Abstract:
A soft sided container that, when filled, is substantially cuboid in shape and has two flaps extending from upper edges of the front and rear panels. The flaps have fold lines such that, the flaps fold together. Holes cut in upper regions of the flaps form handles. Lengthwise across a top panel of the container is an elongated closure device that opens for accessing of the materials stored within and closes to seal the container. The elongated fastener continues at least partially across two triangular side flaps such that, when open, one of the triangular side flaps serves as a pouring spout. In some embodiments, a side flap retainer is connected between the side flaps to removably hold the side flaps in place against the top of the container.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application is a continuation of U.S. patent application Ser. No. 13/546,374, filed Jul. 11, 2012, the disclosure of which is hereby incorporated by reference. 
    
    
     FIELD 
     This invention relates to the field of packaging, particularly to a container suitable to for transporting non-liquid products. 
     BACKGROUND 
     Granular or powdered materials, like cat litter, pet food and grain are typically manufactured, transported, and dispensed from a variety of containers, including paper and biaxially oriented polypropylene (BOPP) bags, boxes, bag-in-boxes (BIB), pails and buckets. For larger quantities up to 40 to 50 pounds, the containers are typically paper and BOPP bags, BIB&#39;s and pails/buckets (four to five gallons). 
     Paper and BOPP bags are sealed at each end by stitching through crepe tape (one to two inch paper or BOPP strips). The ends of the bags are typically v-shaped, which makes the package difficult to display or store in a vertical position. Additionally, once the package is opened, the contents often spill due to the v-shaped bottom of the bag. Since paper and BOPP bags are not self-supporting, they are usually palletized, transported, shelved and advertised in a horizontal position. The horizontal position allows visibility of only a small portion of the container from the end, reducing visibility of advertisements and product claims and requiring greater storage area (shelf space). Paper and BOPP bags that are in excess of 20 pounds and are difficult to carry and typically do not have a handle. 
     Another typical package for such products is pails and buckets, which are generally constructed from high density polyethylene (HDPE). Buckets and pails typically have a snap on/off lid comprised of HDPE and a handle made of either HDPE or metal. Both types of handles often have a HDPE cover or grip to provide comfort while carrying the package. Buckets and pails are often difficult to carry due to their diameter, requiring the individual to attempt to carry the container at a position away from their leg at an awkward position. Oftentimes the bucket will hit the individual&#39;s leg during transport interfering with walking. The snap on/off lids are often difficult to open and/or close to re-seal. While it is easy to access the material via the snap on/off lid, the product cannot be easily dispensed from the container due to the bulk and weight of the container. Buckets and pails can be recycled due to the fact that they are constructed from HDPE. If the container has a metal handle, it must be separated from the container and the HDPE handle cover must be removed from the handle. During recycling, the bucket/pail is rigid, does not compress and consumes excessive space during transportation and at the recycling facility. Storage and palletizing efficiency is reduced, due to the fact that empty space exists between buckets and pails. Some buckets and pails are square or rectangular shaped to reduce the empty space, but do not completely eliminate the space. 
     BIB&#39;s and boxes for granular and powdered material are constructed of corrugated paper. Boxes or BIB&#39;s typically have a top handle made of HDPE or two handles cut into the corrugated paper at the top of each side of the container. Boxes are sealed to prevent the material from leaking from the container, while the BIB utilizes a polyethylene bag to contain the product. Boxes and BIB&#39;s are typically sealed at the top by tape. While this type of container provide easy access to the material within, it is difficult to dispense the material from the bulky container. The boxes are also difficult to carry as described above due to the bulky nature container and the location of the handles on the package. The HDPE handle is uncomfortable while carrying the container and the side handles often tear while being carried. Boxes and BIB&#39;s are either square or rectangular shaped and eliminate wasted space during transportation. Additionally, boxes and BIB&#39;s eliminate wasted space on shelves and the front panel can be utilized for advertising and product claims. While these containers are constructed from recyclable corrugated paper, they are rigid and must be deconstructed prior to recycling. The BIB&#39;s and boxes with HDPE handles must be removed prior to recycling. The polypropylene bag in the BIB must be disposed of separately. 
