Abstract:
A consolidation container includes a back wall, side walls, and a front wall each comprising pockets which receive stiffening panels. The front wall has an openable center portion which provides access to the interior of the container. Support members are positioned in the corners of the container to facilitate stacking. A top normally overlies the wall to close the container and is fully openable to provide access to the interior thereof.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This is a continuation-in-part application under 37 C.F.R. §1.53 of application Ser. No. 09/458,362 filed Dec. 9, 1999, currently pending. 
    
    
     TECHNICAL FIELD 
     The present invention relates generally to flexible intermediate bulk containers, also known as bulk bags, and more particularly to consolidation containers which are adapted for stacking one on top of another. 
     BACKGROUND AND SUMMARY OF THE INVENTION 
     Over the past thirty years flexible intermediate bulk containers, commonly known as bulk bags, have come into widespread use for receiving, storing, transporting, and discharging flowable materials of all types. Although circular bulk bags are known, bulk bags are typically constructed from rectangular panels which are sewn together along their adjacent edges to define a bulk bag which is initially square or rectangular in horizontal cross section. Nevertheless, all bulk bags, whether initially square, rectangular, or circular in cross section tend to assume a circular configuration when filled due to the uniform pressure imposed by the contents of the bulk bag against the flexible fabric side walls thereof. 
     U.S. Pat. No. 4,903,859 discloses a bulk bag comprising four double layer side walls. Stiffeners formed from cardboard are inserted between the layers of the side walls thereby imparting sufficient rigidity to the container for permitting its use with liquids. Although the bulk bag of the &#39;859 patent has been generally well received, its utilization has been somewhat limited by the fact that it cannot be stacked. 
     Co-pending application Ser. No. 09/390,403 assigned to the assignee hereof (doing business as Composite Container Corp.) discloses an improvement over the bulk bag of the &#39;859 patent. In application Ser. No. 09/390,403 there is disclosed a bulk bag having double layer side walls and vertically extending corner pockets. Plywood sheets are received between the layers of the side walls and wooden posts are received in the corner pockets to provide a bulk bag suitable for use with liquids which is stackable. 
     U.S. Pat. No. 5,076,710 discloses a baffle-type bulk bag wherein bridge panels or baffles are sewn across the four corners of a nominally rectangular bulk bag. The baffles prevent the side walls of the bulk bags from bulging outwardly when the bulk bag is filled, thereby retaining the filled bulk bag in a more or less rectangular cross-sectional configuration. The baffles may be provided with apertures which allow material to flow into and out of the corners of the bulk bag during filling and discharging operations. 
     Co-pending application Ser. No. 09/458,362 also assigned to the assignee hereof discloses a baffle-type bulk bag which is stackable. In the bulk bag of application Ser. No. 09/458,362, triangular stiffeners are provided in the triangular corners of baffle-type bulk bags. The stiffeners may be formed from various materials including plastic panels, panels formed from corrugated paperboard and similar materials, etc. The stiffeners may be provided with apertures aligned with the apertures of the baffles thereby permitting the flow of material into and out of the bulk bag during filling and discharging operations. 
     The present invention comprises an improvement over the bulk bags disclosed in the &#39;859 and &#39;710 patents and in the &#39;403 and &#39;362 patent applications which provides a consolidation container that is stackable. In accordance with the broader aspects of the invention, there is provided a consolidated container comprising double layer side walls. Each double layer side wall receives a stiffening panel which extends substantially the entire length and width of the side wall. Each corner of the consolidation container comprises a vertically disposed pocket which receives a support member. 
     The stiffening panels used in the side walls of the consolidation container of the present invention may comprise corrugated plastic panels or similar panels made from other materials which are sufficiently resistant to bending. The support members are preferably formed from wood although other materials can also be used. 
     Consolidation containers incorporating the present invention are adapted for mounting on pallets. The containers may also be provided with lift loops. The containers have openable tops and foldable front wall portions which provide access to the contents of the containers. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     A more complete understanding of the invention may be had by reference to the following Detailed Description when taken in conjunction with the accompanying Drawings, wherein: 
     FIG. 1 is a partial perspective view illustrating the consolidation container of the present invention with the top removed and the front panel partially opened; 
     FIG. 2 is a view similar to FIG. 1 showing the front panel of the consolidation container fully opened; 
     FIG. 3 is a view similar to FIG. 1 showing the front panel of the consolidation container fully closed; 
     FIG. 4 is a rear perspective view of the container of FIG. 1 showing the consolidation container of the present invention with the top secured thereon; 
     FIG. 5 is a view similar to FIG. 4 illustrating an alternative version of the consolidation container of FIG. 1; 
     FIG. 6 is a horizontal sectional view of a consolidation container of FIG. 1; 
     FIG. 7 is a vertical sectional view of the consolidation container of FIG. 1; 
     FIG. 8 is an illustration of containers comprising the invention stacked one upon another; and 
     FIG. 9 is an illustration of the consolidation container of the present invention in its folded configuration. 
