Abstract:
A pallet-free bulk bin container comprises an open-ended bulk bin having a frame base at one end. A pair of channel inserts is configured to be engaged with the frame base to form pallet runners. A pair of center-filler supports is configured to enclose one end of the open-ended bulk bin. The bulk bin container may be shipped in a collapsed or knocked-down state and easily assembled into a larger container for use and being disassembled for re-use.

Description:
FIELD OF THE INVENTION 
       [0001]    This invention relates to shipping containers, and more particularly to corrugated paperboard pallet-free bulk bin container that may be shipped in a collapsed or knocked-down state and easily assembled into a larger container for use and being disassembled for re-use. 
       BACKGROUND AND SUMMARY OF THE INVENTION 
       [0002]    Corrugated paperboard containers are commonly used to store and transport a variety of goods. Many of these containers are quite large, holding from 500 to 2,000 pounds or more of product, and typically are placed on pallets so that the containers may be handled with forklifts or jack trucks and the like. Wooden pallets are used in most conventional systems. These pallets are strong but they also are relatively heavy and expensive and are difficult to transport or recycle after use. Moreover, containers that are stacked upon but not fastened to the pallet may become displaced during handling, thereby causing the forklift operator to waste valuable time in rearranging the containers on the pallet. In extreme cases, the containers may actually fall off the pallet, causing damage to or destruction of the goods being transported. 
         [0003]    To avoid these problems, integrated container and pallet constructions have been developed in the prior art. In these constructions the bottom of the container is configured to have a pallet integrated into it, with outboard runners of the pallet extending along the outer side edges of the container, and openings inboard of the outboard runners for receiving the tines of a forklift. Conventional containers of this type usually are dimensioned to fit on a standard 40 inch by 48 inch pallet, and the tines of a forklift normally are set so that they extend through the openings inboard of the outermost runners. One problem with such containers is the ability to ship the containers in an unassembled or knock-down flattened condition, to reduce initial shipping costs due to its size, while providing the ability to set up such containers at the customer destination or other end user. Another problem is to store, destroy or otherwise handle wooden pallets. 
         [0004]    Therefore, it would be desirable to have a bulk bin container that eliminates the need for a separate pallet and can be shipped in a knocked-down flattened condition or collapsed condition. Further, it would be desirable to have such a bulk bin container that can be easily and quickly set up at the user&#39;s facility and that could be knocked down or disassembled upon completion of the use. 
         [0005]    Some of the advantages of the pallet-free bulk bin container of the present invention are as follows: the pallet-free bulk bin container is a complete bulk bin having a built-in corrugated pallet and an optional integrated lid. There is no need for wooden pallets or additional lid components. The knock-down flattened condition bulk bin folds from the knock-down position to the open position easily and quickly. The knock-down bulk bin is completely recyclable (when comprised of the standard corrugated components). The knock-down bulk bin can be stacked and stored efficiently in a warehouse when in the knock-down configuration. The knock-down position can also provide convenient and efficient returnable packaging for customers. The knock-down bulk bin can include various “kit” items i.e., bags, corner boards, partitions, and pads etc. depending on a customer&#39;s needs. The knock-down pallet-free bulk bin container can also be shipped internationally without having to meet lumber treatment codes as there is no wood in the design. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0006]    The foregoing, as well as other objects and advantages of the invention, will become apparent from the following detailed description when taken in conjunction with the accompanying drawings, wherein like reference characters designate like parts throughout the several views, and wherein: 
           [0007]      FIG. 1  is an exploded perspective view of the pallet-free bulk bin container having an open-ended bulk bin, a pair of channel inserts, a pair of center-filler supports, and a bottom pad in a spaced apart configuration in accordance to a preferred embodiment of the present invention; 
           [0008]      FIG. 2  is a bottom perspective view of the open-ended bulk bin in  FIG. 1  illustrating the pair of channel inserts partially enclosing the bottom of the open-ended bulk bin; 
           [0009]      FIG. 3  is the same as  FIG. 2  and depicting the top perspective view of the open-ended bulk bin with the partially enclosed bottom; 
           [0010]      FIG. 4  is a top perspective view of the open-ended bulk bin in  FIG. 3  illustrating the pair of center-filler supports fully enclosing the bottom of the open-ended bulk bin; 
           [0011]      FIG. 5  is a top perspective view of the open-ended bulk bin in  FIG. 4  illustrating the bottom pad positioned inside the open-ended bulk bin to receive products therein; 
           [0012]      FIG. 6  is a perspective view of the fully assembled pallet-free bulk bin container as depicted in  FIG. 1  in accordance to a preferred embodiment of the present invention; 
           [0013]      FIG. 7  is a top plan view of a blank B 1  for making the open-ended bulk bin of the pallet-free bulk bin container; 
           [0014]      FIG. 8  is a top plan view of a blank B 2  for making the pair of channel inserts used in the open-ended bulk bin to construct the pallet-free bulk bin container; 
           [0015]      FIG. 9  is a top plan view of a blank B 3  for making the pair of center-filler supports used in the open-ended bulk bin to construct the pallet-free bulk bin container; and 
           [0016]      FIG. 10  is a top plan view of a blank B 4  for making the bottom pad used in the open-ended bulk bin to construct the pallet-free bulk bin container. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0017]    While this invention is susceptible of embodiment in many different forms, there is shown in the drawings and will herein be described in detail preferred embodiments of the invention with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the broad aspect of the invention to the embodiments illustrated. In the present invention the use of prime character in the numeral references in the drawings directed to the different embodiment indicate that those elements are either the same or at least function the same. 