     What is needed is a container for granular or powdered material that is ergonomic (easy to carry, provides easy access to and allows the product to be dispensed easily), economic (costs less than HDPE containers or corrugated paper), ecologic (uses less material than HDPE or corrugated paper containers, can be re-used and recycled) and efficient (no space between packages during transport, better utilization of shelf space and conformable to the product in the container). 
     SUMMARY 
     A container typically made of a pliable material such as BOPP (polypropylene film that is extruded and stretched in X and Y directions) that possesses sufficient tensile strength to, for example, pass a standardized drop test with up to 50 pounds of product. The container, when filled, is substantially cuboid (or cube) in shape and has two flaps extending from upper edges of the front and rear panels. The flaps have fold lines such that, the flaps fold together and holes cut in upper regions of the flaps form handles for convenient transportation of the container and contents. Lengthwise across a top panel of the container is an elongated closure device (zipper, Velcro or Ziploc) that opens for accessing the materials stored within and closes to seal the container. The elongated closure device continues at least partially across two triangular side flaps such that, when open, the triangular side flaps serve as pouring spouts. In some embodiments, a side flap retainer is connected between the side flaps to removably hold the side flaps in place against the top of the container and to stow the flaps during filling and transportation. 
     In one embodiment, a container is disclosed including four connected and substantially rectangular panels including a front panel, rear panel, left panel and right panel. The container is sealed on the bottom by a substantially rectangular bottom section that has four edges. Each edge of the bottom section is connected to a respective bottom edge of a corresponding one of the four substantially rectangular panels. A first flap extends from an upper edge of the front panel and has a first fold line. The first fold line is substantially parallel to the upper edge of the front panel and divides the first flap into an upper first flap and a lower first flap. A second flap extends from an upper edge of the rear panel and has a second fold line. The second fold line is substantially parallel to the upper edge of the rear panel and divides the second flap into an upper second flap and a lower second flap. When the first flap is bent to approximately 90 degrees at the first fold line and the second flap is bent to approximately 90 degrees at the second fold line, the upper first flap abuts the upper second flap. A top section completes and seals the container. Each edge of the top section is connected to one of the upper edge of the front panel, the upper edge of the rear panel and upper edges of each of the left and right panel. The top section, the front panel, the rear panel the left and right panels and the bottom section are for containing a dry material, and when filled, substantially form a cuboid. 
     In another embodiment, a method of transporting a material is disclosed including inverting a container as previously described so that the bottom section is facing upwardly. The bottom section is bifurcated into a first bottom panel and a second bottom panel and the edge of the first bottom panel closest to the second bottom panel is disengaged with the edge of the second bottom panel closest to the first bottom panel. Next, the container is filled with the material then the edge of the first bottom panel closest to the second bottom panel is affixed to the edge of the second bottom panel closest to the first bottom panel, thereby sealing the container (e.g. by stitching, adhesives, heat-seal, etc.). The container is then inverted such that the first flap and the second flap are upward and picked up and carried by the first flap and the second flap. 
     In another embodiment, a container for holding, storing and transporting dry materials is disclosed. The container includes four connected and substantially rectangular panels: a front panel, rear panel, left panel and right panel. A substantially rectangular bottom section includes four edges, such that each edge of the bottom section is connected to a respective bottom edge of a corresponding one of the four substantially rectangular panels enclosing a bottom area of the container. A first flap extends from an upper edge of the front panel and has a first fold line. The first fold line is substantially parallel to the upper edge of the front panel and divides the first flap into an upper first flap and a lower first flap. A first handle hold is cut/formed in the upper first flap. A second flap extends from an upper edge of the rear panel and has a second fold line. The second fold line is substantially parallel to the upper edge of the rear panel and divides the second flap into an upper second flap and a lower second flap. A second handle hold is cut/formed in the upper second flap. When the first flap is bent to approximately 90 degrees at the first fold line and the second flap is also bent to approximately 90 degrees at the second fold line, the upper first flap abuts the upper second flap. The container has a top section. Each edge of the top section is connected to one of the upper edges of the front panel, the upper edge of the rear panel and upper edges of each of the left and right panel, thereby closing the container for holding a dry material such that the container substantially forms a cuboid. The top section of the container has a first and second triangular side flap and a side flap retainer. A first edge of the first triangular side flap is connected to the upper edge of the left panel and a first edge of the second triangular side flap is connected to the upper edge of the right panel. A first end of the side flap retainer is interfaced to a vertex of the first triangular side flap and a distal end of the side flap retainer is interfaced to a vertex of the second triangular side flap, thereby urging the vertex of the first triangular side flap towards the vertex of the second triangular side flap and urging the first and second triangular side flaps to lay against the top section. The side flap retainer has a fastener that disengageably connects a first length of the side flap retainer that is interfaced to the vertex of the first triangular side flap from a second length of the side flap container that is interfaced to the vertex of the second triangular side flap. Thereby, when the fastener is disengaged, the first triangular side flap and second triangular side flaps are free to bend outwardly and away from the top section. The top section also includes an elongated closure device running substantially parallel to both the upper edge of the front panel and the upper edge of the rear panel and continuing across a portion of each of the first and second triangular side flaps. The elongated closure device has a closed position in which the container is sealed and an opened position in which access to the material in the container is provided. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The invention can be best understood by those having ordinary skill in the art by reference to the following detailed description when considered in conjunction with the accompanying drawings in which: 
         FIG. 1  illustrates a perspective view of a container, with handles flat against the top of the container. 
