Abstract:
An improved corrugated paper bin blank, collapsed bin, and bin for holding bulk goods are disclosed. According to an embodiment, the bin blank comprises three longitudinal sections, one for a bottom section, another for rectangular outer walls, and a third for octagonal inner walls. Various cut and/or scored portions of the longitudinal sections fold and overlap each other to create the final bin, and can be secured with matching tabs and slots.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS  
       [0001]    The invention claims priority under 35 U.S.C. §119 to provisional application serial No. 60/450,042, filed Feb. 26, 2003, the disclosure of which is incorporated herein by reference in its entirety. 
     
    
     
       FIELD OF THE INVENTION  
         [0002]    This invention relates to containers.  
           [0003]    More particularly, the present invention relates to storage and transport bins.  
         BACKGROUND  
         [0004]    In the art of storage and shipping bins, especially those used in retail markets, safety and durability are very important. Conventional bins used for transport and storage are formed of corrugated paper formed in an octagonal shape and carried on a rectangular pallet. These bins typically have an open top and are used to hold a variety of bulk items, such as watermelons and pumpkins in grocery stores, stuffed animals, balls, etc. in toy stores, and the like. While simple, inexpensive and effective at holding items, the octagonal shape solves some problems, but creates more. Specifically, the shape provides greater structural rigidity than rectangular bins. However, the shape also leaves the corners of the rectangular pallets, upon which they sit, uncovered. These exposed corners can and have resulted in injuries and lawsuits. It would be highly advantageous, therefore, to remedy the foregoing and other deficiencies inherent in the prior art.  
           [0005]    Accordingly, it is an object of the present invention to provide a new and improved bin.  
           [0006]    Another object of the invention is to provide a bin having structural rigidity and having outer walls matching a supporting pallet.  
           [0007]    And another object of the invention is to provide a rectangular bin having an octagonal inner wall.  
           [0008]    Still another object of the present invention is to provide a unitary sheet folded into a double walled bin. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0009]    The foregoing and further and more specific objects and advantages of the instant invention will become readily apparent to those skilled in the art from the following detailed description of a preferred embodiment thereof taken in conjunction with the drawings, in which:  
         [0010]    [0010]FIG. 1 is a perspective view illustrating a bin according to the present invention.  
         [0011]    [0011]FIG. 2 is a top plan of an unfolded bin sheet;  
         [0012]    [0012]FIG. 3 is a perspective view of a glued and collapsed bin;  
         [0013]    [0013]FIG. 4 is a side view of the collapsed bin of FIG. 2;  
         [0014]    [0014]FIG. 5 is a perspective view illustrating folding the bin sheet into a bin; and  
         [0015]    [0015]FIG. 6 is a perspective view illustrating the final folds forming the bin. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0016]    Turning now to the drawings in which like reference characters indicate corresponding elements throughout the several views, attention is first directed to FIG. 1 which illustrates a bin generally designated  10  supported upon and substantially covering a pallet  12 . As can be seen, the footprint of bin  10  substantially matches the surface of pallet  12 . Bin  10  includes outer walls  13  and bottom  14  defining a substantially rectangular volume and inner walls  15  define an octagonal volume within outer walls  13 . It will be understood that while a rectangular bin is illustrated, outer walls  13  can also define other shapes such as a square.  
         [0017]    Referring now to FIG. 2, a bin blank  16  is shown to illustrate the various scores and cuts used to create bin  10  from a single integral sheet of material. Blank  16  is preferably formed of multiple walled corrugated paper well known in the art. Single, double, triple or more layers of corrugated paper can be employed as desired. Blank  16  is then processed to create the scores, perforated scores and cuts as shown, in any manner or method, but preferably by die cutting. Through cuts are designated A, standard scores are designated B, perforated scores are designated C. Blank  16  is divided into longitudinal rows  17 ,  18  and  19 . Row  17  is separated from row  18  by scores B. Row  18  is separated from row  19  by a combination of scores B and cuts A.  
         [0018]    With additional reference to FIG. 2, bottom flaps  21 ,  22 ,  23  and  24  are formed in row  17  of blank separated by through cuts A. Flaps  21  and  23  each include a pair of slots  26  formed in the score separation from row  18  and are shaped to include tabs  27 . Flaps  22  and  24  include a pair of slots  28  formed in the score separation from row  18  and include slots  29  formed therein for receiving tabs  27 . Flaps  22  and  24  each additionally include a pair of slots  30  formed diagonally therein, for purposes which will be described presently and slots  31 . Tabs  27  are received within slots  29  to form flaps  21 ,  22 ,  23 , and  24  into bottom  14 . It should be understood that other types of bottom configurations can be employed.  
         [0019]    Still referring to FIG. 2, row  18  is separated into panels  35 ,  36 ,  37  and  38  by standard scores B, and a glue tab  40  extending from panel  38  for attachment to panel  35  to create a collapsed bin  10  as illustrated in FIG. 3. Row  19  is separated into two 3-wall panels  43 , and  44 , and two end walls  45  and  46  by through cuts A. 3-wall panels  43 , and  44 , and end walls  45  and  46  each include a pair of tabs  47  along their cut edge which correspond to and are received within slots  26  and  28 . End walls  45  and  46  include additional slots  50  formed in the separation from row  18 . 3-wall panels  43  and  44  each include a central portion  52  and opposing end portions  54  and  55  separated from central portion  52  by perforated scores C. Each end portion is further divided by a perforated score C to form an angle wall  58  and an end flap  59 . Angle walls  58  include a tab  61  extending from the cut edge and end flaps  59  include a tab  62  extending from the cut edge.  
         [0020]    Due to processing constraints, 3-wall portion  44  is completed in the gluing process which creates collapsed bin  10 . Thus, end portion  55  of 3-wall portion  44  is created by providing end flap  59  thereof with a glue tab  65 . Glue tab  65  is adhered to angle wall  58  to create the correct 3-wall panel. While this is the preferred process, one skilled in the art will understand that 3-walled panel  44  can be formed without end portion  55 . It will also be seen that additional scores  70  are formed in 3-wall panels  43  and  44 . This is to facilitate proper folding into collapsed bin  10  for use on existing machinery.  
         [0021]    Turning now to FIGS. 1, 5 and  6 , bin  10  is created from collapsed bin  10  by first folding bottom flaps  21 ,  22 ,  23  and  24  to form bottom  14  and outer walls  13 . Referring to FIG. 5, 3-wall panels  43  and  44  are then folded over in the direction of the arrowed lines to create six of the sides of octagonal inner walls  15 . Tabs  47  of 3-wall panels  43  and  44  are received within slots  28  formed in bottom  14  to position and retain 3-wall panels  43  and  44  in position. Tabs  61  are received in slots  30  of bottom  14 , and tabs  62  are received in slots  31  of bottom  14 . With reference to FIG. 6, end walls  45  and  46  are folded over in the directed of the arrowed lines with tabs  47  being received within slots  26  formed in bottom  14  to position and retain end walls  45  and  46 . Additionally, end walls  45  and  46  overlie end flap  59 , further securing them. Tabs  70  of end flaps  59  are received within slots  50  to further retain end flaps  59 . The interconnections provide a secure and rigid bin.  
         [0022]    Various changes and modifications to the embodiments herein chosen for purposes of illustration will readily occur to those skilled in the art. To the extent that such modifications and variations do not depart from the spirit of the invention, they are intended to be included within the scope thereof.