastic material. The utilization of two sectionβ not only assists in the manufacturing process, but alβo allows container 10 to be made larger aβ by positioning a spacer between upper section 11 and lower section 12. As will hereinafter be described with specific reference to Figβ. 19-22, sections 11 and 12 are attached to each other to form an integral housing for bottle 13. Bottle 13 or an equivalent bag may be employed when container 10 is utilized to carry a liquid material. If used to hold dry materialβ, bottle 13 may not be neceββary and could, if deβired, be replaced by a bag or, alternatively, container 10, with some modifications, could directly carry the dry materialβ. But firβt describing upper shell or βection 11 with specific reference to Figs. 1-8, it is open at the bottom and includes a top, external, irregularly configured surface, generally indicated by the numeral 15, having a central circular hub 16 which surrounds and giveβ access to a twist off cap 18 of bottle 13. A plurality of structural ribβ 19 (Fig. 5) radiate generally diagonally outwardly from hub 16 and are tied together by upper arcuate surfaces 20. Flat ledges 21 are formed at the ends of ribs 19 at the four corners of top surface 15 which, aβ will hereinafter be deβcribed, are adapted to receive the feet 14 of an appropriately configured or like container for stacking purposes. To that end, arcuate lips 22 extend upwardly from top βurface 15 at the lateral edge of ledgeβ 21 βo aβ to laterally confine and assist in the positioning of the feet 14 of a like container when stacked on container 10. Top surface 15 also includes βtructural ribs 23 (Fig. 5) radiating toward the rear and sides of container 10 which are tied together by upper arcuate surfaces 24. While similar ribs 23 radiate partially toward the front of container 10, preferably they are not tied together so aβ to form a flat βurface 25 at that area βo that the container may receive a company logo or other identifying indicia or information if deβired. To provide further strength to container 10 and to allow spaces for expansion of bottle 13, ribβ 23 and βurfaceβ 24 extend downward from the top 15 partially along container sidewalls generally indicated by the numeral 26 and container back wall generally indicated by the numeral 28. Top surface 15 is also provided with eight upwardly projecting ribs 29 which begin generally midway along arcuate βurfaceβ 20 and extend outwardly to sidewalls 26 and back wall 28, as well aβ toward container front wall generally indicated by the numeral 30. Ribβ 29 alβo continue downwardly on sidewalls 26, back wall 28 and front wall 30 and extend generally all the way to the bottom of upper container section 11. As will be hereinafter deβcribed in more detail, ribs 29 are open to the inside of top surface 15, thereby defining channels 31 (Fig. 5) which assist in the drainage of any liquid which might be in container 10. With reference to Fig. 1, it can be seen that front wall 30 of upper βection 11 includes a generally flat receββed βurface 32 which iβ a continuation of top flat βurface 25 and which mergeβ with a flat raiβed βurface 33 positioned below βurface 32. To the βideβ of βurfaceβ 32 and 33, and βeparated therefrom by ribβ 29, are receββed βurfaceβ 34 which have staggered sightholes 35 formed therein βo that one can view the contents of bottle 13 which iβ preferably made of a translucent blow molded high density polyethylene material but which, of course, may be made by any equivalent process and of any equivalent material. The bottom of each receββed surface 34 is provided with an arcuate lip 36 which together with the bottom of βurface 33 carry a castellated surface, generally indicated by the numeral 38, which foriαβ part of the connection mechanism βhown in detail in Figβ. 19-22 and indicated generally by the numeral 39 to be hereinafter deβcribed in detail. On each side of recessed surfaces 34, corner columnar legβ 40 are formed extending downwardly from lips 22. Legs 40 terminate at their lower end as an arcuate skirt 41 which extend outwardly and thereby serve to protect connection mechaniβm 39 from damage aβ containers 10 may be moved about adjacent to walls or the like. The sidewalls 26 and back wall 28 of upper section 11 are much the same in configuration as front wall 30 and thus like elements have been given the same reference numerals. Thus, as beet βhown in Figβ. 3 and 4, sidewalls 26 and back wall 28 each have the flat recessed surface 32 (onto which upper arcuate surfaces 24 extend) , the flat raiβed βurface 33, the receββed βurfaceβ 34 with sightholes 35, the drainage ribs 29, the arcuate lips 36, the castellated surface 38, and corner columnar legs 40 with their arcuate skirtβ 41. Aβ βhown in Fig. 6, sidewalls 26, back Wcill 28 and front wall 30 are all provided with vertical internal ribs 42 thereon which can be an extension of top ribs 23 or which can be βeparate and/or additional ribβ. Ribβ 42 not only provide structural support for wallβ 26, 28 and 30, but alβo