         FIG. 2  illustrates a second perspective view of the container, with handles extended. 
         FIG. 3  illustrates a top plan view of the container, with handles extended. 
         FIG. 4  illustrates a top plan view of the container with handles pulled aside and end-flaps connected. 
         FIG. 5  illustrates a top plan view of the container with handles pulled aside and end-flaps extended. 
         FIG. 6  illustrates a top plan view of the container with handles pulled aside, end-flaps extended, and closure device open for access to the contents. 
         FIG. 7  illustrates a front plan view of a plurality of the containers on a pallet (We can attach a photograph of a completed pallet, if required). 
         FIG. 8  illustrates a third perspective view of the container situated in an inverted position being filled with material. 
         FIG. 9  illustrates a bottom plan view of the container situated in an inverted position after filled with a material and sealed by stitching. 
     
    
    
     DETAILED DESCRIPTION 
     Reference will now be made in detail to the presently preferred embodiments of the invention, examples of which are illustrated in the accompanying drawings. Throughout the following detailed description, the same reference numerals refer to the same elements in all figures. 
     Although the container disclosed is ideal for advertising, transporting, storing and dispensing pet products such as litter (e.g. granular clay) or animal food, the container is not limited to any particular use or contained material. It is anticipated that the disclosed container be used to contain any loose, solid, powdered or granular material, including, but not limited to: cement, pebbles, stones, sand, mulch, softener salt, pool chemicals, laundry detergent, cereal, grain, seed, fertilizer, etc. The disclosed container is also useful for use with many other forms of dry material such as rags, clothing, nails, scrap, etc. 
     Referring to  FIGS. 1 and 2 , perspective views of a container  10  is shown. Generally speaking, the container  10  generally forms a cuboid or rectangular prism when full having substantially rectangular sides, a width, height and depth, though the sides do not necessarily meet at right angles (e.g. smoothed edges, rolled edges, etc.). It is anticipated that the preferred embodiment, when filled, the edges of the container  10  are rounded, thought there is no restriction and it is also anticipated that the edges are not rounded. 
     It is anticipated that the sides be made of a cloth-like, flexible material that, in some embodiments, has sufficient tensile strength to survive a drop test with up to 50 pounds of material, as will be described providing what is known as soft sides (as opposed to rigid side as would be found with corrugated cardboard box containers, pails or buckets. 
     Throughout the description and in the figures, the container  10  is shown in a filled configuration or shown as if it were full of a material such as animal litter (e.g. granular clay), water softener salt (pellets or granular), sand, concrete, dry animal feed, seed, fertilizer, etc. As shown in  FIGS. 1 and 2 , one can appreciate that the container  10  stands upright providing several advantages not limited to providing greater visibility to descriptive material or product claims printed on side surfaces, easy of pausing while carrying, ease of stacking/dispensing, ease of access to contents, etc. As one example of the listed attributes, when a person is carrying 60 pounds of dog food in the container  10  and needs a rest, the person extends their reach slightly and the container  10  will rest upright on the ground next to the person. To resume, the person only need extend their arm far enough to engage with the handle  16  and resume carrying the container  10 . In contrast to existing bag/sack technology, the person would have to bend over to lay the bag on its face or back, then to resume the person would have to bend over to pick up the bag and, possibly, reposition the bag between the person&#39;s arm and body or carry the bag with two arms. Carrying of such a bag-type container often results in back strain or other issues. 
