Patent Publication Number: US-9415898-B2

Title: Bulk container with angled side wall to base installation

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     The present application is a continuation of U.S. patent application Ser. No. 12/963,751 filed on Dec. 9, 2010, the contents of which are incorporated herein by reference. 
     The present application claims the benefit of Chinese Patent Application No. 200930355384.9, entitled Nine Feet Geometric Bulk Plastic Container—No Door, filed Dec. 16, 2009, issued Jul. 28, 2010; Chinese Patent Application No. 200930355383.4, entitled Stringer Geometric Bulk Plastic Container, filed Dec. 16, 2009, issued Jul. 28, 2010; Chinese Patent Application No. 200930355382.X, entitled Nine Feet Geometric Bulk Plastic Container, filed Dec. 16, 2009, issued Jul. 28, 2010; Chinese Patent Application No. 201020111642.6, entitled Bulk Plastic Container Panel By Geometric Structure, filed Feb. 10, 2010, issued Nov. 3, 2010; Chinese Patent Application No. 201020132357.2, entitled Universal Latch for Bulk Plastic Container, filed Mar. 16, 2010, issued Jan. 19, 2011; Chinese Patent Application No. 201020145498.8, entitled Floating Hinge Lock Structure, filed Mar. 30, 2010, issued Dec. 1, 2010; Chinese Patent Application No. 201020159206.6, entitled Erected Side Wall Lock Structure, filed Apr. 14, 2010, issued Dec. 29, 2010; Chinese Patent Application No. 201020169698.7, entitled 45 Degree Assembly Structure for Side Wall, filed Apr. 23, 2010, issued May 4, 2011; Chinese Patent Application No. 201020198781.7, entitled Notch Structure for Low Profile Container, filed May 19, 2010, issued Dec. 29, 2010; Chinese Patent Application No. 201020218085.8, entitled Lock Structure for Connecting Panel—Long Ribs and Short Ribs, filed Jun. 4, 2010, issued Apr. 13, 2011; Chinese Patent Application No. 201020218082.4, entitled Double Rib Structure on Panels, filed Jun. 4, 2010, issued Jan. 19, 2011, the contents of all of which are incorporated herein by reference. 
     The present application also claims the benefit of U.S. patent application Ser. No. 12/963,791 filed on Dec. 9, 2010, entitled “Collapsible Bin,” now U.S. Pat. No. 8,413,831 issued on Apr. 9, 2013; and U.S. patent application Ser. No. 12/963,769 filed Dec. 9, 2010, entitled “Fork Tine Notch,” the contents of which are incorporated herein by reference. 
    
    
     FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
     N/A 
     FIELD OF THE INVENTION 
     The present invention generally relates to a bulk bin container having a base and a plurality of side walls that must be positioned at a particular angle to install in the base; and more particularly, to a bulk bin having a base and a plurality of side walls having integrally formed hinge lugs with an angled flat portion (e.g., 45° with respect to horizontal) that cooperates with an opening in a hinge slot in the base to require installation of the side wall at a first angle. 
     DESCRIPTION OF THE PRIOR ART 
     Bulk bin containers are typically formed from molded plastic and include a base and four side walls extending upward from the base. To decrease the volume of the containers for efficient shipment when empty, the side walls are hingedly connected to the base so that they can be collapsed inward. 
     Many bulk bin containers include four separate hinge rods (one for each side wall) typically made of fiberglass to provide the hinged connection. This requires additional parts and labor (i.e., a secondary installation operation during the molding process) in the manufacture of the containers and increases the costs of such containers. 
     When utilizing a hinge rod, the bulk bin container can be formed to allow the hinge (and attached side wall) to float, that is, move up or down in a slot. Each side wall can be provided with a different amount of float by adjusting the length of the slot, or alternatively, each side wall can be given the same maximum float length. In each alternative, the side walls can be can be stacked horizontally, one on top of the other. However, in instances where each slot length is different, the side walls typically must be collapsed in a particular order. In the alternative, the side walls can be collapsed in any order. 
     Other bulk bin containers are formed with integrally formed hinge elements. Such elements can include cylindrical projections in one component of the container (base or side wall) that cooperate with corresponding cylindrical holes in the other component. In this configuration it is more difficult to provide any float length in the hinge. 
     The present invention provides an improved bulk bin having a four foldable side walls with a unique integrally form hinge element. 
     SUMMARY OF THE INVENTION 
     The present invention provides a bulk bin container that includes a base portion and a plurality of side walls hingedly connected to the base portion. The base portion and side walls of the bulk bin container can be formed from plastic in a molding operation. Alternatively, other conventional materials or processes can be used to form the base portion and side walls. 
