Patent Publication Number: US-9428299-B2

Title: Collapsible bulk bin and methods for constructing the same

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation application of U.S. patent application Ser. No. 11/533,233, filed Sep. 19, 2006, entitled “COLLAPSIBLE BULK BIN AND METHODS FOR CONSTRUCTING THE SAME,” the disclosure of which is hereby incorporated herein by reference in its entirety. 
    
    
     BACKGROUND OF THE INVENTION 
     This invention relates generally to packaging and, more particularly, to a collapsible bulk bin and methods for forming a collapsible bulk bin that includes a self-erecting bottom wall. 
     Containers are frequently utilized to store and aid in transporting products. These containers can be square, hexagonal, or octagonal. At least some known bulk containers used to transport products are designed to fit a standard sized pallet. The shape of the container can provide additional strength to the container. For example, a hexagonal-shaped bulk container provides greater resistance to bulge over conventional rectangular or square containers. An empty bulk bin can be shipped in a knocked-down flat state and opened to form an assembled bulk bin that is ready for use. Shipping and storing bulk bins in a knocked-down flat state saves money and space, however, the size and configuration of bulk bins can make the setup of the bin difficult for an individual to complete and often requires more than one person for assembly. A bulk bin that requires more than one person to complete assembly can cause unwanted expenses and wasted time for a user of the bulk bin. 
     BRIEF DESCRIPTION OF THE INVENTION 
     In one aspect, a container configured to be selectively moved between a substantially flat position and a deployed position is provided. The container includes a first blank of sheet material for forming side walls of the container, and a second blank of sheet material for forming a bottom wall of the container. The first blank having an interior surface and an opposing exterior surface, a top edge and a bottom edge. The first blank includes a first side panel, a second side panel, a third side panel, a fourth side panel, a fifth side panel, and a sixth side panel wherein each of the side panels are coupled across a fold line. The first blank also includes end flaps extending from the bottom edge of each of the side panels wherein at least two of the end flaps includes a tab joint. The second blank having a plurality of side edges equal to a number of side panels of the first blank, each side edge having a width substantially equal to a width of the side panels of the first blank. The second blank is foldable and is coupled to at least one end flap of the first blank for forming a bottom wall of the container. 
     In another aspect, a container configured to be selectively moved between a substantially flat position and a deployed position is provided. The container including a first blank of sheet material for forming side walls of the container, and a second blank of sheet material for forming a bottom wall of the container. The first blank having an interior surface and an exterior surface, a top edge and a bottom edge. The first blank is foldable along a plurality of fold lines to form a plurality of side walls of the container, wherein the side walls each have an end flap extending from the bottom edge and at least two of the end flaps having a tab joint extending across a fold line. Each tab joint is coupled to an adjacent end flap. The second blank of sheet material having an interior surface and an exterior surface. The second blank is foldable along a fold line and is coupled to at least one end flap of the first blank, wherein the end flaps and the tab joints of the first blank support the second blank when in the deployed position to form a bottom wall of the container. 
     In another aspect, a method for constructing a container is provided. The method includes providing a first blank of sheet material having an interior surface and an opposing exterior surface, a top edge and a bottom edge. The first blank includes a first side panel, a second side panel, a third side panel, a fourth side panel, a fifth side panel, and a sixth side panel, wherein the panels are coupled together across a fold line. The first blank includes end flaps extending from the bottom edge of each of the side panels, wherein at least two of the end flaps further include a tab joint extending across a fold line. The method further includes providing a second blank of sheet material having an interior surface and an opposing exterior surface. The second blank having a plurality of side edges equal to a number of side panels of the first blank of sheet material with each side edge having a width substantially equal to a width of the side panels of the first blank. The method further includes forming side walls of the container by folding the first blank along the plurality of fold lines separating the plurality of side panels and coupling the glue panel to the first side panel, coupling each tab joint to an adjacent end flap for forming a foldable connection between adjacent end flaps, and forming a bottom wall of the container by coupling the interior surface of at least two end flaps to the corresponding exterior surface of the second blank. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a top plan view of a first blank of sheet material for forming a container according to one embodiment of this invention. 