     In  FIGS. 1 and 2 , the container  10  is shown and the front panel  12 , side panel  9  and two flaps  14 / 18  (upper flap section  14  and lower flap section  18 ) are visible (the other side panel, back panel and bottom panel are not visible). The flaps  14 / 18  are made of a continuous sheet of material that is folded along a fold line  13 . The lower flap sections  18  extend from a top edge of the front panel  12  and a top edge of the back panel (not visible). In a preferred embodiment, a handle  16  is cut-out in the upper flap section  14  of the flaps  14 / 18 , although it is anticipated that in some embodiments, no handle  16  is present. In  FIG. 1 , the flaps  14 / 18  are folded along the fold line  13  to lay flat for storage and stacking of the container  10 . In  FIG. 2 , the flaps  14 / 18  are folded at approximately right angles along the fold line  13  to stand upright, side-by-side for carrying of the container  10 . It is further anticipated that the container be carried by a single flap  14 / 18  (and handle  16 ) or that each flap  14 / 18  (and handle  16 ) is held by a different person and, in as much, carried between two people. 
     Referring to  FIGS. 3-6 , top plan views of the container  10  are shown. In  FIG. 3 , the flap sections  14 / 18  are folded at substantially right angles to each other as in  FIG. 2 , and the lower flap sections  18  are visible but only the edges of the upper flap sections  14  are visible (the sides of the upper flap section  14  not visible). 
     In  FIG. 4 , the flaps  14 / 18  are extended and positioned away from the container  10 , exposing the side flaps  20  and side flap retainer  22 / 24 / 26 / 28 . The side flap retainer  22 / 24 / 26 / 28  holds the side flaps  20  closed for transportation and storage of the container  10  and has a fastener  24 / 28  that is open to extend the side flaps  20  outward for access to the contents of the container  10 . In  FIG. 4 , the fastener  24 / 28  is shown engaged, thereby holding the side flaps  20  against the top surface  11  of the container  10 . In  FIG. 5 , the fastener  24 / 28  is shown disengaged and the side flaps  20  are extended outwardly, exposing the elongated fastening mechanism  30 / 32 / 34  which is preferably a zipper that includes two sets of mating teeth  32 / 34  and a slider  30  that engages/disengages the teeth of the zipper  32 / 34 . Although not required, it is preferred that the elongated fastening mechanism  30 / 32 / 34  cross the entire width of the top surface  11  and extend outwardly at both ends across the side flaps  20  so that, when the elongated fastening mechanism  30 / 32 / 34  is open, the side flaps  20  also open providing access to the contents  40  of the container  10  as shown in  FIG. 6 . In this, the opening for access to the contents  40  is substantially the full width and depth of the container  10 , allowing uninhibited access to the contents  40 . 
     Additionally, when the fastening mechanism  30 / 32 / 34  is open (or at least partially open), the side flaps  20  that are open function as a pour spouts. 
     The body of the container  10  is preferably made from a polypropylene material. For example, the container is made from polypropylene film that is extruded and stretched in X and Y directions, called Biaxially Oriented Polypropylene (BOPP). This material has increased strength and has been widely used as a package material (e.g. for fresh produce). Biaxially Oriented Polypropylene (BOPP) is easy to coat, print, and laminate. Polypropylene recycles well and, after the contents of the container  10  are depleted, the container  10  collapses, requiring a low amount of space during transportation to incinerators/recycling centers. Furthermore, after depletion of the contents of the container  10 , the container  10  is useful for many home/business uses such as trash, leaf collection, etc. Since the container  10  is not destroyed or damages during typical use, the container  10  is refillable and/or fully recyclable and refillable. 
     It is anticipated that the container  10  be produced in any dimension. In some embodiments, the container  10  is produced in standard width and depth sizes with different height sizes depending upon the volume and weight of the contents  40 . By standardizing on a particular width and depth, the same pallet size and storage shelf size works for several different volume/weight containers  10 . For example, in a sample embodiment, a container  10  for containing 40 pounds of clay litter measures 11 inches wide, 8 inches deep and 14 inches high. By making 60 pound containers  10  with the same width (11 inches), same depth (8 inches), but different height, 21 inches, the same floor space dimensions, shelf dimensions, and/or pallet dimensions holds the same number of containers  10  in one layer, enabling transitions from one capacity container  10  to another capacity container  10  without changing storage/transportation arrangements. Since the containers  10  stack well, the horizontal space is then used to store/transport more or less containers  10 . For example, two layers of 60 pound containers  10  or three layers of 40 pound containers  10 . 