support the walls of bottle 13 when it iβ full of material aβ will be more fully hereinafter deβcribed. Similar corner ribβ 43 are alβo provided for the same purposes. Ribβ 43 are preferably a downward extension of ribs 19. As βhown in Figβ. 7 and 8, top ribs 23, near central hub 16, extend downwardly to hold down the peripheral area 44 around neck 45 of bottle 13. When bottle 13 is in an expanded condition, aβ βhown in Fig. 8, bottle 13 may even extend into the area defined by upper arcuate βurfaceβ 24. Aβ will be hereinafter deβcribed, with the expansion space provided between ribs 42 and 43, and with the support provided by ribs 42 and 43, βuch tends to fully confine bottle 13 in its proper position. With reference to Figβ. 1 and 9-17, lower shell or section 12 will now be deβcribed in detail. Except that it has an open top, lower βection 12 iβ in most respects like upper βection 11. As βuch, it includes a front wall indicated generally by the numeral 46 having a flat βurface 48 complementing upper βection βurface 33, and two receββed βurfaceβ 49 to the βideβ thereof which carry staggered sightholes 50. The top of surface 48, together with arcuate lips 51 positioned above surfaces 49, carry a castellated surface, generally indicated by the numeral 52, which mates with castellated surface 38 of upper section 11 to form part of the connection mechanism 39. Drainage ribβ 53 are formed between βurface 48 and βurfaceβ 49 to mate with similar ribβ 29 of upper βection 11 and extend, with their internal drainage channel 54 (Fig. 16), to the bottom of lower βection 12. Below βurface 48 of front wall 46 iβ a plate 55 reinforced by ribs 56 which defines a pocket or opening 58 (Fig. 11) in front of wall 46 for a valve assembly, generally indicated by the numeral 59, of bottle 13. Pocket 58 may be opened and closed, for access to and the protection of valve assembly 59, by a valve access closure mechanism, generally indicated by the numeral 60, shown in a closed position in Fig. 1, and βhown in detail in Figβ. 32-34, to be hereinafter deβcribed. On each side of recessed surfaces 49, columnar corner legs 61 are formed to mate with legs 40 of upper section 11. When mated together, columnar legβ 40 and 61 provide extraordinary strength to container 10. An arcuate βkirt 62 iβ formed at the top of legs 61 to mate with βkirt 41 and form the protective mechaniβm for connection mechaniβm 39 aβ previously described. The sidewalls 63 of lower section 12 are much the same in configuration as front wall 46 and thus like elements have been given the same reference numerals. The rear wall 64 (Fig. 16) of lower section 12 iβ esuentially identical to the sidewalls 63 and is therefore not shown in detail. Sidewalls 63 therefore include the flat βurface 48, the receββed βurfaceβ 49, the sightholes 50, the upper arcuate lips 51, the castellated surface 52, the drainage ribβ 53, and the columnar legβ 61 having upper skirts 62. Instead of the valve pocket 58, however, sidewalls 63 have a receββed flat wall 65 poβitioned below wall 48 with a downwardly directed raiβed arcuate βurface 66 poβitioned thereon which ties together a plurality of support ribs 68 that also extend into the bottom of lower βection generally indicated by the numeral 69 (Figβ. 9 and 17) . Alβo like upper βection 11, as shown in Fig. 6, front wall 46, sidewalls 63 and rear wall 64 of lower βection 12 are all provided with vertical internal ribβ 70 thereon which not only provide structural support for walls 46, 63 and 64, but also support the walls of bottle 13 when filled. Similar internal corner ribβ 71 can alβo be provided for the same purpose. This support is enhanced by the fact that bottle 13 may expand, as necessary, into the βpaceβ between ribβ 70 and ribs 71 just as previously described with reβpect to ribs 42 and 43 of upper section 11. Such prevents rupture of bottle 13 under expansion conditions. The bottom 69 of lower section 12 is best, βhown in Fig. 9. Aβ βhown, a plurality of external βupport ribs 72 radiate outwardly from a central hub 73 generally diagonally toward the cornerβ. Theβe ribβ extend downwardly from the bottom βurface 74 of lower shell 12. Additional ribs 75 are located at various locationβ on the underside of bottom βurface to aββiβt in βupporting, along with ribβ 73, a drainage βyβtem, generally indicated by the numeral 76 and now to be deβcribed. Aβ best shown in Figβ. 9 and 12-15, for containers designed to carry liquids, drainage βyβtem 76 may be provided and includeβ a network of channelβ or troughβ formed in the bottom 69 of lower βection 12. Aβ βuch, drainage βyβtem 76 includeβ four primary channelβ 78, two extending from side to side and two extending from front to back. System 76 alβo includeβ a central front-to-back channel 79 and a central side-to-side channel 80 which intersect generally at the area of rib hub 73. Another feeder channel 81 extends between side-to-side primary channels 78 and intersects with one end of channel 79. A drain hole 82 through bottom surface 76 is provided