Bulk bin with auto-closing bottom
A bin (10, 40, 50, 70, 80) has an auto-closing bottom and can be manufactured and shipped and stored in a flattened configuration and moved to an open expanded configuration at a point of use. The bin has opposed sidewalls (11, 12) and opposed end walls (13, 14 and 15, 16) and major bottom flaps (18, 19) on the sidewalls and minor bottom flaps (20, 21 and 22, 23) on the end walls. The flaps automatically move to their closed position when the bin is moved from its flattened configuration to its expanded configuration. A connecting web (25-28, 43) is foldably connected between each major bottom flap and an adjacent first side edge of an adjacent minor bottom flap, and adjacent side edges of the minor bottom flaps are foldably interconnected (29, 30 or 44), so that when the sidewalls and end walls are moved from their flattened configuration to their open expanded configuration, the major and minor bottom flaps automatically fold inwardly toward one another to close the bottom of the bin.
This application claims the benefit of U.S. provisional application Ser. No. 60/636,073, filed Dec. 14, 2004.
TECHNICAL FIELDThis invention relates to containers, and more particularly to large bulk bins for shipping and storing product in bulk quantities.
BACKGROUND ARTMany products, such as, e.g., fresh meat and poultry, are commonly stored and shipped in bulk bins constructed of corrugated paperboard. These bins typically have either four, six or eight sides and since they are designed to hold 2,000 pounds or more of product they are constructed of heavy-duty materials. They are usually shipped and stored in a flattened condition and manually set up into an expanded position at the point of use.
The sidewalls in a four-sided bin are relatively wide and can experience substantial outward bulge, resulting in pallet overhang and interfering with storage and handling of the bins. To minimize this bulge, eight-sided bulk bins of the type disclosed in U.S. Pat. No. 6,588,651, for example, are commonly used. Because of the narrower sidewalls in an eight-sided bin, less outward bulge is experienced. However, manual set up of an eight-sided bulk bin can be relatively difficult because of the more complex bottom flap construction. Six-sided bins, on the other hand, offer some of the advantages of both four-sided bins and eight-sided bins, in that they experience less sidewall bulge than a four-sided bin and are easier to set up than an eight-sided bin.
Whether constructed of four, six or eight sides, due to their heavy construction these bulk bins can be difficult to set up. In practice, the flattened bins are turned upside down and supported on the floor while they are expanded into a tubular configuration and the bottom flaps folded into operative relationship, after which the bin is inverted into an upright position and placed on a pallet to receive product. However, when the bin is to be used for containing a food product, contact between the top of the bin and the floor is prohibited. This obviously presents a problem with regard to setting up the bin.
It would be advantageous to have a bulk bin that is easy to set up and whose bottom flaps can be moved to closed position automatically, without having to invert the bin and rest it on its top end to close the bottom flaps.
DISCLOSURE OF THE INVENTIONThe present invention solves the aforementioned problems by providing a six-sided bin with a bottom flap construction that automatically moves into closed position when the bin is supported on its bottom end and moved from its flattened condition to its expanded condition. Thus, the flattened bin of the invention can be supported in an upright position with its bottom end resting on a pallet, and the sidewalls then moved into an expanded open position, with some downward pressure exerted against the bottom flaps, whereupon the bottom flaps automatically move into operative closed position, thereby preparing the bin for use without requiring any further steps. This eliminates the steps required in the prior art of first orienting the flattened bin in an upside down position, with its top resting on a floor, and then manually folding the bottom flaps to their operative position, followed by inverting the bin to an upright position and then placing it on a pallet.
The bin of the invention comprises opposed sidewalls each having a top edge, opposite side edges and a bottom edge, and end walls connected to respective opposite side edges of the sidewalls, said end walls each having a top edge, a bottom edge, and opposite side edges. A major bottom flap is foldably connected to the bottom edge of each of the sidewalls, and each major bottom flap has opposite side edges. A minor bottom flap is foldably connected to the bottom edge of each said end wall, and said minor bottom flaps each have opposite first and second side edges. Connecting webs interconnect said major and minor bottom flaps, including a connecting web foldably connected between each side edge of each major bottom flap and a respective first side edge of an adjacent minor bottom flap, so that when the sidewalls and end walls are moved from a flattened condition of said bin to an open expanded position, the major and minor bottom flaps automatically fold inwardly toward one another to close the bottom of the bin.