     The fastening mechanism  30 / 32 / 34  is any edge coupling fastening mechanism such as the zipper  30 / 32 / 34  as shown. Other fastening mechanisms  30 / 32 / 34  are envisioned, including, but not limited to, plastic snap seals, plastic slider zippers, hook and loop material, etc. In some embodiments, the fastening mechanism  30 / 32 / 34  is a destructive mechanism such that, after opening, there are no resealing capabilities. Examples of such are perforated tear lines, pull strings that break the top surface, etc. 
     Although it is preferred that the container  10  is made from a polypropylene material, any suitable material is anticipated including, but not limited to, low density polyethylene, canvas, paper, etc. It is anticipated, but not required, that a container  10  made of Polypropylene resin requires less raw material during manufacture that an equivalent volume pail/bucket/jug, resulting in lower cost and less resource usage. 
     The side flap retainer  22 / 24 / 26 / 28  shown has two resilient cords  22 / 26 , one resilient cord  22  attached to the slider  30  and the other resilient cord  26  attached to an opposing side flap  20 . Alternately, it is anticipated that the first resilient cord  22  is attached to the first side flap  20 . Ends of the resilient cords  22 / 26  are preferably equipped with latching mechanism  24 / 28 . Any latching mechanism  24 / 28  is anticipated, including, but not limited to, snap locks  24 / 28  (as shown), hooks, a hook and a loop, etc. It is also anticipated that the cords  22  and  26  are less resilient or not resilient (e.g. cotton cord like a shoe string) with or without a latching mechanism  24 / 28 . In examples where there is no latching mechanism  24 / 28 , it is anticipated that the ends of the cords  22 / 26  be tied together (e.g. slip knot or bowtie). 
     Referring to  FIG. 7 , a front plan view of a plurality of the containers  10  on a pallet  50  is shown. This figure shows that, being that the containers  10  are substantially cuboid or rectangular prism in shape, the containers  10  stack well and are easily shrink-wrapped. The containers  10  efficiently utilize pallet and shelf space and “shrink” as contents are depleted using less space as when they were full (pails/buckets do not have this feature). Although other packaging as previously describe are capable of being stacked on a pallet, for example 60 pound bags of dog food, when stacked, the front label and predominant advertising space is not visible, except from the top of the pallet. This reduces product recognition, advertising, etc. 
     Referring to  FIGS. 8 and 9 , perspective views of the container  10  situated in an inverted position being filled with a material  40  from a spout  42  are shown. Although it is anticipated that the container  10  is perfectly suited for filling through the fastening mechanisms  30 / 32 / 34 , it is anticipated that the container  10  be filled from the bottom panels  8  before the bottom panels  8  are sealed. In  FIG. 8 , the container  10  is inverted and the bottom panels  8  open while material  40  (e.g. clay litter, animal feed, seed, etc.) is dispensed into the container  10 . After the container  10  is filled to the appropriate/desired level, the bottom panels  8  are sealed, for example using a paper strip  60  and stitching  62 . After the bottom panels  8  are sealed, the bottom panels  8  form a substantially flat surface as shown in  FIG. 9  with rounded edges or squared edges, as desired. The seal  60 / 62  folds down and will lay flat against the bottom panels  8  for improved stability. Although a paper strip  60  and stitching  62  are shown in this example, any sealing mechanism device is anticipated, including, but not limited to, an adhesive seal, an ultrasonic weld, braiding, etc. 
     Equivalent elements can be substituted for the ones set forth above such that they perform in substantially the same manner in substantially the same way for achieving substantially the same result. 
     It is believed that the system and method as described and many of its attendant advantages will be understood by the foregoing description. It is also believed that it will be apparent that various changes may be made in the form, construction and arrangement of the components thereof without departing from the scope and spirit of the invention or without sacrificing all of its material advantages. The form herein before described being merely exemplary and explanatory embodiment thereof. It is the intention of the following claims to encompass and include such changes.