         FIG. 2  is a top plan view of a second blank of sheet material for forming a container according to one embodiment of this invention. 
         FIG. 3  is a perspective view of the container formed from the first and second blanks as shown in  FIGS. 1 and 2 . 
         FIG. 4  is a perspective view of the first blank and the second blank in one step of assembly. 
         FIG. 5  is a perspective view of the first blank and the second blank in another step of assembly. 
         FIG. 6  is a perspective view of the first blank and the second blank in another step of assembly. 
         FIG. 7  is a plan view of the first blank and the second blank in another step of assembly. 
         FIG. 8  is a plan view of the container of  FIG. 3  in a knocked-down flat configuration and including reinforcing straps. 
         FIG. 9  is a perspective view of the container of  FIG. 3 , including reinforcing straps. 
         FIG. 10  is a schematic illustration of a mechanism for producing a knocked-down flat, and applying reinforcing straps around the knocked-down flat. 
     
    
    
     Corresponding reference characters indicate corresponding parts throughout the several views of the drawings. 
     DETAILED DESCRIPTION OF THE INVENTION 
     A collapsible bulk bin and methods of constructing a collapsible bulk bin are described herein. More specifically, a collapsible bulk bin, including reinforcing straps and a self-erecting solid bottom wall, and methods of constructing the same are described herein. However, it will be apparent to those skilled in the art and guided by the teachings herein provided that the invention is likewise applicable to any storage container including, without limitation, a carton, a tray, a box, or a bin. 
     In one embodiment, the container is fabricated from a paperboard material. The container, however, may be fabricated using any suitable material, and therefore is not limited to a specific type of material. In alternative embodiments, the container is fabricated using cardboard, corrugated board, plastic and/or any suitable material known to those skilled in the art and guided by the teachings herein provided. The container may have any suitable size, shape, and/or configuration (i.e., number of sides), whether such sizes, shapes, and/or configurations are described and/or illustrated herein. For example, in one embodiment, the container includes a shape that provides functionality, such as a shape that facilitates transporting the container and/or a shape that facilitates stacking and/or arrangement of a plurality of containers. 
     Referring now to the drawings,  FIG. 1  is a top plan view of a first blank of sheet material  10  for forming a container according to one embodiment of this invention. Specifically, blank  10  is a body blank utilized to form a body of the container. In one embodiment, blank  10  is made of cardboard, corrugated board, plastic, and/or any suitable material. Further, in one embodiment, blank  10  has a width W 1  of 149.5 inches and a length L 1  of 44 inches. Blank  10  includes an interior surface  12  and an exterior surface  14 . Blank  10  also includes a top edge  16  and a bottom edge  18 . Blank  10  includes a first side panel  20 , coupled across a fold line  22 , to a second side panel  24 . In one embodiment, first side panel  20  has a width W 2  of 29.5 inches and a length L 2 , and second side panel  24  has a width W 3  of 21.5 inches and a length L 2 . Further, blank  10  includes a third side panel  26 , coupled across a fold line  28 , to second side panel  24 . In one embodiment, third side panel  26  has a width W 4  of 21.5 inches and a length L 2 . Blank  10  also includes a fourth side panel  30 , coupled across a fold line  32 , to third side panel  26 , and a fifth side panel  34 , coupled across a fold line  36 , to fourth side panel  30 . In one embodiment, fourth side panel  30  has a width W 5  of 29.5 inches and a length L 2 , and fifth side panel  34  has a width W 6  of 21.5 inches and a length L 2 . Blank  10  also includes a sixth side panel  38 , coupled across a fold line  40 , to fifth side panel  34 . In one embodiment, sixth side panel  38  has a width W 7  of 21.5 inches and a length L 2 . Sixth side panel  38  includes a glue tab  42  extending across a fold line  44 , from an edge opposed to fifth side panel  34 . In one embodiment, glue tab  42  has a width W 8  of four inches and a length L 2 , and fold line  44  has a width W 9  of one half inch and a length L 2 . 
