Abstract:
A collapsible bulk bin, formed from a sheet that is folded upon itself to form a tube, having a plurality of bottom panels pivotably connected to respective side walls of the bulk bin. A plurality of connector panels foldably connect adjacent ones of the bottom panels, to provide a slotless bottom configuration to provide reinforcing strength to the bottom, and bottom regions of the side walls of the bulk bin.

Description:
BACKGROUND OF THE DISCLOSURE 
     1. Field of the Invention 
     The present invention relates in general to cartons fabricated from paper, paperboard and/or corrugated paperboard material, particularly collapsible bulk bin containers. 
     2. Background Art 
     Bulk bins fabricated from paperboard, particularly corrugated paperboard are known. Many of these bulk bins are fabricated so that they may be collapsed after use, shipped back to their original loading point, and re-used. 
     A typical collapsible bulk bin construction will be a bin that has eight side walls, four “long” side walls, and four “short” side walls, disposed in alternating fashion along a blank. Usually, one of the “short” side walls will be formed from two “half” panels, located at the ends of the blank, each of which has a width which is greater than one-half the width of a “short” side wall. Bottom closure flaps, which are die cut separate from one another, emanate from the bottom edges of each of the panels that form the long and short side walls. Each of the bottom closure flaps typically has a width corresponding to its respective side wall panels. To form the bulk bin, the blank will be turned upon itself so that the free edges of the long side wall halves overlap. These panels will be affixed to one another, e.g., by staples or adhesive, so that the folded blank has formed a tube. The bottom closure flaps are folded inwardly to overlap one another and form the bottom of the bin. The bin may be placed on a pallet or slip sheet for transportation purposes. 
     Although some of these bins can be quite strong, it has been a challenge in the industry to provide a collapsible bulk bin which is capable of holding a load in excess of 2000 pounds. Such prior art bins may be susceptible to failure, which is believed to be caused by the presence of the slots and gaps that are formed in the bottom, as a result of the use of the separately emanating overlapping bottom flaps. Therefore, in order to support such loads, the bulk bins may have to be provided with additional support, in the form of external bands, which may be fabricated from metal or plastic material, which add to the cost of the bin, and which complicate its use. 
     Accordingly, it would be desirable to provide a collapsible bulk bin which is capable of withstanding heavy loading with reduced likelihood of failure, and without requiring the addition of further structural support, such as external banding. 
     These and other desirable characteristics of the invention will become apparent in view of the present specification, claims and drawings. 
     SUMMARY OF THE INVENTION 
     The present invention comprises, in part, a collapsible bulk bin, fabricated from a foldable material, which comprises a plurality of side walls, arranged in the form of a tube and connected to one another along a plurality of parallel-extending fold lines. A plurality of bottom panels extends from bottom edge regions of the side walls, with a fold line disposed between each bottom panel and its respective side wall. Each bottom panel is pivotable between an unfolded position substantially parallel to its corresponding side wall, and a folded position substantially perpendicular to its corresponding side wall. A plurality of connector panels is provided, in which each connector panel is disposed between and emanating, along lines of weakness, from side edge regions of adjacent ones of the plurality of bottom panels. Each connector panel is pivotable between an unfolded position disposed substantially parallel to and coplanar with one of its corresponding adjacent bottom panels, to a folded position disposed in sandwiched orientation between its adjacent bottom panels. Each connector panel is further operably configured such that upon folding of one of its adjacent bottom panels from its unfolded position to its folded position, the connector panel prompts the other of the adjacent bottom panels from its unfolded position to its folded position. The connector panels provide slotless interconnections between adjacent bottom panels, the slotless interconnections extending from lower end regions of the fold lines which extend between adjacent ones of the side walls, so as to bridge gaps, which may otherwise be formed between adjacent ones of the bottom panels, upon articulation of the bottom panels into their folded positions, toward precluding the creation of gaps at corner regions of a bottom area of the collapsible bulk bin which may prompt failure of the collapsible bulk bin, subsequent to loading thereof. 
     In a preferred embodiment of the invention, each connector panel has a substantially triangular configuration. 
     The collapsible bulk bin further comprises an aperture disposed in at least one of the bottom panels, operably configured to interlockingly receive a corner of another of the bottom panels, when the bottom panels have been pivoted to their folded positions, for releasably holding the bottom panels in their respective folded positions. 
     In a preferred embodiment of the invention, the bulk bin has one of four, six or eight side walls. 
     Preferably, two of the bottom panels, disposed opposite one another on the bulk bin, are substantially rectangular, and the remaining bottom panels are substantially non-rectangular. 