at that intersection, and all of the network of channels are sloped downwardly toward drain hole 82 so that any liquid which reaches any of the channelβ and below bottle 13 may pass through drain hole 82 if desired. If such is not deβired, a plug may be poβitioned in drain hole 82. Even liquid which may accumulate at the top or βideβ of bottle 13 is conveyed to drain hole 82 because the eight ends of primary channels 78 communicate with the bottom of drainage channels 54 in lower section 12 which, in turn, communicate with drainage channelβ 31 in upper section 11. The manner in which upper βection 11 iβ attached to lower βection 12 by meanβ of connection mechanism 39 is shown in detail in Figs. 19-22. Each castellated surface 38 of upper βection 11 includeβ a series of lugs 83 separated by βpaceβ 84. A notch 85 is formed at the top of and behind the outer surface of each lug 83, and a groove 86 is formed underneath each lug 83, that iβ, opposed to notch 85. Similarly, each castellated surface 52 of lower βection 12 iβ provided with a series of lugs 88 separated by spaceβ 89. A notch 90 iβ formed at the bottom of and behind the outer surface of each lug 88 and a tongue 91 is poβitioned at the top of each lug 88 oppoβed to notch 90. A C-shaped clip is shown in Fig. 19 and iβ generally indicated by the numeral 92. A clip 92 iβ provided for each wall of container 10, and each clip 92 iβ βhown aβ being an elongate member having opposed upper and lower tongs 93 alternating with recesses 94, the tongs being formed at the ends of the branches of the C shape. The back of the C-shaped clip 92 is provided with a plurality of darts 95 to stiffen the same as would be evident to one skilled in the art. To connect upper βection 11 to lower βection 12, firβt luge 83 are aligned with luge 88 aβ the lower open end of upper βection 11 iβ placed on the upper open end of lower βection 12. The alignment iβ simplified and the connection iβ assured because tongue 91 iβ received in groove 86. In Eact, it iβ preferable that tongue 91 and groove 86, in addition to being formed in luge 88 and 83, reβpectively, are alβo provided along the entire peripherieβ of upper βection 11 and lower βection 12. Then, aβ βhown in Fig. 20, clip 92 can be poβitioned on castellated surfaces 38 and 52 by pushing tongβ 93 into aligned spaces 84 and 89. Of course, at the same time, lugs 83 and 88 are received within recesses 94 of clip 92. Clip 92 may then be slid to the left, as viewed in Fig. 20, to the Fig. 21 position. Aβ βuch, tongβ 93 elide in notcheβ 85 and 90 and behind luge 83 and 88 βuch that receββeβ 94 are then aligned with βpaceβ 84 and 89. The movement from the Fig. 20 to the Fig. 21 position alβo aligns complementary apertureβ 96, formed near each end of castellated surfaceβ 38 and 52, with apertureβ 97 formed near each end of clips 92. Bolts 98 may then be inserted through aligned apertures 96 and 97, and when nut 99 iβ tightened, the connection iβ complete. In addition to making the connection of upper section 11 to lower section 12, it should also be appreciated that the connection mechanism 39 adds hoop strength to container 10 to prevent any tendency of the container to bulge at the middle. If deβired to seal container 10 so that any liquid therein not in bottle 13 would not seep out, a conventional o-ring seal (not βhown) could be utilized at the junction of upper βection 11 and lower βection 12 aβ would be evident to one skilled in the art. Such secondary containment of any such liquid would alβo of course require that drain hole 82 be plugged and sealed and that all other areas of possible leakage, for example, at the area of valve assembly 59, also be βealed, aβ would also be evident to one skilled in the art. It should alβo be appreciated that the height and therefore the βize of container 10 could be rendered adjustable by providing a spacer, not βhown in the drawings, between upper section 11 and lower βection 12. Such a spacer would be open at the bottom and top and would have side wallβ with a castellated surface at the top and bottom thereof to mate with the castellated surfaces 38 and 52. Additional clips 92 would attach the spacer to the upper and lower sections thereby providing even additional hoop βtrength. Aβ βuch, the height of container 10 could be adjusted to essentially any size dependent on the height of the spacer selected. Container 10 is supported by unique feet 14 now to be described with particular reference to Figs. 23-26. As shown in Fig. 23, each foot 14, in plan view, takes on the profile of a pie-shaped quarter of a circle having an arcuate ledge 100 and radial or linear ledges 101 and 102, with ledge 102 extending inwardly further than ledge 101. A plurality of arcuate, spaced, long tabs 104, 105, 106, 107 and 108 extend upwardly from and are spaced slightly inwardly from the edge of ledge 100, the tabs alβo extending upwardly above an upper arcuate bevelled lip 109. Three spaced short tabs 110, 111 and 112 extend upwardly from and are spaced slightly inwardly