    
    
     DETAILED DESCRIPTION 
     Referring now to the Drawings, and particularly to FIGS. 1-4 thereof, there is shown a consolidation container  10  comprising the preferred embodiment of the invention. The consolidation container  10  comprises a back wall  12 , opposed side walls  14  and  16 , and a front wall  18 . 
     The side walls  14  and  16  each comprise a front portion  20  and a back portion  22  which are separated by a vertically disposed seam  24 . The front wall  18  comprises side portions  26  and  28  and an openable center portion  30 . 
     Referring particularly to FIG. 3, the center portion  30  of the front wall  18  comprises a fixed section  32  which is secured to the side portions  26  and  28  by seams  34 . The center portion  30  of the front wall  18  further comprises three hingedly secured sections including a lower section  36  which is hingedly secured to the fixed section  32  by a fabric hinge  38 , a center section  40  which is hingedly secured to the lower section  36  by a fabric hinge  42 , and an upper section  44  which is hingedly secured to the center section  40  by a fabric hinge  46 . 
     As is clearly shown in FIGS. 1,  2 , and  3 , the lower section  36 , the center section  40  and the upper section  44  of the center portion  30  of the front wall  18  are pivotable between the fully closed position of FIG.  3  through the partially opened position of FIG. 1 to the fully opened positioned of FIG.  2 . The openable center portion  30  of the front wall  18  is preferably provided with hook-and-loop fasteners of the type sold under the trademark VELCRO® which are employed to secure the lower section  36 , the center section  40 , and the upper section  44  either in the fully closed position of FIG. 3 or in the fully open position of FIG.  2 . Other types and kinds of fasteners, such as zippers and snaps, can also be used in the practice of the invention. 
     Specifically, cooperating hook-and-loop fastener strips  48  and  50  or zippers may be provided on the inner edges of the side wall portions  26  and  28  and on the outer edges of the sections  36 ,  38 , and  44  to secure the center portion  30  of the front wall  18  in the closed position of FIG.  3 . Cooperating hook-and-loop fastener portions  52  and  54  or snaps likewise may be provided on the outwardly facing surfaces of the sections  32 ,  36 ,  40 , and  44  of the center portion  30  to secure the center portion  30  in the fully open configuration of FIG.  2 . 
     Referring to FIG. 4, the consolidation container further includes a top  56 . The top  56  includes a top panel  58  which overlies the interior of the consolidation container  10  as defined by the back wall  12 , the side walls  14  and  16 , and the front wall  18 . The top  56  further includes a skirt  60  which extends downwardly from the top panel  58 . The top  56  may be either fully removable or hingedly secured to the back wall  12 . In either case the top  56  is fully openable. 
     Straps  62  are secured to the top  56  for engagement with loops  64  mounted on the back wall  12 , the side walls  14  and  16 , and the front wall  18  to secure the top  56  in place. Other types and kinds of fasteners can also be used to secure the top in place. 
     As is best shown in FIG. 6, the back wall  12  of the consolidation container  10  comprises a double layer wall defining a stiffening panel receiving pocket  66 . The side walls  14  and  16  each comprise double layer walls which define two stiffening panel receiving pockets  66  separated by the seams  24 . The side portions  26  and  28  of the front wall  18  likewise comprise double layer walls defining stiffening panel receiving pockets  66 . Each stiffening panel receiving pocket  66  receives a stiffening panel  68  therein. The stiffening panels  68  are substantially identical in length and width to the stiffening panel receiving pockets  66  in which they are received. As is best shown in FIG. 7, the top  56  may comprise a stiffening panel receiving pocket  66  which receives a stiffener panel  68 , depending upon the particular application of the invention. 