     The bulk bin is preferably fabricated from at least one of paper, paperboard, corrugated paperboard. The bulk bin is preferably fabricated from a blank formed from a single sheet of foldable material. The collapsible bulk bin may also have a plurality of top reinforcement panels emanating from top edges of the side wall panels, wherein the top reinforcement panels are provided with slots for enabling the top reinforcement panels to be interdigitated, for providing resistance to outward bulging of the side wall panels, when the bulk bin formed from the blank is loaded. 
     The invention also comprises, in part, a blank for forming a collapsible bulk bin. The blank comprises a substantially rectangular sheet fabricated from a foldable material. A plurality of side wall panels are formed therein and separated from one another by a plurality of parallel-extending lines of weakness, the side wall panels disposed at opposite ends of the sheet having free edges. A plurality of bottom panels extend from bottom edge regions of the side wall panels, with a fold line disposed between each bottom panel and its respective side wall panel, the bottom panels disposed at opposite ends of the sheet having free edges. Connector panels are disposed between and emanating, along lines of weakness, from side edge regions of adjacent ones of the plurality of bottom panels. The side wall panels disposed at opposite ends of the sheet are operably configured to be overlapped to form a composite side wall panel, upon folding of the sheet upon itself to form a tube. The bottom panels disposed at opposite ends of the sheet are operably configured to be overlapped to form a composite side wall panel, upon folding of the sheet upon itself to form a tube, the connector panels providing slotless interconnections between adjacent bottom panels, the slotless interconnections extending from lower end regions of the fold lines which extend between adjacent ones of the side walls so as to bridge gaps, which may otherwise be formed between adjacent ones of the bottom panels, upon articulation of the bottom panels into their folded positions, toward precluding the creation of gaps at corner regions of a bottom area of the collapsible bulk bin which may prompt failure of the collapsible bulk bin, subsequent to loading thereof. 
     In the blank, each connector panel preferably has a substantially triangular configuration. 
     An aperture is disposed in at least one of the bottom panels, for interlockingly receiving a corner of another of the bottom panels, when the blank is articulated into a deployed bulk bin configuration. 
     Two of the bottom panels are preferably substantially rectangular, and the remaining bottom panels are preferably substantially non-rectangular. 
     The blank is preferably fabricated from at least one of paper, paperboard, corrugated paperboard. The blank is preferably formed from a single sheet of foldable material. The blank may also have a plurality of top reinforcement panels emanating from top edges of the side wall panels, wherein the top reinforcement panels are provided with slots for enabling the top reinforcement panels to be interdigitated, for providing resistance to outward bulging of the side wall panels, when the bulk bin formed from the blank is loaded. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a plan view of a blank for forming a collapsible bulk bin according to a preferred embodiment of the invention. 
         FIG. 1A  is a plan view of the bulk bin, in a folded flat configuration, after the blank has been folded upon and joined to itself. 
         FIG. 2  is perspective view of the bulk bin, according to the present invention, in which the blank has been formed into a tube, with the free ends affixed to one another, but prior to folding of any of the bottom panels. 
         FIG. 3  is a perspective view of the bulk bin, according to the embodiment of  FIGS. 1 and 2 , with the bottom panels slightly folded. 
         FIG. 4  is a perspective view of the bulk bin, according to the embodiment of  FIGS. 1 and 2 , with the bottom panels further folded. 
         FIG. 5  is a perspective view of the bulk bin, according to the embodiment of  FIGS. 1 and 2 , with the bottom panels completely folded and tucked. 
         FIG. 6  is a plan view for a blank for a bulk bin, according to the principles of the present invention, which is used to form a four-sided bulk bin, according to an alternative embodiment of the invention. 
         FIG. 7  is a plan view for a blank for a bulk bin, according to the principles of the present invention, which is used to form a six-sided bulk bin, according to an alternative embodiment of the invention. 
         FIG. 8  is a plan view for a blank for a bulk bin, according to the principles of the present invention, which is used to form an eight-sided bulk bin, according to an alternative embodiment of the invention. 
         FIG. 9  is a plan view for a blank for a bulk bin, according to the principles of the present invention, which is used to form an eight-sided bulk bin, according to an alternative embodiment of the invention. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     While this invention is susceptible of embodiment in many different forms, there is shown in the drawings and will herein be described in detail, a preferred embodiment with the understanding that the present disclosure should be considered as an exemplification of the principles of the invention and is not intended to limit the invention to the embodiment so illustrated. 