from the edge of ledge 101, the space forming a lower linear lip 113. Two spaced shorter tabs 114 and 115 extend upwardly from and are spaced slightly inwardly from the edge of ledge 102, the space forming a lower linear lip 116. Transition surfaceβ 117 extend downwardly from the endβ of upper arcuate lip 109 to the endβ of lower linear lipβ 113 and 116, aβ βhown in Figβ. 24 and 25, with linear lipβ 113 and 116 interβecting at their other endβ. A βubβtantially hollow foot member 118, open at the top, extendβ downwardly from ledges 100, 101 and 102. A block of energy-absorbing foam 119, preferably made of a polyurethane material, iβ inserted into each foot member 118 to substantially fill the same and, aβ βhown by the dotted lines in Figs. 24 and 25, extends upwardly to approximately the height of upper lip 109 and between all of the tabs. As shown in Fig. 26, the bottom 119 of each foot member 118 is preferably pie-shaped in profile and is provided with a downwardly depending, irregularly-shaped tread pattern 120 having receβsed areas 121 therebetween. A plurality of friction pads 122, extending to the same level as tread pattern 120, may be provided in receββed areaβ 121. Because the ledges 20 of top βurface 15 of upper βection 11 take on substantially the same pie shape profile as does the bottom 119 of each foot member, the manner in which feet 14 may βecurely βtack on ledges 21, being located and confined by βurfaceβ 22 of a similar or like container, as previously described, can readily be seen. The manner in which each foot 14 may be atttached to and interrelate to lower section 12 is best βhown with βpecific reference to Fig. 18 and to Fig. 9. Fig. 18 shows the side of a foot 14 as viewed in Fig. 25 which would be received on the bottom of lower section 12, at the lower right-hand corner as viewed in Fig. 9. As ehown in Fig. 9, a rib pattern of a pie-βhaped quarter of a circle iβ formed at each corner of the bottom of lower βection 12 at the endβ of ribβ 72 and includeβ radial ribs 123 and 124 connected to each other at their inner end and connected at their outer end to an arcuate rib 125. Additional ribbing 126 iβ provided and effectively forme ten βpaceβ 127 along and between ribβ 123, 124 and 125 to receive the ten tabs of foot 14 adjacent thereto. Thus, each tab is positioned just inside of ribs 123, 124 and 125, with each of the ten tabs of foot 14 being received between adjacent ribbing 126. At leaβt selected of the tabs are connected to their adjacent ribs. For example, as shown in Fig. 18, tab 108 iβ connected by a suitable fastener 128 to rib 125, as the bottom of rib 125 rests on upper arcuate lip 109, and tab 114 is connected by a suitable fastener 129 to rib 124, as the bottom of rib 124 rests on lower linear lip 116. With all feet βo connected, bottle 13 within container 10 iβ protected from rupture in the event the container iβ dropped in a manner now to be deβcribed. An analyβiβ of the approximate loading at the area of feet 14 that occurs when a container 10 is dropped is shown in Fig. 27 which is a plot of load measured in pounds, over time, meaβured in seconds, when a container 10 would be dropped from a height of four feet onto a level surface. After initial impact, stresses would build up until point A is reached at a load of about 18800 pounds after approximately 0.00125 seconds. Were it not for the crushable feet 14, such stresses would go much higher and eventually drop and generally level out at about 16000 pounds for a period of time, all of which would damage bottle 13. However, feet 14 are designed to fail and to absorb much of the energy. As βuch, upon impact, container 10 will tend to want to go to the left (as viewed in Fig. 18) on bevelled lip 109 and foot 14 will tend to want to move to the right causing the rupture of arcuate tabs 104, 105, 106, 107 and 108 at the predetermined threshold failure level, point A. Then, because of voidβ in the foot 14, the stresses drop to about 1000 pounds after about 0.0033 seconds, point B, at which time the compression of foam 119 begins to take place. At this time, point B, impact energy begins to riβe again but at a much gentler elope than aβ seen between time zero and point A aβ the foam resists compression. Such slope is indicative of the resistance of the foam to compression, that is, the steeper the slope, the more the foam is reβiβtant to compreβeion. One skilled in the art could readily βelect the deβired resistance characteristics of the foam to create the optimum balance between foam compression and the transfer of energy to the container to meet the particular design circumstances. The foam can only compress and absorb βo much energy before it beginβ to bottom out at point C, approximately 11900 pounds and 0.0153 seconds of elapsed time. At point C, foam 119 is thus compresβed to itβ maximum and at point D (12200 pounds load at 0.01775 secondβ) the center of the bottom of container 10, the point of itβ most concentrated and maximum deflection, has contacted the impact