In a first preferred embodiment, the bin has six sides, comprising two opposed parallel sidewalls and two opposed pairs of diagonally oriented end walls. A major bottom flap is foldably connected to the bottom edge of each of said opposed sidewalls, and a minor bottom flap is foldably connected to the bottom edge of each of said end walls. Generally triangularly shaped connecting webs are foldably connected between the side edges of the major bottom flaps and the respective adjacent side edges of adjacent minor bottom flaps, and generally triangularly shaped glue flaps are connected between the adjacent side edges of adjacent minor bottom flaps. In its flattened condition, the major and minor bottom flaps and connecting webs extend outwardly of the bin. To erect the bin, it is placed upright on the flaps and the sidewalls are expanded or opened up to a tubular, generally hexagonal configuration. This movement of the side and end walls causes the major and bottom flaps to fold inwardly, closing the bottom of the bin.
In a second preferred embodiment, the bin also has six sides, comprising two opposed parallel sidewalls and two opposed pairs of diagonally oriented end walls. A major bottom flap is foldably connected to the bottom edge of each of the opposed sidewalls, and a minor bottom flap is foldably connected to the bottom edge of each of the end walls. Generally triangularly shaped connecting webs are foldably connected between the side edges of the major bottom flaps and the respective adjacent side edges of adjacent minor bottom flaps, and between the adjacent side edges of adjacent minor bottom flaps. In its flattened condition, the major and minor bottom flaps and connecting webs extend outwardly of the bin. To erect the bin, it is placed upright on the flaps and the sidewalls are expanded or opened up to a tubular, generally hexagonal configuration. This movement of the side and end walls causes the major and bottom flaps to fold inwardly, closing the bottom of the bin.
BRIEF DESCRIPTION OF THE DRAWINGSThe 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:
The bulk bin of the invention is indicated generally at 10, and comprises opposed parallel sidewalls 11 and 12, and two opposed pairs of angularly oriented end walls 13, 14 and 15, 16 connected between respective opposite side edges of the sidewalls, defining a six-sided container having a generally hexagonal shape in transverse cross-section and adapted to fit on a 48×40 inch pallet 17.
Major bottom flaps 18 and 19 are foldably connected to the bottom edges of respective opposite sidewalls, and minor bottom flaps 20, 21, 22 and 23 are foldably connected to the bottom edges of respective end walls.
Generally triangularly shaped connecting webs 25, 26, 27 and 28 are foldably connected between the side edges of the major bottom flaps 18 and 19 and the respective adjacent side edges of adjacent minor bottom flaps 20, 22 and 21, 23, respectively. Generally triangularly shaped glue flaps 29 and 30 are foldably connected to a side edge of respective minor flaps 22 and 20.
In the embodiment of
It will be noted that the adjacent corners of minor bottom flap 21 and glue flap 30, and of partial minor bottom flap 23B and minor glue flap 29, between which the respective cut lines 32 and 31 extend, are respectively cut away at 36.
The assembled blank may then be placed in stacked compression, and shipped to a point of use. At the point of use, the flattened bin is stood on its bottom edge on a pallet and pressure exerted on the sidewalls to expand the side and end walls away from one another into a generally hexagonally shaped tubular configuration, as depicted in
A second embodiment of the bin is indicated generally at 40 in
A third embodiment of the bin is indicated generally at 50 in
A sixth embodiment 80 is illustrated in
As seen best in
A procedure for setting up a bin made from the blanks of
Although particular embodiments of the invention are illustrated and described in detail herein, it is to be understood that various changes and modifications may be made to the invention without departing from the spirit and intent of the invention as defined by the scope of the appended claims.