     The cartons of the present invention are preferably fabricated from paper, paperboard and/or corrugated paperboard, although other materials having similar performance characteristics may be employed, as desired or dictated by the requirements of a particular application. 
     When referring to the plan illustrations of the blanks, the usual drawing conventions for illustration of carton blanks fabricated from paper, paperboard and/or corrugated paperboard, as are customarily employed in the art, are applied. That is, unless otherwise noted, broken lines on the interior of a blank indicate scores, fold lines or other lines of weakness such as perforations; scalloped lines on the interior of a blank indicate lines of weakness forming a tear strip or similar structure; and solid lines within the interior of, or extending to the edge of, a blank, indicate through-cuts. 
     Bulk bin  10  is formed from blank  11 , shown in plan form (from an “inside” view) in  FIG. 1 . Blank  11  includes corner panels  12 ,  14 ,  16  and  18 ; “long” side wall panels  20 ,  22 ; “short” side wall panel  24 ; and “half” panels  26 ,  28 ; as well as vertical fold lines  30 ,  32 ,  34 ,  36 ,  40 ,  42  and  44 . The bottom structure for bulk bin  10  includes bottom panels  46 ,  50 ,  54 ,  58 ,  66 ,  72 ,  76 ,  80  and  86 ; connector panels  48 ,  52 ,  56 ,  64 ,  70 ,  74 ,  78  and  84 ; clearance flaps  62 ,  60 ,  68  and  82 ; fold lines  88 ,  89 ,  90 ,  96 ,  98 ,  100 ,  104 ,  106 ,  108 ,  110 ,  112 ,  116 ,  118 ,  120 ,  124 ,  128 ,  132 ,  136 ,  138 ,  140 ,  144 ,  146 ,  148 ,  150 ,  154 ,  156 ,  158 ,  160 ,  162 ; die cuts  92 ,  94 ,  102 ,  114 ,  122 ,  126 ,  130 ,  134 ,  142 ,  152 ,  164 ,  166 ; and triangular holes  170 ,  172 . 
     Bulk bin  10  is of an octagonal configuration, with two sets of parallel side walls, namely “long” side walls  20 ,  22 ; “short” side walls  24  and  26 / 28  and corner side walls  12 ,  14 ,  16 , and  18 . The corresponding respective “long” bottom panels  54  and  76  are rectangular, while “short” bottom panels  66  and  46 / 86  are hourglass-shaped; while the corner bottom panels  50 ,  58 ,  72  and  80  are “K”-shaped. Connector panels, which are disposed between corner bottom panels and the long bottom panels, namely connector panels  52 ,  56 ,  74  and  78  are in the form of approximately isosceles triangles, extending to the free edge  13  of the blank, which have one of their short sides defined by a die cut. The connector panels that are disposed between the corner bottom panels and the short bottom panels, namely connector panels  48 ,  64 ,  70  and  84  are triangular flaps that do not extend to the free edge  13  of the blank, but are adjacent the clearance flaps. 
     The clearance panels typically may have shapes that are the same as the connector panels (i.e., triangular). Alternatively, they may be as configured, with rectangular ends (which may prevent fraying). Similarly, the corners of the locking tabs are usually not pointed, also for purposes of inhibiting fraying. In further alternative embodiments of the invention, the clearance flaps may be die cut entirely from the blank, provided that the presses used to cut/print the blanks are capable of physically removing all the cut-away scrap material from the blanks. 
     To form bulk bin  10 , first blank  11  is folded into a tubular form, with half panels  26 ,  28  overlapping so that their combined width is approximately equal to the width of short side wall panel  24 . Half panels  26 ,  28  are then affixed to one another by any suitable method, such as adhesives or staples, or a combination thereof. This stage in the formation process is shown in  FIG. 2 . In a preferred method of manufacture, the affixation of panels  26  and  28  may be accomplished by first folding blank  11  about fold lines  44 ,  154  and  156 , so that half panel  28  overlies corner panel  18 ; and bottom panel  86 , connector panel  84  and clearance panel  82  overlie bottom panel  80 . Then, blank  11  is then folded about fold lines  36 ,  116  and  124 , so that half panel  26  overlies panel  28 , and can be affixed thereto. This results in a flattened tubular structure, as shown in  FIG. 1A , in which configuration, bulk bin  10  may be readily transported. 