     The base portion and side walls of the bulk bin container are designed such that no hinge rods are needed (and thus no secondary installation operations are required) to hingedly connect the side wall to the base portion. Instead, the hinge rod is replaced with a plurality of integrally molded lugs in the side walls. The molded lugs are formed on the ends of one or more hinge knuckles that extend from a lower portion of each side wall. For example, depending on the size of the bin and side wall, the side wall can include four hinge knuckles extending downward from a bottom of the side wall, in which each knuckle has a first lug extending outward from a first side of the knuckle, and a second lug extending outward from a second side of the knuckle. 
     The lugs are designed to fit into and cooperate with hinge slots formed in the base portion. In some instances, the slots can be a sufficient length to provide a floating hinge connection between the side wall and base portion. In this regard, the hinge lug is able to move up and down in the slot. This can be used to allow the side wall to lay flat in a collapsed position regardless of the order in which each side wall is collapsed. 
     At least one of the lugs on a side wall is provided with an angled flat portion that decreases the overall diameter of the lug. Preferably, the flat portion is on a 45° angle (with respect to the horizontal when the side wall is in an upright position), however, other angles can be utilized. In this configuration, the angled flat portion starts on the bottom of the lug (when the side wall is positioned upright). However, the angled flat portion can be positioned at other locations on the lug. Moreover, other angles can be used (and when positioned on the top of the lug, the angle would be negative). 
     The base includes at least one lug slot or pocket that includes an entrance sized to accept the at least one lug having an angled flat portion. That is, the at least one lug slot includes a corresponding entrance having a flat portion matching the flat portion on the lug that leads to a hinge pivot slot in which the lug can float. 
     Other lugs in the side wall can include an angled flat portion, or have a conventional cylindrical shape. The base will include corresponding lug slots or pockets for each of the lugs in the side walls. Preferably, the two outermost lugs on opposing sides of the side wall have an angled flat portion. 
     The side wall is installed in the base by holding the side wall at the angle of the flat portion of the at least one lug (such that the flat portion is substantially horizontal or otherwise in alignment with the corresponding flat portion in the opening of the lug slot, and the side wall extends at the angle of the flat portion with respect to a horizontal plane), and bringing it into engagement with the lug slots. For example, if the angle of the flat portion is 45°, the side wall is held at this angle, and the hinge knuckles are move toward the base slots or pockets. The lugs on the hinge knuckles are aligned with the openings of the respective slots in the base, and are moved toward the openings until the lugs are engaged in the slots. At this point, the side wall can float up and down in the slots in the base. Moreover, the side wall can rotate about the lugs to lay flat (in a collapsed position), or to stand up perpendicular to a support surface of the base (in an erect position). The only way the side wall can be removed is to raise the side wall so that the lugs are proximate the openings in the slots, and rotate the side wall to a 45° angle. Due to the size of the slot in the base and the size of the lug on the side wall, the side wall cannot be removed unless it is aligned to the position in which it was installed. The installation position is placed in such a manner that is not normal to normal operation of the bulk bin container. 
     In accordance with one aspect of the invention, a bulk bin container configured to have side walls installable at an angle is provided. The bulk bin container comprises a generally rectangular base portion having a first end, an opposing second end, a first side and an opposing second side. The first end of the base portion includes a first hinge slot configured to cooperate with a hinge lug of a side wall. The first hinge slot including an opening proximate a top portion of the hinge slot. The container also includes a first side wall having a bottom portion, and a first hinge lug connected to the bottom portion. The first hinge lug is formed having a first generally cylindrical portion and a second angled flat portion. The first hinge lug is configured to be received in the opening of the first hinge slot to hingedly connect the first side wall to the base. 
     The first hinge slot can further include a flat horizontal portion proximate the opening of the hinge slot. When the side wall is installed, the angled flat portion of the first hinge lug of the side wall is set at a first angle with respect to horizontal when the first side wall is in an upright position. This first angle is preferably approximately 45°; however, other angles can be used. During installation the opening is configured such that the flat angled portion of the lug must be positioned horizontally to allow the lug to be inserted. This forces the side wall to be positioned at the first angle. 
     The first end of the base portion is configured to have a plurality of hinge slots to match with a plurality of hinge lugs in the side wall. Moreover, the other end and each side of the base portion are similarly configured. 
     The first side wall includes a first knuckle portion extending from the bottom portion of the first side wall. The first lug extends outward from a first side of the first knuckle. Additional knuckles and lugs can be provided on the bottom portion of the first side wall. 