βurface. Because the initial impact of the bottom of the container iβ at the center, and because the loading for this analysis was measured at the area of feet 14, there is little difference in the load at the foot area between points C and D. However, aβ the remainder of the bottom βurface contacts the impact βurface, the load again peaks one last time at point E, approximately 16200 pounds after 0.0189 eecondβ of elapβed time. Thereafter, the load slowly dissipates over time but bottle 13 iβ not damaged aβ would have been the case in the absence of feet 14 where a significantly greater initial load would have been experienced and a significantly greater overall load experienced over a longer period of time. The small peaks and valleys βhown between points A-E in Fig. 27 represent miscellaneous load "noiεie" caused by a variety of interaction that iβ taking place between the broken pieces of the feet 14 and foam 119 aβ they are being cruβhed under the weight of the container. For example, when a particle of the feet breakβ, it releases energy and is no longer supporting a load. Thus, there would be a slight downturn or "noise" in the load curve. However, then another particle of the foot or container will start absorbing more energy and a corresponding upturn in the load is observed. Nevertheless, feet 14 protect bottle 13 from rupture, with the details of bottle 13 now to be deβcribed with particular reference to Figβ. 28-31. As previously indicated, bottle 13 ie preferably blow molded of a high denβity polyethylene and while it iβ formed to take the shape βhown in the drawings, aβ previouβly deβcribed, it is somewhat flexible and will expand somewhat when filled, or may alβo tend to expand under high temperature and/or pressure conditions or if container 10 iβ dropped. Such expansion, for example, may be outwardly against and even between ribs 42, 43, 70 and 71 and upwardly against top bottle hold down ribs 23. Aβ βuch, all βurfaceβ of bottle 13 are fully supported in container 10. Aβ previouβly described, the top βurface 130 of bottle 13 has a threaded neck 45 defining the bottle opening 131 and adapted to receive cap 18. The front wall 132 iβ formed with a recess 133 within which valve assembly 59 is carried. Side bottle surfaces 134 and rear bottle surface 135 are rather uniform and uninterrupted, with upper shoulders 136 being formed between side βurfaceβ 134 and top βurface 130. When bottle 13 iβ poβitioned in container 10, itβ valve assembly 59 is exposed as it extends into pocket 58 of front wall 46 of lower βection 12. Valve assembly 59 is rather conventional and includes a valve body 138, operating handle 139, and a cap 140 which can be threaded onto and which thereby closeβ the discharge spout 141 which communicates with the material in bottle 13. Cap 140 may be provided with tabs 142 to assist in its twisting manipulation. Alternatively, instead of threading cap 140 onto βpout 141, tabs 142 can be formed as moveable levers and be rotatable in a forward direction, in a cam lock fashion, to lock cap 140 on spout 141 as would be readily apparent to one skilled in the art. Valve access closure mechanism 60 is provided to protect valve assembly 59 when not in use and is shown in detail in Figs. 32-34. Mechanism 60 includes a door generally indicated by the numeral 143 having a front face 144 with lower grip slots 145 and an upper grip slot 146 formed therethrough. Side flanges 148 extend laterally outward at the rear of door 143 and each flange 148 haβ a guide rail 149 extending forwardly and rearwardly therefrom. A lock notch 150 iβ formed near the top of the lateral edge of each flange 148 and another lock notch 151 iβ formed near the bottom of the lateral edge of each flange 148. Track members, generally indicated by the numeral 152, have a hooked laterally outer end 153 which can be received over and thereby carried by drainage ribs 53 of lower container βection 12. A U-shaped track 154, having a base 155 and branches 156 and 157 having one end extending from the endβ of base 155, is formed at the laterally inner end of each track member 152. The other end of brancheβ 156 and 157 are provided with oppoβed nubs 158 which can engage guide rail 149 of door 143 to limit itβ lateral aβ well aβ front to back movement to thereby guide, and prevent any cocking of, door 143. Each base 155 of each track 154 carries a lower lock lug 159 (Fig. 34) and an upper lock lug 160 (Fig. 32) extending outwardly therefrom between branches 156 and 157. Door 143 may be moved up and down relative to track members 152 by grasping slots 145 and/or slot 146, as may be convenient, and is held in the open position aβ upper luge 160 βnap into upper lock notches 150. When closed, door 143 is held in a stable condition as lower lugs 159 have been snapped into lower lock notches 151. Based on the foregoing discloβure of the invention, it should be evident that a container 10, constructed aβ deβcribed, accomplishes the objects of the invention and otherwise βubβtantially improves the art.