     The stiffening panels  68  of the present invention may be manufactured from plastic panels of the type sold by Coroplast of Dallas, Tex., under the trademark COREX™. Other types of plastic panels may also be used, depending upon the requirements of particular applications of the invention. The stiffening panels  68  may also be formed from various types of paperboard; fiberboard, including medium density fiberboard (MDF); cardboard; plywood; and other materials depending upon the ability of stiffening panels formed from such materials to resist bending. 
     The corners between the back wall  12  and the side walls  14  and  16  and the corners between the front wall  18  and the side walls  14  and  16  have pockets  70  formed therein which extend the entire height of the consolidation container  10 . The pockets  70  receive support members  72  therein. The support members  72  are preferably formed from wood, however, other materials may be used in the fabrication of the support members depending upon the requirements of particular applications of the invention. 
     Referring to FIG. 7, the fixed section  32 , the lower section  36 , the center section  40 , and the upper section  44  of the center portion  30  of the front wall  18  comprise double layer walls each having stiffening panels  74  received therein. The stiffening panels  74  extend substantially the entire length and width of the sections in which they are received. FIG. 7 further illustrates a bottom wall  76  of the consolidation container  10  which is secured to the lower edges of the back wall  12 , the side walls  14  and  16 , and the front wall  18  by a seam  78 . Adjustable straps  80  extend upwardly from the bottom wall  76  for use in securing cargo within the interior of the consolidation container  10 . 
     The back wall, the side walls, the front wall, the bottom wall, and the top may be formed from fabric. Preferably, woven polypropylene fabric is used to fabricate the consolidation container  10 . When fabric is used, the several sections thereof are connected by stitching. Various plastic films can also be used to fabricate the consolidation container  10 . When films are used, the several sections thereof are joined by heat sealing or by means of adhesives. 
     A primary advantage deriving from the use of the present invention is illustrated in FIG.  8 . The stiffening panels  66  and  74  in the back wall  12 , the side walls  14  and  16 , and the front wall  18  together with the support members  72  located in the pocket  70  allow consolidation containers incorporating the invention to be stacked one upon another to a total height of up to six containers depending upon the density of the material received therein. 
     Another advantage deriving from the use of the invention is illustrated in FIG.  9 . The seams  24  of the side walls  14  and  16  allow the side walls to be folded inwardly. Inward folding of the side walls  14  and  16  in turn allows the consolidation container  10  to be fully collapsed in the manner illustrated in FIG.  9 . In this manner, return shipment and/or storage of consolidation containers incorporated in the invention is facilitated. 
     Referring again to FIG. 1-4, inclusive, consolidation containers constructed in accordance with the invention are adapted for mounting on pallets  82 . In such instances the consolidation container is preferably provided with releaseable straps  84  which are secured to the container  10  and which releaseably secure the container  10  to the pallet  82 . As will be appreciated by those skilled in the art, the pallet  82  facilitates the transportation and positioning of the consolidation container  10 . 
     Referring to FIG. 5, the consolidation container  10  of the present invention may be provided with lift loops  86 . The lift loops  86  may be provided either in addition to or in lieu of the pallet  82 . Like the pallet  82 , the lift loops are utilized in the transportation and positioning of the consolidation container  10  and the contents thereof. 
     As will be understood by those skilled in the art, the consolidation container  10  of the present invention differs from prior consolidation container designs in that it employs a fully openable top and a front wall which is fully openable by pivoting the component parts thereof downwardly into the configuration illustrated in FIG.  2 . By this means the interior of the consolidation container  10  is fully accessible to facilitate loading and unloading thereof. The consolidation container of the present invention is readily adapted for receiving, transporting, and storing newspapers and other printed materials, packaged food products, beverage containers, packaged automotive parts, home improvement parts, roofing shingles and similar materials, office supplies, and other unitized products. 
     In addition to providing unprecedented accessibility, the use of the consolidation container of the present invention is advantageous in that it is ready-to-use, both stackable and collapsible, and adapted both for reuse and/or recycling. It will therefore be understood that the use of the consolidation container of the present invention reduces both transportation and labor costs. Other advantages inherent in the use of the consolidation container of the present invention include reduced weight and resistance to damage from water and mildew. 
     Although preferred embodiments of the invention have been illustrated in the accompanying drawings and described in the foregoing Detailed Description, it will be understood that the invention is not limited to the embodiments disclosed, but is capable of numerous rearrangements, modifications, and substitutions of parts and elements without departing from the spirit of the invention.