     Preferably, the first lug is positioned proximate a first side of the side wall, and a second lug—also having a first generally cylindrical portion and a second flat angled portion—is positioned approximate a second side of the first side wall. Additional lugs can be generally cylindrical and not include a flat angled portion or segment. A larger opening can be utilized with hinge slots associated with such lugs. 
     The first hinge slot has a length greater than a diameter of the first lug. This allows the first hinge lug to move upward or downward (or “float”) within the first hinge slot. When each side or end of the base portion has similar hinge slots, the side walls can be collapsed flat in any order. 
     In accordance with another embodiment of the invention, a collapsible bulk bin container with installable side walls is provided. The container comprises a generally rectangular base portion having a first side, an opposing second side, a first end, and an opposing second end. A first side wall is hingedly connected to the first side of the base portion, a second side wall is hingedly connected to the second side of the base portion, a third side wall is hingedly connected to the first end of the base portion and a fourth side wall is hingedly connected to the second end of the base portion. The first side of the base portion includes a first hinge slot having a slot opening and the first side wall includes a first hinge lug having a first generally cylindrical portion and a second angled flat portion configured to be received by the first hinge slot when the first side wall is positioned at a first angle. 
     The second side of the base portion also includes a second hinge slot having a slot opening and the second side wall includes a first hinge lug having a first generally cylindrical portion and a second angled flat portion configured to be received by the second hinge slot when the second side wall is positioned at a second angle. Preferably, the second angle is equal to the first angle. 
     Further aspects of the invention are disclosed in the description of the invention including the Figures. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       To understand the present invention, it will now be described by way of example, with reference to the accompanying drawings in which: 
         FIG. 1  is a perspective view of a bulk bin container for use with the present invention; 
         FIG. 2  is a perspective view of a base portion of the bulk bin container of  FIG. 1 ; 
         FIG. 3  is a cross-sectional view showing a side of the base portion and a plurality of hinge slots; 
         FIG. 4  is a perspective view showing an enlargement of the hinge slot on an end of the base portion; 
         FIG. 5  is an enlarged perspective view of an opening to the hinge slot shown in  FIG. 4 ; 
         FIG. 6  is a plan view of a first type of side wall that can be hingedly connected to the base portion; 
         FIG. 7  is a perspective view of a second type of side wall that can be hingedly connected to the base portion; 
         FIG. 8  is a front plan view of a bottom portion of a side wall showing first and second hinge knuckles; 
         FIG. 9  is a side view of a hinge knuckle of a side wall showing a hinge lug with a flat angled portion in accordance with the present invention; 
         FIG. 10  is an enlarged perspective view of a hinge lug with an angled flat portion positioned in an opening of a hinge slot in a base portion; 
         FIG. 11  is a perspective view of a side wall being installed to a base portion; 
         FIGS. 12  A-I are side views showing in progression installation of a hinge lug with a flat angle portion of a side wall to the base; and, 
         FIG. 13  is an enlarged view of a hinge lug (without a flat angled portion) of the side wall positioned at the top of a hinge slot in the base portion. 
     
    
    
     DETAILED DESCRIPTION 
     While this invention is susceptible of embodiments 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. 
     The present invention provides integrally formed hinge elements for use in a collapsible bulk bin container. The use of such integrally formed hinge elements means that a separate hinge pin is not required and does not have to be installed. This lowers the cost of manufacturing the containers and eliminates a part that is prone to damage. 
     The structure of the hinge elements—both on the side walls and the base portion—requires the installation of the side walls at specific angles. This lessons the likelihood of a side wall becoming unexpectedly unhinged during use. 
     Referring to  FIGS. 1 and 2 , the bulk bin container  10  includes a generally rectangular or square base portion  12  with four, collapsible side walls  14 ,  16 ,  18 ,  20  extending upward (when in a fully erect configuration) from each of two opposing sides  22 ,  24  and two opposing ends  26 ,  28  of the base portion  12 . The base portion  12  includes a generally flat central bottom wall having an upper support surface  30  for supporting goods or other items in the container  10 . Additionally, the base portion  12  includes a plurality of support legs  32  extending downward. The support legs are positioned to allow tines from a fork lift, hand cart or other similar apparatus to be placed under the container  10  in order to lift it. 
     The base portion  12  also includes short wall panels  34 ,  36  extending upward from the sides  22 ,  24 , and even shorter wall panels  38 ,  40  extending upward from each end  26 ,  28  of the base portion  12 . The wall panels  34 ,  36 ,  38 ,  40 , include pockets for receiving hinge elements on the respective side walls. 
     As illustrated in  FIGS. 3 and 4 , each wall panel  34 ,  36 ,  38 ,  30  of the base portion  12  includes a number of pockets  42  and hinge slots  44  for receiving hinge knuckles and associated hinge lugs on the side walls (the side walls are described in more detail below). The pockets  42  are sized and configured to correspond in shape to the knuckles on the side walls. 