Claims: CLAIMS I. A container compriβing a firβt βection having a top βurface, wallβ extending downwardly from βaid top βurface, and an open bottom; a βecond βection having a bottom βurface, wallβ extending upwardly from βaid bottom βurface to mate with βaid wallβ of βaid firβt βection, and an open top; and meanβ to connect mating of βaid wallβ of βaid firβt βection to mating of βaid wallβ of βaid βecond βection βo that said open bottom communicates with said open top to form the container. 2. A container according to claim 1 wherein βaid means to connect includeβ a clip member for each of βaid mating wallβ. 3. A container according to claim 2 further compriβing meanβ to attach each βaid clip member to βaid firβt and βecond sections. 4. A container according to claim 2 further compriβing spaced lugs formed near the bottom of said wallβ of βaid firβt βection, spaced luge formed near the top of βaid wallβ of βaid βecond βection and alignable with βaid spaced lugs of said firβt βection, a notch formed on top of βaid luge of βaid firβt βection, and a notch formed on the bottom of βaid luge of βaid βecond βection, each βaid clip member having oppoβed tongβ received in said notches. 5. A container according to claim 4 further compriβing a tongue on βaid luge of one of βaid sections and a groove on said luge of the other of βaid sections, βaid tongue being received in βaid groove. 6. A container according to claim 1 further compriβing a plurality of foot assemblies βupporting βaid bottom βurface; each βaid foot assembly including a hollow foot having a plurality of breakable tab members extending upwardly therefrom, a crushable foam block in said hollow foot, and means to attach at leaβt βome of βaid tab members to βaid bottom surface βo that when a load is applied to the container, said at leaβt βome of βaid tab members will break and said foam block will crush to absorb the energy of the load. 7. A container according to claim 1 further compriβing an internal container supported by βaid bottom βurface and having a valve assembly therein, an opening in one of said walls to provide access to said valve aββembly, a door for selectively opening and closing said opening, and means for maintaining βaid door in an open position. 8. A container according to claim 1 further compriβing spaced ribs extending inwardly from said walls, and a flexible internal container supported at least in part by said ribs, βaid internal container being capable of expanding into the spaces between βaid ribβ. 9. A container according to claim 1 further compriβing drainage channelβ formed on the inside of said bottom βurface, and a drain hole in one of βaid channelβ, all of βaid channelβ being eloped βo that any liquid in the container may be directed in βaid channels to βaid drain hole. 10. A container according to claim 1 wherein βaid top βurface iβ irregularly configured and further compriβing a plurality of foot assemblies attεtched to said bottom βurface and having a predetermined profile, and generally flat ledges formed at the cornerβ of βaid top βurface and being generally of the same profile aβ said predetermined profile so that the container can be stacked on a like container by poβitioning βaid foot assemblies of the container on the ledges of the like container. 11. A container according to claim 1 further comprieing corner columns formed between each of said wallβ of βaid firβt βection and corner columns formed between each of βaid wallβ of βaid βecond βection, said corner columns of said first βection mating with the corner columns of said βecond βection to provide structural strength to the container. 12. A container compriβing a bottom βurface; wallβ extending upwardly from βaid bottom βurface; and a plurality of foot aββemblies supporting βaid bottom βurface and βaid wallβ; each βaid foot assembly including a hollow foot having a plurality of breakable tab members extending upwardly therefrom, a crushable foam block in βaid hollow foot, and meanβ to attach at leaβt βome of βaid tab members to said bottom βurface βo that when a load iβ applied to the container, βaid at leaβt some of said tab members will break and βaid foam block will crush to absorb the energy of the load. 13. A container according to claim 12 further comprising a plurality of rib members extending downwardly from said bottom βurface and poβitioned adjacent to βaid tab members, said meanβ to attach including fasteners extending through selected of βaid tab members and βelected of βaid rib members. 14. A container according to claim 12, each said foot aββembly further including a βecond plurality of tab members extending upwardly from said foot, said second plurality of tab members being shorter than βaid plurality of tab members, said foam block extending to a point higher than βaid second plurality of tab members but lower than βaid plurality of tab members. 15. A container according to claim 14, each said foot aββembly further including meanβ to attach at leaβt βome of βaid βecond plurality of tab members to- βaid bottom βurface. 16. A container according to claim 12, each βaid foot aββembly further including an upper arcuate ledge carrying βaid plurality of tab members, βaid bottom surface having a plurality of rib memberβ extending downwardly therefrom and adjacent to βaid tab memberβ. 17. A container according to claim 16, each said foot aββembly further including a bevelled lip on βaid ledge, βaid rib memberβ resting on said bevelled lip. 18. A container according to claim 16, each βaid foot member further including lower linear ledges and a βecond plurality of tab memberβ extending upwardly from βaid lower linear ledges, βaid bottom having a βecond plurality of rib memberβ extending downwardly therefrom to rest on said lower linear ledges adjacent to βaid βecond plurality of tab memberβ. 19. A container according to claim 12 further comprieing an internal container βupported by βaid bottom surface and having a valve assembly therein, an opening in one of said walls to provide access to said valve assembly, a door for selectively opening and closing said opening, and means for maintaining said door in an open position. 