         [0018]      FIG. 1  is an exploded perspective view of a pallet-free bulk bin container  10  having open-ended bulk bin  12 , a pair of channel inserts  14   a,    14   b,  a pair of center-filler supports  16   a ,  16   b,  and a bottom pad  18  all in spaced relationship with one another in accordance to a preferred embodiment of the invention. The open-ended bulk bin  12  includes four side walls  20   a,    20   b,    20   c,  and  20   d.  Each of the two side wall  20   a,    20   b  includes a respective pair of fork access entry  22   a,    22   b  and  22   c,    22   d  formed by folding a plurality of inside and outside ledge panels that extend from respective bottom of the four side walls  20   a,    20   b,    20   c,  and  20   d  as will be discussed in greater detail hereinafter. The fork access entry  22   a,    22   b  and  22   c,    22   d  are generally rectangular in shape and spaced apart from one another. The pair of channel inserts  14   a,    14   b  each of each is inserted into two of the fork access entry. For example, the channel insert  14   a  is attached to the fork access entries  22   a,    22   c,  and the channel insert  14   b  is attached to the fork access entries  22   b,  and  22   d  as depicted best in  FIG. 2 . It should be noted that by attaching the respective channel inserts  14   a,    14   b  to the respective fork access entries  22   a,    22   b ,  22   c,  and  22   d,  the bottom of the open-ended bulk bin  12  is now partially enclosed as seen best in  FIG. 3 . Each of the pair of center-filler supports  16   a,    16   b  is press fit or friction fit inside the open-ended bulk bin  12  to fully enclose the bottom of the open-ended bulk bin  12  as shown in  FIG. 5 . Finally, the bottom pad  18  is disposed inside the open-ended bulk bin  12  to provide support for the products received in the interior space  24  as shown in  FIG. 6 . The pallet-free bulk bin container  10  is sized sufficiently to contain articles therein for shipment and/or storage. Furthermore, the channel inserts  14   a,    14   b,  and the center-filler supports  16   a,    16   b  are respectively sized so that the bulk bin  12  can support the weight of the articles shipped and/or stored therein. However, one of ordinary skill in the art would appreciate that the claimed invention is not limited to two channel inserts or two center-filler supports since there can be one channel insert and one center-filler support for the purpose of the invention. The pallet-free bulk bin container  10  is adapted to be stacked on one or more of the same pallet-free bulk bin container  10 . 