     Blank  10  also includes a plurality of end flaps or major flaps. A first end flap  50  extends from bottom edge  18  of first side panel  20  across a fold line  52 . In one embodiment, a portion of first end flap  50  extends a length L 3  of five inches from first side panel  20 . A second end flap  54  extends from bottom edge  18  of second side panel  24  across a fold line  56 . In one embodiment, a portion of second end flap  54  extends length L 3  from second side panel  24 . A third end flap  58  extends from bottom edge  18  of third side panel  26  across a fold line  60 . In one embodiment, a portion of third end flap  58  extends length L 3  from third side panel  26 . A fourth end flap  62  extends from bottom edge  18  of fourth side panel  30  across a fold line  64 . In one embodiment, a portion of fourth end flap  62  extends length L 3  from fourth side panel  30 . A fifth end flap  66  extends from bottom edge  18  of fifth side panel  34  across a fold line  68 . In one embodiment, a portion of fifth end flap  66  extends length L 3  from fifth side panel  34 . A sixth end flap  70  extends from bottom edge  18  of sixth side panel  38  across a fold line  72 . In one embodiment, a portion of sixth end flap  70  extends length L 3  from sixth side panel  38 . 
     In alternative embodiments, blank  10  and any portions thereof have any dimensions suitable for forming a bulk bin as described herein. 
     As shown in  FIG. 1 , third end flap  58  includes a tab joint or minor flap  80 , having a first portion  82  and a second portion  84 . First portion  82  is coupled to third end flap  58  across a fold line  86 , and second portion  84  is coupled to first portion  82  across a fold line  88 . Further, fifth end flap  66  includes a tab joint or minor flap  90  having a first portion  92  and a second portion  94 . First portion  92  is coupled to fifth end flap  66  across a fold line  96 , and second portion  94  is coupled to first portion  92  across a fold line  98 . 
       FIG. 2  is a top plan view of a second blank of sheet material  100  for forming a container according to one embodiment of this invention. Specifically, blank  100  is a bottom blank utilized to form the container. In one embodiment, blank  100  is a hexagonal shaped blank of sheet material. Blank  100  includes a first edge  102 , a second edge  104 , a third edge  106 , a fourth edge  108 , a fifth edge  110 , and a sixth edge  112 . Blank  100  includes a fold line  114 , connecting the junction of second edge  104  and third edge  106  with the junction of fifth edge  110  and sixth edge  112 . Fold line  114  separates blank  100  into a first portion  116  and a second portion  118 . 
       FIG. 3  is a perspective view of a container  150  formed from first blank  10  of  FIG. 1  and second blank  100  of  FIG. 2 . Container  150  includes an interior  152  and an exterior  154 . Container  150  also includes a top opening  156  and a bottom portion  158 . Container  150  includes a first side wall  160 , coupled across a fold line  162 , to a second side wall  164 . Container  150  includes a third side wall  166 , coupled across a fold line  168 , to second side wall  164 . Container  150  includes a fourth side panel  170 , coupled across a fold line  172 , to third side wall  166 . Container  150  includes a fifth side wall  174 , coupled across a fold line  176 , to fourth side wall  170 . Container  150  includes a sixth side wall  178 , coupled across a fold line  180 , to fifth side wall  174 . Sixth side wall  178  includes a glue tab  182  extending across a fold line  184 , from an edge opposed to fifth side wall  174 . Interior  152  of glue tab  182  is coupled to exterior  154  of first side wall  160 . In one embodiment, glue tab  182  is adhesively coupled to first side wall  160  using glue. However, any other chemical or mechanical fastener is acceptable for this coupling and any others described below. 