     To form bulk bin  10  into a container, the bin is opened into a tube, as shown in  FIG. 2 , in which each of bottom panels  46 ,  50 ,  54 ,  58 ,  66 ,  72 ,  76 ,  80  and  86  are extending straight up from their respective side wall panels  26 ,  12 ,  20 ,  14 ,  24 ,  16 ,  22 ,  18  and  28 . “Corner” bottom panels  50 ,  58 ,  72  and  80  are then folded inwardly, about their respective fold lines  89 ,  110 ,  138  and  158 . As this is done, connector panels  48 ,  52 ,  56 ,  64 ,  70 ,  74 ,  78  and  84  pivot along their respective fold lines  90 ,  96 ;  100 ,  104 ;  108 ,  112 ;  116 ,  118 ;  128 ,  132 ;  140 ,  144 ;  148 ,  150 ; and  154 ,  162 , so that the connector panels move toward, and then past, positions that are perpendicular to their respective corner bottom panels, to positions in which they begin to be folded “under” bottom panels  54 ,  66 , and  76  and composite bottom panel  86 / 46 . As corner bottom panels  50 ,  58 ,  72  and  80  continue to be folded to positions perpendicular to side wall panels  12 ,  14 ,  16  and  18 , connector panels  48 ,  52 ,  56 ,  64 ,  70 ,  74 ,  78  and  84  “pull” bottom panels  54 ,  66 , and  76  and composite bottom panel  86 / 46  down into overlapping positions over the bottom corner panels.  FIGS. 3 and 4  illustrate the relative positions of the respective bottom panels, during the folding process. During the folding process, clearance flaps  62 ,  60 ,  68  and  82  pivot, as necessary, about their respective fold lines  98 ,  124 ,  136  and  156 , to enable the edges of the adjacent bottom panels to move past. As the folding process is completed, the free edge of one of bottom panels  54  and  76  will overlap the other. 
     At the end of the folding process, as bottom panel  66  and composite bottom panel  86 / 46  approach perpendicularity relative to their respective side wall panels  24  and  26 / 28 , opposing free corners of panels  66  and  86  are tucked into triangular apertures  170  and  172 , respectively, to help hold the bottom panels in their folded configurations, both during formation, and after bin  10  is flipped over, and placed, if desired, on a pallet or skid sheet, prior to loading. At the end of the folding process, all of the bottom area of the bin will be closed or covered by one or more of the bottom panels. 
     Because all of the bottom panels are connected to one another along their peripheral edge regions, in the vicinity of the bottom edges of the side wall panels, there are no slots, and thus no points of weakness which can provide origination points for tears or rips that might lead to failure of the bin when under stress. By interconnecting the bottom panels with the connector panels, it is believed that the overall strength and resistance to bulging, particularly in the area of the side wall panels closest to the bottom of the bin, is enhanced, thereby reducing or eliminating the need for additional external support in the form of circumferentially extending bands or straps. 
     While in the embodiment of the invention illustrated in  FIGS. 1-5 , the bulk bin is in the form of an octagonal bin (when viewed from above), it is to be understood that the number of side walls of the bin may be modified, e.g., to a four-sided bin, or other number of side walls, without departing from the scope of the invention, and the principles of the present invention may be readily adapted by one of ordinary skill in the art of bin design, having the present disclosure before them, to bins having greater or fewer side walls than that illustrated in  FIGS. 1-5 . 
     For example, a blank for a four-sided bulk bin is shown in  FIG. 6 . Blank  200  includes long side panel  202 ; short side panels  204 ,  206 ; and half side panels  208 ,  210  which are overlapped to form a composite long side panel, opposite long side panel  202  upon articulation and gluing of the bulk bin blank  200 . Blank  200  also includes long bottom panel  212 ; short bottom panels  214 ,  215  with tabs  284 ,  286 ,  288 ,  290 ; half bottom panels  240 ,  242 ; connector panels  218  (defined by fold  220  and cut  222 ),  223  (defined by fold  224  and cut  226 ),  228  (defined by fold  232  and cut  234 ) and  230  (defined by fold  236  and cut  238 ); tab receiving openings  244 ,  246 ,  248  and  250 . Blank  200  also includes top reinforcing flaps  260 ,  262 ,  264 ,  266  and  268 , with notches  270 ,  272 ,  274 ,  276 ,  278 ,  280 ,  282  and  284 . 