         [0019]      FIG. 7  is a top plan view of a blank B 1  for making the open-ended bulk bin  12  of the pallet-free bulk bin container  10 . The blank B 1  is substantially flat symmetrical with respect to its lateral axis and preferably is an integral piece of a material such as continuous sheet of conventional corrugated paperboard. The blank B 1  is cut along its outer margins to form its specific shape. The blank B 1  is foldably divided into four side wall panels  20   a,    20   b,    20   c,  and  20   d  by lateral fold lines  30   a,    30   b,    30   c,  and  30   d.  Four cover tuck flaps  28   a,    28   b,    28   c,  and  28   d  are formed on one longitudinal edge of the blank B 1  by the longitudinal fold line  32   a.  Two outside ledge panels  34   a,    34   b  and two inside ledge panels  36   a,    36   b  are formed on other longitudinal edge of the blank B 1  by fold line  32   b.  The respective outside ledges  34   a,    34   b  are formed on one lateral end of the respective side wall panels  20   a  and  20   b  and the respective inside ledges  36   a,    36   b  are formed on one lateral end of the respective side wall panels  20   c  and  20   d.  The respective outside ledges  34   a,    34   b  and the inside ledges  36   a,    36   b  are foldably attached to one another to form a base frame  35  so that the pair of channel inserts  14   a,    14   b,  and the pair of center-filler supports  16   a,    16   b  can be foldably attached thereto to enclose the bottom of the open-ended bulk bin  12  when the blank B 1  is constructed. The frame base  35  functions as pallet runners which eliminates using a separate pallet for the bulk bin. The outside ledges  34   a  includes inner and outer panels  38   a,    38   b  foldably joined to one another by fold line  40 . Similarly, outside ledges  34   b  includes inner and outer panels  38   c,    38   d  foldably joined to one another by fold line  40 . Each of the respective outside ledges  34   a  and  34   b  includes two identical cut outs  22   a ′,  22   b ′,  22   c ′, and  22   d ′ which forms the fork access entries when the blank B 1  is fully constructed. Each of the respective free edges of the outside ledges  34   a  and  34   b  includes first slots  44   a,    44   b  and  44   c,    44   d  that are formed to engage with inside ledge panels  36   a,    36   b.  Furthermore, the inside ledge panels  36   a  includes inner and outer panels  42   a,    42   b  foldably joined to one another by fold line  40  and the inside ledge panels  36   b  includes inner and outer panels  42   c,    42   d  foldably joined to one another by fold line  40 . Each of the respective inside ledge panels  36   a,    36   b  includes two identical second slots  46   a,    46   b  and  46   c,    46   d  that are formed to engage with the respective first slots  44   a,    44   b  and  44   c,    44   d  so that the inside and outside ledges are securely attached to one another to form the base frame  35  at noted hereinbefore. A glue flap  26  is used to connect opposed ends of the blank B 1  to one another in an end-to-end relation. 
         [0020]    The folding sequence of the blank B 1  is easily accomplished. However, an ordinary skilled in the art would appreciate that a folding machine may alternatively perform the forming operations. First, the both ends of the blank B 1  are brought together and the glue flap  26  is used to connect opposed ends of the blank B 1  to one another in an end-to-end relation. Next, the respective inside ledge panels  36   a,    36   b  are folded inwardly with respect to fold lines  32   b  and  40  toward the interior space of the bulk bin and then the outside ledge panels  34   a  and  34   b  are also folded inwardly in a manner that the respective first slots  44   a,    44   b  and  44   c,    44   d  and second slots  46   a,    46   b  and  46   c,    46   d  are fully engaged with one another. When the inside ledge panels  36   a,    36   b  and the outside ledge panels  34   a  and  34   b  are fully constructed, the base frame  35  functions as pallet runners which eliminates using a separate pallet for the bulk bin. 
         [0021]      FIG. 8  is a top plan view of a blank B 2  for making the pair of channel inserts  14   a ′,  14   b ′ used in the open-ended bulk bin  12  to construct the pallet-free bulk bin container  10 . The blank B 2  is substantially flat symmetrical with respect to its longitudinal axis and preferably is an integral piece of a material such as continuous sheet of conventional corrugated paperboard. The blank B 2  is cut along its outer margins to form its specific shape of two identical channel inserts  14   a ′and  14   b ′. The channel insert panel  14   a ′ is foldably divided into a central panel  50   a ′ with two flaps  54   a ′,  54   b ′ each of which foldably extends from opposed longitudinal edges of the central panel  50   a ′ via fold lines  52   a,    52   b.  The central panel  50   a ′ and the two flaps  54   a ′,  54   b ′ are generally rectangular shaped so that they correspond exactly to the shape of the pallet runners of the bulk bin. Each of the respective flap  54   a ′ and  54   b ′ includes two locking tabs  56   a ′,  56   b ′ and  56   c ′,  56   d ′ which they foldably extend from opposed lateral edges of each respective flap  54   a ′and  54   b ′. The channel insert panel  14   a ′ is positioned inside one of the two fork access entries and is securely locked-in via the locking tabs  56   a ′,  56   b ′ and  56   c ′,  56   d ′ as seen best in  FIGS. 1 and 2 . Similarly, The channel insert panel  14   b ′ is foldably divided into a central panel  50   b ′ with two flaps  54   c ′,  54   d ′ each of which foldably extends from opposed longitudinal edges of the central panel  50   b ′ via fold lines  52   c,    52   d.  The central panel  50   b ′ and the two flaps  54   c ′,  54   d ′ are generally rectangular shaped so that they correspond exactly to the shape of the pallet runners of the bulk bin  12 . Each of the respective flap  54   c ′and  54   d ′ includes two locking tabs  56   e ′,  56   f  and  56   g ′,  56   h ′ which they foldably extend from opposed lateral edges of each respective flap  54   c ′and  54   d ′. The channel insert panel  14   b ′ is positioned inside one of the two fork access entries and is securely locked-in via the locking tabs  56   e ′,  56   f  and  56   g ′,  56   h ′ as seen best in  FIGS. 1 and 2 . 