     Referring further to  FIG. 3 , blank  100  of  FIG. 2  is aligned to form a bottom wall  190 . The plurality of end flaps  50 ,  54 ,  58 ,  62 ,  66 , and  70  hold bottom wall  190  within container  150 . An interior surface of first bottom flap  50  is coupled to an exterior surface of bottom wall  190 . An interior surface of fourth bottom flap  62  is coupled to the exterior surface of bottom wall  190 . An interior surface of tab joint  80  is coupled to an exterior surface of second end flap  54  and an interior surface of tab joint  90  is coupled to an exterior surface of sixth end flap  70 . The combination of coupling end flaps  50  and  62  to bottom wall  190 , and coupling tab joint  80  to end flap  54  and tab joint  90  to end flap  70 , holds bottom wall  190  within container  150 . 
     In one embodiment, container  150  may include a liner made of plastic or a similar material for providing a moisture-resistant barrier. Bottom wall  190  is configured to not puncture or cut such liner, which may be placed within container  150 . In one embodiment, bottom wall  190  is a solid one-piece construction that has a substantially smooth internal surface. In one embodiment, the internal surface of bottom wall  190  does not include any slits, slots, die-cuts corners, or edges that may pierce or puncture a liner that is positioned within the container. 
     In one embodiment, bottom wall  190  comprises a single-wall bottom. This design allows a manufacturer to use less material in constructing the bulk container. Because these types of bulk containers are designed to be placed on a pallet for carrying the container, a single-wall construction for bottom wall  190  can be used. In some embodiments, bottom wall  190  is a single-wall bottom and sides  160 ,  170 ,  164 ,  166 ,  174 , and  178  are thicker than bottom wall  190 . For example, the sides can be double-wall or triple-wall sides. 
       FIGS. 4-8  illustrate one exemplary method of assembling container  150 .  FIG. 4  is a perspective view of first blank  10  and second blank  100  in one step of assembly. Specifically, first blank  10  has been folded such that glue tab  42  is coupled to first side panel  20  to form a hexagonal body, and the hexagonal body is partially erected such that second blank  100  can be inserted therein. 
       FIG. 5  is a perspective view of first blank  10  and second blank  100  in another step of assembly. Second blank  100  is folded substantially ninety degrees along fold line  114  and is inserted into blank  10 . Specifically, edge  108  of second blank  100  is aligned with fold line  64  of first blank  10 , and edge  102  of second blank  100  is aligned with fold line  52  of first blank  10 . 
       FIG. 6  is a perspective view of first blank  10  and second blank  100  in another step of assembly. Major flap  62  of first blank  10  is folded towards and adhered to panel  118  of second blank  100 . Further, major flap  50  of first blank  10  is folded towards and adhered to panel  116  of second blank  100 . 
       FIG. 7  is a plan view of first blank  10  and second blank  100  in another step of assembly. First blank  10  is in a collapsed configuration with second blank  100  coupled thereto and positioned therein. Minor flap  90  is folded towards and adhered to major flap  70 , and minor flap  80  is folded towards and adhered to major flap  54 . 
       FIG. 8  is a plan view of an assembled knocked-down flat  200  created from blank  10  (shown in  FIG. 1 ) and blank  100  (shown in  FIG. 2 ) and having a plurality of reinforcing straps  210  wrapped around an exterior surface thereof. Knocked-down flat  200  requires a great deal less space to store, and less space to transport, than fully assembled container  150  (shown in  FIG. 3 ). However, before use, knocked-down flat  200  must be articulated into a usable container. In a first embodiment, to form container  150  from knocked-down flat  200 , first side wall  160  is moved out of communication with fourth side wall  170 . In one embodiment, top edge  16  of first side wall  160  is pulled away from top edge  16  of fourth side wall  170 . In another embodiment, bottom edge  18  of first side wall  160  is pulled away from bottom edge  18  of fourth side wall  170 . In yet another embodiment, fold line  168  is pushed toward fold line  180 , forcing first side wall  160  apart from fourth side wall  170 . 