     Each hinge slot  44  includes an opening  46  at the top of the slot  44 . The opening  46  includes a lower horizontal segment  48  at the mouth of the opening  46 . The lower horizontal segment  48  is connected to an angled segment  50  that slants downward into the slot  44 . The slot  44  is a sufficient length to allow a hinge lug on a side wall to move up and down within the slot. 
       FIG. 6  discloses a first side wall embodiment for use with the bin container  10 .  FIG. 7  discloses a second embodiment of a side wall for use with the bin container  10 . The second embodiment includes a door hingedly connected to the side wall (and forming part of the side wall when closed). Such doors allow access to the interior of the bin container when the container includes a top, or multiple containers are stacked upon each other. 
     In either case, each side wall includes two sets of hinge knuckles  52  that extend downward from the bottom edge of the side wall. Each set includes two hinge knuckles  54  for a total of four hinge knuckles  54  (however, the number of knuckles can be fewer or greater than four depending on the requirements and dimensions of the bin container). 
     Also referring to the enlargement of  FIG. 8 , each hinge knuckle  54  includes a first hinge lug  56  extending from a first side of the knuckle  54 , and a second hinge lug  56  extending from a second side of the hinge knuckle  54 . As explained below, the first and second hinge lugs are not necessarily identical. 
     In accordance with aspects of the present invention, at least one or more of the hinge lugs  56  on a side wall include a flat angled segment. Referring to the side view of  FIG. 9 , the hinge lug  56  shown includes a first flat angled segment  58 , and a second generally cylindrical segment  60  which spans the remainder of the lug. As shown, the flat angled segment  58  is at a 45° with respect to a horizontal line when the side wall is in an upright position, however, other angles may work. 
     Referring to  FIG. 10 , the opening  46  of the hinge slot  44  is sized to require the flat angled segment  58  to initially line up with the horizontal opening segment  48  in order to fit in the opening  46 . This forces the side wall to be positioned at a 45° with respect to the base portion  12  (or more particularly, the upper support surface  30  of the bottom of the base portion  12 ) as shown in  FIG. 11 . 
       FIGS. 12A-12I  provide a cross-sectional view of the hinge lug  56  moving into the hinge slot  44 . That is, these Figures show, in progression, installation of a side wall with a hinge lug  56  having a flat angled segment  58  into a hinge slot  44  on a base portion  12 . 
     Referring to  FIG. 12A , it is necessary for the flat angled segment  58  of the hinge lug  56  to be positioned so that it is horizontal or parallel to the support surface  30  of the base portion  12  in order to properly fit in the opening  46  of the hinge slot  44 . As discussed above, moving the side wall to position the flat angled segment horizontally forces the side wall to assume a 45° with respect to the upper support surface  30  of the bottom of the base portion  12 . Keeping the side wall in this position, the hinge lug  56  can be moved back into the hinge slot  44  as shown in  FIGS. 12B and 12C . 
     As shown in  FIGS. 12A-12I , the slot  44  is sufficiently long enough to allow the hinge lug  56  (and thus the side wall) to move a significant distance up and down the slot (sometimes referred to in the industry as “floating,” e.g., “a floating hinge”).  FIGS. 12D-12I  show the hinge lug  56  moving downward toward the bottom of the slot  44  as the side wall is rotated into an upright position. 
     While each hinge knuckle  54  includes an integrally formed hinge lug  56  on each side of the knuckle  54 , both hinge lugs  56  do not have to include a flat angled segment  58 . Instead, one of the hinge lugs  56  can be made with the flat angled segment  58  and the other hinge lug can be generally cylindrical around its entire periphery. Such a hinge lug  56 ′ is shown in  FIG. 13 .  FIG. 13  also shows an opening to the hinge slot that does not limit the size or the positioning of the hinge lug  56 ′ entering the slot (thus, both the fully cylindrical lug  56 ′, or a lug with a flat angled segment could be accommodated by such hinge slots). 
     Preferably, the two extreme hinge lugs  56 —the ones closest to each side of the side wall, include a flat angled segment  58 , and the remaining hinge lugs  56  (between the two extreme hinge lugs  56 ) do not. In this instance, interior hinge knuckles  54  can include generally cylindrical hinge lugs  56  (without flat angled segments  58 ) on both sides of the hinge knuckle  54 . 
     Many modifications and variations of the present invention are possible in light of the above teachings. It is, therefore, to be understood within the scope of the appended claims the invention may be protected otherwise than as specifically described.