     To form a bulk bin from blank  200 , the blank is folded upon itself so that half side panels  208 ,  210  are slightly overlapped and glued to each other. Similarly, half bottom panels  240 ,  242  are overlapped and glued to one another. To help reinforce the top edges of the side panels, top reinforcing flaps  260 ,  262 ,  264 ,  266  and  268  are folded perpendicular to the side panels, and the notches of adjacent top reinforcing flaps are interdigitated, so that the top reinforcing flaps interlock. Formation of the bottom is accomplished by first folding long bottom panel  212 , and the composite bottom panel formed by half bottom panels  240 ,  242  to positions perpendicular to the side panels. This action causes the connector panels to be pivoted about the respective fold lines connecting them to their respective adjacent bottom panels. Finally, bottom panels  214  and  216  are folded down, and tabs  284 ,  286 ,  288  and  290  are received by openings  244 ,  246 ,  248  and  250 , respectively. 
       FIG. 7  illustrates a blank for forming a six-sided (hexagonal) bulk bin. Upon articulation and folding, blank  300 , as illustrated, will form a regular hexagonal bulk bin, although in alternative embodiments, one or more opposing pairs of side panels may be longer than others, to form an elongated configuration. Blank  300  includes side panels  302 ,  304 ,  306 ,  308 ,  310  and half side panels  312 ,  314 ; bottom panels  316  (with tabs  315 ,  317 ),  318 ,  320 ,  322 ,  324 , and half bottom panels  326  (with tab  327 ),  328  (with tab  329 ); connector panels  330  (defined by fold  332  and cut  334 ),  336  (defined by fold  338  and cut  340 ),  342  (defined by folds  344 ,  346 ),  348  (defined by folds  350 ,  352 ),  354  (defined by fold  356  and cut  358 ), and  360  (defined by fold  362  and cut  364 ); and tab openings  366 ,  368 . 
     After folding blank  300  and gluing panels  326  and  328  together (with a slight overlap), to form the bottom, first bottom panels  332 ,  320  are folded perpendicular to the side panels, with bottom panels  318 ,  324 , following (with their respective adjacent connector panels swinging to positions sandwiched between the bottom panels). Finally bottom panels  316  and the composite bottom panel formed from panels  326 ,  328  are folded down, so that tabs  327  is received by aperture  366  while tab  317  is received by aperture  368 . 
     Blank  400 , shown in  FIG. 8 , is for forming an alternative construction of an eight-sided bulk bin. Blank  400  includes long side panels  402 ,  404 ; short side panel  406 ; diagonal corner panels  408 ,  410 ,  412 ,  414 ; and half side panels  416  and  418  which, when overlapped and glued together, form a composite short side panel, which will be positioned opposite short side panel  406 , upon full articulation of the resultant bin. Blank  400  also includes long bottom panels  420  (with slot  458 ),  422  (with slot  460 ); short bottom panel  424 ; diagonal bottom panels  426 ,  428 ,  430 , and  432 ; and half bottom panels  434  and  436 , which similarly when overlapped and glued together form a composite short bottom panel which will be positioned opposite short bottom panel  424 , upon articulation of the bin. Blank  400  further includes connector panels  438 ,  440 ,  442 ,  444 ,  446 ,  448 ,  450  and  452 , which are connected by pairs of converging fold lines to their respective adjacent bottom panels. Unlike the embodiment of  FIGS. 1-5 , there are no clearance flaps. Articulation and folding of the various bottom and connector panels is substantially identical to that employed in the articulation and folding of the bottom and connector panels in the embodiment of  FIGS. 1-5 . Blank  400  may further include reinforcement tapes, known as “Sesame Tape” to those of ordinary skill in the art of designing and fabricating bulk bins from corrugated paperboard material, for providing additional resistance to bulging for especially large loads. 
       FIG. 9  illustrates blank  400 ′ which is substantially identical to blank  400 , and so has similarly situated panels indicated by like reference numerals, but augmented by primes (′). Blank  400 ′ differs principally from blank  400  in that connector panels  440 ′,  442 ′,  448 ′ and  450 ′ are substantially enlarged and extend to the peripheral edge of the blank; and that instead of just one tab receiving slot in each of bottom panels  420 ′ and  422 ′, there are two. As such, blank  400 ′ includes additional slots  462 ′ and  464 ′ and tabs  466 ′ and  468 ′. Aside from those differences, articulation and folding of the various bottom and connector panels is substantially identical to that employed in the articulation and folding of the bottom and connector panels in the embodiment of  FIGS. 1-5 . Blank  400 ′ also may include reinforcing “Sesame Tape”, if desired, as in the embodiment of  FIG. 8 . 
     The foregoing description and drawings merely explain and illustrate the invention, and the invention is not so limited as those skilled in the art who have the disclosure before them will be able to make modifications and variations therein without departing from the scope of the invention.