     Moving first side wall  160  out of communication with fourth side wall  170  causes blank  100  to rotate about fold line  114 , removing first portion  116  (shown in  FIG. 2 ) from communication with second portion  118  (shown in  FIG. 2 ). Moving first side wall  160  out of communication with fourth side wall  170  also removes second end flap  54  from planar communication with third end flap  58 . However, tab joint  80  remains coupled to second end flap  54 . Second end flap  54  and third end flap  58  rotate about fold lines  56  and  60  respectively, into a substantially perpendicular relationship to side walls  164  and  166  (shown in  FIG. 3 ). When fully articulated, blank  100  is in communication with, and supported by, interior surface  12  (shown in  FIG. 1 ) of end flaps  54  and  58 , which are coupled by tab joint  80 . 
     Moving first side wall  160  out of communication with fourth side wall  170  also removes fifth end flap  66  from planar communication with sixth end flap  70 . However, tab joint  90  remains coupled to sixth end flap  70 . Fifth end flap  66  and sixth end flap  70  rotate about fold lines  68  and  72  respectively, into a substantially perpendicular relationship to side panels  174  and  178  (shown in  FIG. 3 ). When fully articulated, blank  100  is in communication with, and supported by, interior surface  12  (shown in  FIG. 1 ) of end flaps  66  and  70 , which are coupled by tab joint  90 . 
     This articulating process can be performed by a single person and without special equipment. By only requiring a single person, employment expenses may be reduced. Also, the time necessary to articulate an assembled container from a knocked-down flat may be reduced, which increases productivity. These benefits are achieved while providing a structurally stable container. 
       FIG. 9  is a perspective view of an assembled knocked-down flat  200  created from blank  10  and blank  100  and including reinforcing straps  210 . When articulated container  150  is filled with a product to be stored or transported, the product applies pressure to the walls of container  150 . One method of reinforcing container  150  to prevent outward bowing of the walls of container  150 , is to wrap reinforcing straps  210  around container  150 . In one specific example, the straps are made of plastic, but any other material of suitable strength could be utilized. 
     In one embodiment, the reinforcing straps are flexible plastic straps for providing girth support when the container is in an erected position. The straps are frictionally held in tension around the container vertical side walls. The girth support is provided by the horizontally placed straps at longitudinally spaced locations along the panels. In one embodiment, the straps are polypropylene plastic or of a polyester-type material which are thermally fused or welded together at their ends which secures the straps in sufficient tension outside the container panels for frictionally holding the straps to the container. In one embodiment, the plastic straps include prestretched polypropylene straps, prestretched to provide a low elongation factor and preferably to reduce a typical stretching by approximately fifty percent. 
       FIG. 10  is a schematic illustration of a second exemplary method of forming knocked-down flat  200 , and a mechanism to perform the method. More specifically,  FIG. 10  is a schematic illustration of a machine  220  for producing knocked-down flat  200  and applying reinforcing straps  210  around knocked-down flat  200 . 
     Machine  220  includes a bin body pre-stage station  222 , for receiving a stack of bin body blanks  224  (i.e., first blank of sheet material  10  of  FIG. 1 ). Stack  224  includes a plurality of individual bin body blanks  226 . In one embodiment, stack  224  includes eighty-eight bin body blanks  226 . In an alternative embodiment, stack  224  includes any suitable number of blanks that may be formed by machine  220 . In operation, an individual body blank  226  is provided to machine  220  for forming knocked-down flat  200 . Stack  224  is provided to machine  220  with top edges  16  aligned with a first side  228  of machine  220 , and bottom edges  18  aligned with a second side  230  of machine  220 . 