20. A container according to claim 12 further comprising spaced ribβ extending inwardly from βaid wallβ, and a flexible internal container βupported at leaβt in part by βaid ribs, βaid internal container being capable of expanding into the βpaceβ between βaid ribβ. 21. A container according to claim 12 further compriβing drainage channelβ formed on the inside of said bottom βurface, and a drain hole in one of βaid channelβ, all of βaid channelβ being eloped βo that any liquid in the container may be directed in βaid channelβ to βaid drain hole. 22. A container according to claim 12 further compriβing an irregularly configured top βurface connecting the tope of βaid wallβ, βaid foot assemblies having a predetermined profile, and generally flat ledges formed at the corners of said top βurface and being generally of the same profile as said predetermined profile so that the container can be stacked on a like container by positioning βaid foot assemblies of the container on the ledges of the like container. 23. A container according to claim 12 further compriβing corner columns formed between each of βaid wallβ to provide structural strength to the container. 24. A container comprising a bottom surface, walls extending upwardly from said bottom βurface, an internal container βupported by at leaβt βaid bottom βurface and having a valve aββembly therein, an opening in one of βaid walls to provide access to said valve assembly, a door for selectively opening and closing said opening, and means for maintaining said door in an open position. 25. A container according to claim 24 further comprising vertical track members poβitioned along the βideβ of βaid opening and carried by βaid one of said walls, said door having side flanges, each including a rail riding within said track members. 26. A container according to claim 25 wherein βaid meanβ for maintaining βaid door in an open poβition includeβ a notch formed near the top of each βaid flange and a lug formed on each βaid track member to engage βaid notch to maintain βaid door open. 27. A container according to claim 26 further compriβing a βecond notch formed near the bottom of each said flange, and a βecond lug engaging βaid βecond notch to maintain βaid door in a closed position. 28. A container according to claim 24 further compriβing at leaβt one hand grip slot in βaid door. 29. A container according to claim 24 further comprieing βpaced ribβ extending inwardly from βaid wallβ and βupporting βaid internal container, βaid internal container being flexible βo that it may expand into the βpaceβ between βaid ribβ. 30. A container according to claim 24 further compriβing drainage channelβ formed on the ineide of βaid bottom βurface, and a drain hole in one of said channels, all of said channels being eloped βo that any licruid in the container may be directed in βaid channels to βaid drain hole. 31. A container according to claim 24 further compriβing an irregularly shaped top surface connecting the tops of said walls, a plurality of foot aββemblies attached to said bottom βurface and having a predetermined profile, and generally flat ledges formed at the corners of βaid top βurface and being generally of the same profile aβ βaid predetermined profile βo that the container can be stacked on a like container by positioning βaid foot assemblies of the container on the ledges of the like container. 32. A container according to claim 24 further comprising corner columns formed between each of βaid wallβ to provide structural strength to the container., 33. A container compriβing a top βurface, wallβ having one end extending downwardly from βaid top βurface, a bottom βurface joining the other end of βaid wallβ to form the encloβed container, βpaced ribβ extending inwardly from βaid wallβ, and a flexible internal container βupported at leaβt in part by βaid ribβ, said internal container being capable of expanding into the βpaceβ between βaid ribβ. 34. A container according to claim 33 further compriβing βpaced ribβ extending downwardly from βaid top βurface to hold down βaid internal container aβ it may want to expand, βaid internal bottle being capable of expanding into the βpaceβ between βaid βpaced ribβ of said top βurface. 35. A container according to claim 33, βaid internal container being translucent, and further comprising sightholes in βaid wallβ βo that the amount of contentβ in βaid internal container may be identified. 36. A container according to claim 33 further comprieing arcuate βurfaceβ formed in βaid top surface and spaced ribs formed within βaid arcuate βurfaceβ, said internal container being capable of expansion into the βpace formed between βaid spaced ribs in said arcuate surfaces. 37. A container according to claim 36 wherein said arcuate surfaces and said βpaced ribs formed within said arcuate surfaces extend partially down said walls. 38. A container according to claim 33 further comprising drainage channelβ formed on the inside of said bottom βurface, and a drain hole in one of βaid channelβ, all of βaid channelβ being eloped βo that any liquid in the container may be directed in βaid channelβ to βaid drain hole. 39. A container according to claim 33 wherein βaid top βurface iβ irregularly configured and further compriβing a plurality of foot assemblies attached to said bottom surface and having a predetermined profile, and generally flat ledges formed at the corners of βaid top βurface and being generally of the same profile as βaid predetermined profile βo that the container can be stacked on a like container by positioning said foot assemblies of the container on the ledgeβ of the like container. 40. A container according to claim 33 further compriβing corner columns formed between each of said walls to provide structural strength to the container. 