         [0022]      FIG. 9  is a top plan view of a blank B 3  for making the pair of center-filler supports  16   a ,  16   b  used in the open-ended bulk bin  12  to construct the pallet-free bulk bin container  10 . The blank B 3  is substantially flat symmetrical with respect to its longitudinal axis and preferably is an integral piece of a material such as continuous sheet of conventional corrugated paperboard. The blank B 3  is cut along its outer margins to form its specific shape of two identical center-filler supports  16   a ′and  16   b ′. The center-filler supports  16   a ′ is foldably divided into a central panel  60   a ′ with four flaps  62   a ′,  62   b ′,  62   c ′, and  62   d ′ in which two flaps  62   a ′,  62   b ′ foldably extend from longitudinal edges thereof and two flaps  62   c ′,  62   d ′ foldably extend from lateral edges thereof via respective fold lines  64   a,    64   b,    64   c,  and  64   d.  In folding position, the central panel  60   a ′ and the four flaps  62   a ′,  62   b ′,  62   c ′, and  62   d ′ forms a generally shallow rectangular tray that is used to cover the cavity inside interior space  24  as seen best with respect to  FIGS. 3 and 4 . Similarly, the center-filler supports  16   b ′ is foldably divided into a central panel  60   b ′ with four flaps  66   a ′,  66   b ′,  66   c ′, and  66   d ′ in which two flaps  66   a ′,  66   b ′ foldably extend from longitudinal edges thereof and two flaps  66   c ′,  66   d ′ foldably extend from lateral edges thereof via respective fold lines  68   a,    68   b,    68   c,  and  68   d.  In folding position, the central panel  60   b ′ and the four flaps  66   a ′,  66   b ′,  66   c ′, and  66   d ′ forms a generally shallow rectangular tray that is used to cover the cavity inside the interior space  24  as seen best with respect to  FIGS. 3 and 4 . 
         [0023]      FIG. 10  is a top plan view of a blank B 4  for making the bottom pad panel  18 ′ used in the open-ended bulk bin  12  to construct the pallet-free bulk bin container  10 . The bottom pad panel is disposed in the bottom of the interior space  24  so that variety of products can be packaged therein. 
         [0024]    In use, variety of bulk products are placed in the interior space  24  of the pallet-free bulk bin container  10  and a optional lid can be used to enclose the top-end of the bulk bin or alternatively, the pallet-free bulk bin container can be shrink-wrapped for shipment. For example, in a warehouse or retail store, the tines of a forklift are inserted into the fork access entries  22  so that the pallet-free bulk bin container can be lifted and moved around the warehouse. 
         [0025]    The pallet-free bulk bin container  10  assembly of the present invention avoids the drawbacks of prior art knock down containers, including general structural weakness, loose fitting top cover and bulkiness of shipping. The inventive the pallet-free bulk bin container  10  assembly eliminates the need for a separate wooden or other pallet when transported and folds up or can be assembled rapidly without the use of tools. The knock down pallet-free bulk bin container  10  can be stacked and stored efficiently when in the knocked-down position. When in the knocked-down position, the pallet-free bulk bin container  10  provides a convenient and efficient returnable package for customers and is completely recyclable at the end of its effective use cycle. Unlike wooden pallets, the inventive pallet-free bulk bin container  10  can be shipped internationally without having to meet lumber treatment standards. 
         [0026]    While the invention has been described and illustrated with reference to one or more preferred embodiments thereof, it is not the intention of the Applicants that the invention be restricted to such detail. Rather, it is the intention of the Applicants that the invention be defined by all equivalents, both suggested hereby and known to those of ordinary skill in the art, of the preferred embodiments.