     Machine  220  also includes a transport mechanism to move stack  224  to a bin body feed station  232 . In one embodiment, the transport mechanism includes at least one of a powered conveyor, rollers, and any other mechanism suitable for moving stack  224  as described herein. Bin body feed station  232  includes a scissor lift to lift stack  224  towards a vacuum. The vacuum utilizes suction to remove one blank  226  from stack  224 . Blank  226  is then moved by the vacuum to a squaring station  234 . As each blank  226  is removed from stack  224 , the scissor lift lifts the remaining blanks  226  on stack  224 , such that the next blank  226  can be removed from stack  224  by the vacuum. The blank  226  that has been moved to squaring station  234  is squared and lowered to a plurality of rollers. The plurality of rollers then move blank  226  into an erecting station  236 . 
     As each blank  226  is placed on squaring station  234  a bottom pad or bottom blank  238  (i.e., second blank of sheet material  100  of  FIG. 2 ) is removed from a bottom pad magazine  240  and prepared for insertion into blank  226 . While bottom pad  238  is positioned between bottom pad magazine  240  and erecting station  236 , a glue applicator gun  242  applies glue to predetermined locations of bottom pad  238 . 
     At erecting station  236 , an erecting device partially erects blank  226  such that bottom pad  238  can be inserted therein. In one embodiment, the erecting device includes a pair of vacuums for suctioning a top portion and a bottom portion of blank  226 . Further, bottom pad  238  is folded to a substantially ninety degree angle to provide a female end and a male end. An insertion mechanism  244  located at erecting station  236  is inserted into the female end of folded bottom pad  238 , such that insertion mechanism  244  forces the male end of bottom pad  238  toward an opening in the partially erect blank  226 . Insertion mechanism  244  continues to insert bottom pad  238  until bottom pad  238  is positioned entirely within blank  226 . A first attachment device then folds at least one major flap toward the glued portions of bottom pad  238  and a compression device  246  applies pressure to the portions of bottom pad  238  having glue thereon. As such, the glued portions of bottom pad  238  are forced against blank  226 , such that bottom pad  238  is secured to blank  226  to form knocked-down flat  200 . In one embodiment, the first attachment device includes a plurality of fingers. 
     Knocked-down flat  200  is then transported to a collapsing station  248  where knock-down flat  200  is collapsed with bottom pad  238  glued within blank  226 . A plurality of rollers then transport knocked down flat  200  to a tab joint or minor flap sealing station  250 . Glue is applied to tab joints  80  and  90  and a second attachment device folds tab joints  80  and  90  such that they are sealed against second end flap  54  and sixth end flap  70 , respectively. In one embodiment, the second attachment device includes a plurality of fingers. Knocked-down flat  200  is then transferred to a strapping station  252  where a plurality of straps are simultaneously applied around knocked-down flat  200 . Knocked-down flat  200  is then placed on a unitizing station  254  to be stacked with other knocked-down flats  200 . Knocked-down flats  200  are positioned on unitizing station  254  in an alternating configuration. Specifically, a first flat  200  is positioned such that top edge  16  is aligned with first side  228  of machine  200 . A second flat  200  is then positioned on top of the first flat with bottom edge  18  aligned with first side  228  of machine  200 . By alternating flats  200 , the weight of flats  200  is distributed to facilitate forming a level stack  256 . 
     As used herein, an element or step recited in the singular and proceeded with the word “a” or “an” should be understood as not excluding plural said elements or steps, unless such exclusion is explicitly recited. Furthermore, references to “one embodiment” of the present invention are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the recited features. 
     The above-described apparatus and methods facilitate providing a bulk bin assembly capable of being erected and collapsed by a single person. Further, the above-described apparatus and methods provide a bulk bin assembly that is reinforced to facilitate providing strength against a weight of materials placed therein. 
     Although the apparatus and methods described herein are described in the context of a reinforced bulk bin assembly and method for making the same, it is understood that the apparatus and methods are not limited to reinforced bulk bin assemblies. Likewise, the reinforced bulk bin assembly components illustrated are not limited to the specific embodiments described herein, but rather, components of the reinforced bulk bin assembly can be utilized independently and separately from other components described herein. 
     While the invention has been described in terms of various specific embodiments, those skilled in the art will recognize that the invention can be practiced with modification within the spirit and scope of the claims.