41. A container compriβing a top βurface, wallβ having one end extending downwardly from βaid top βurface, a bottom βurface joining the other end of βaid wallβ to form the encloβed container, drainage channelβ formed on the inβide of βaid bottom βurface, and a drain hole in one of βaid channels, all of βaid channelβ being eloped βo that any liquid in the container may be directed in βaid channelβ to βaid drain hole. 42. A container according to claim 41 wherein there are drainage channelβ running between each of βaid wallβ, and further compriβing vertical drainage channelβ formed in each of βaid walls communicating with βaid drainage channelβ running between each of βaid wallβ βo that liquid in said vertical drainage channels may be directed to βaid drain hole. 43. A container according to claim 41 wherein βaid top βurface iβ irregularly configured and further compriβing a plurality of foot assemblies attached to said bottom surface and having a predetermined profile, and generally flat ledges formed at the corners of said top surface and being generally of the same profile as βaid predetermined profile so that the container can be stacked on a like container by positioning said foot assemblies of the container on the ledges of the like container. 44. A container according to claim 41 further compriβing corner columns formed between each of βaid wallβ to provide structural βtrength to the container. 45. A container compriβing an irregularly configured top βurface, wallβ having one end extending downwardly from βaid top βurface, a bottom eurface joining the other end of βaid wallβ to form the encloβed container, a plurality of foot assemblies attached to said bottom βurface and having a predetermined profile, and generally flat ledges formed at the corners of said top surface and being of generally the same profile as βaid predetermined profile βo that the container can be stacked on a like container by positioning βaid foot assemblies of the container on the ledges of the like container. 46. A container according to claim 45 wherein said profile is pie shaped having an arcuate outer βurface and two linear outer βurfaceβ. 47. A container according to claim 46 further compriβing a lip extending upwardly from βaid arcuate βurface of each βaid ledge to laterally confine the like container on the container. 48. A container according to claim 45 further compriβing corner columne formed between each of βaid wallβ to provide structural βtrength to the container. 49. A container according to claim 48 wherein βaid corner columns are positioned below said ledges to assist in supporting the like container. 50. A container comprising a top surface, walls having one end extending downwardly from said top surface, a bottom surface joining the other end of said walls to form the encloβed container, and corner columns formed between each wall to provide structural βtrength to the container. 51. A container according to claim 50 wherein βaid wallβ are receββed within βaid corner columns so aβ to protect said wallβ from damage. 52. A container according to claim 50 further compriβing an upper section including βaid top surface and a portion of said wallβ and said corner columns, a mating lower section including said bottom surface and a portion of said wallβ and said corner columns, and means to attach βaid upper βection to βaid lower section, said means alβo adding hoop strength to the container. 53. A container according to claim 52 further comprising mating arcuate skirts on βaid corner columns of βaid upper βection and said lower section, said arcuate βkirts extending outwardly to protect βaid meanβ to attach which iβ receββed therebetween. 54. A container according to claim 50 further comprising crushable feet attached to said bottom βurface beneath βaid corner columnβ. 55. A container according to claim 54 further comprising ribβ on βaid top βurface, βaid wallβ, and βaid bottom βurface to, with βaid corner columnβ, provide βtructural βtrength to the container. 56. A container comprising a first section having an irregularly configured top βurface, wallβ extending downwardly from βaid top βurface, and an open bottom; a βecond βection having a bottom βurface, wallβ extending upwardly from βaid bottom βurface to mate with βaid wallβ of βaid firβt section, and an open top; means to connect mating of βaid wallβ of βaid firβt βection to mating of βaid walls of said second βection βo that βaid open bottom communicates with βaid open top; corner columns formed between each βaid wall of βaid firβt βection and each βaid wall of eaid βecond βection; βpaced ribβ extending inwardly from each βaid wall of βaid firβt βection and each βaid wall of βaid βecond βection; a flexible internal container βupported at leaβt in part by βaid bottom βurface and βaid ribs, βaid internal container being capable of expanding into the βpaceβ between βaid ribs and having a valve assembly therein; an opening in one of said walls of βaid βecond βection to provide access to said valve aββembly; a door for selectively opening and closing βaid opening; means for maintaining said door in an open position; drainage channelβ formed on the inside of βaid bottom βurface; a drain hole in one of βaid channelβ, all of βaid channelβ being eloped βo that any liquid in the container may be directed in βaid channelβ to βaid drain hole; a plurality of foot assemblies supporting said bottom surface; each eaid foot aββembly including a hollow foot of a predetermined profile and having a plurality of breakable tab memberβ extending upwardly therefrom, a crushable foam block in said hollow foot, and means to attach at leaβt βome of said tab members to said bottom surface so that when a load is applied to the container, said at leaβt βome of βaid tab memberβ will break and βaid foam block will crush to absorb the energy of the load; and generally flat ledges formed on said top surface and being of generally the same profile as said predetermined profile of each said foot βo that the container can be stacked on a like container by poβitioning each βaid foot of the container on the ledges of the like container.

Inventors: BROMWELL ROBERT A, HARRIS JACK E, IMBODEN ALAN M, SOMMER KARL L, WITKOWSKI THOMAS G, BROMWELL, ROBERT, A., HARRIS, JACK, E., IMBODEN, ALAN, M., SOMMER, KARL, L., WITKOWSKI, THOMAS, G.
Applicants: ROMEO RIM INC, ROMEO-RIM, INC.
Application year: 1996
Main classification: B67D5
IPC codes: B65D8, B65D19, B65D77, B65D88, B65D90, B67D5