Claims
1. A bin having an auto-closing bottom and that can be manufactured and shipped and stored in a flattened condition and moved to an open expanded position at a point of use, comprising:
- opposed sidewalls each having opposite side edges and a bottom edge;
- opposed end walls connected to respective opposite side edges of the sidewalls, said end walls each having a bottom edge;
- a major bottom flap foldably connected to the bottom edge of each said sidewall, said major bottom flaps each having opposite side edges;
- a minor bottom flap foldably connected to the bottom edge of each said end wall, said minor bottom flaps each having opposite first and second side edges; and
- a connecting web foldably connected between each side edge of each major bottom flap and an adjacent first side edge of an adjacent minor bottom flap, wherein said connecting webs interconnect said major and minor bottom flaps so that when the sidewalls and end walls are moved from a flattened condition of said bin to an open expanded position, the major and minor bottom flaps automatically fold inwardly toward one another to close the bottom of the bin.
2. A bin as claimed in claim 1, wherein:
- there are two said sidewalls disposed in opposed, spaced apart, parallel relationship to one another, and there are two opposed pairs of angularly disposed end walls connected between respective opposite side edges of said sidewalls, defining a six-sided container having a generally hexagonal shape in transverse cross-section.
3. A bin as claimed in claim 2, wherein:
- adjacent side edges of the minor bottom flaps on the bottom edges of adjacent end walls in at least one pair of end walls are foldably interconnected.
4. A bin as claimed in claim 3, wherein:
- adjacent side edges of the minor bottom flaps on the bottom edges of one pair of adjacent end walls are separated from one another by a cut; and
- the foldable interconnection between adjacent side edges of the minor bottom flaps on said one pair of adjacent end walls comprises a glue flap on one minor bottom flap adhesively attached to an adjacent minor bottom flap.
5. A bin as claimed in claim 1, wherein:
- the major and minor bottom flaps have free edges opposite their folded connection with the respective sidewalls and end walls; and
- the width of the major bottom flaps between their free edge and their folded connection is greater than the width of the minor bottom flaps between their free edge and their folded connection.
6. A bin as claimed in claim 5, wherein:
- the connecting webs are generally triangularly shaped, having two sides converging to substantially a point at the juncture of the folded connections between adjacent major and minor bottom flaps.
7. A bin as claimed in claim 6, wherein:
- the minor bottom flaps have generally a trapezoidal shape; and
- the major bottom flaps have generally a rectangular shape.
8. A bin as claimed in claim 7, wherein:
- there are two said sidewalls disposed in opposed, spaced apart, parallel relationship to one another, and there are two opposed pairs of angularly disposed end walls connected between respective opposite side edges of said sidewalls, defining a six-sided container having a generally hexagonal shape in transverse cross-section.
9. A bin as claimed in claim 8, wherein:
- adjacent side edges of the minor bottom flaps on the bottom edges of adjacent end walls in each pair opposed end walls are foldably interconnected.
10. A bin as claimed in claim 9, wherein:
- the foldable interconnections between adjacent side edges of the major and minor bottom flaps comprise triangularly shaped webs.
11. A bin as claimed in claim 10, wherein:
- the webs have two sides converging to substantially a point at the juncture of the folded connections between adjacent minor bottom flaps; and
- the webs are crushed.
12. A bin as claimed in claim 1, wherein:
- the bin is made of corrugated paperboard.
13. A bin as claimed in claim 1, wherein:
- an area of said bin at said juncture of the folded connections is crushed.
14. A bin as claimed in claim 11, wherein:
- the webs are connected to adjacent major and minor bottom flaps along a fold line, a fold-promoting cut is made in the fold line, and said fold-promoting cut terminates in a J shaped end adjacent said juncture.
15. A blank for making a collapsible paperboard bin that may be changed from a flattened condition for shipment and storage to an expanded open position at the point of use, wherein the container has an auto-closing bottom, said blank comprising:
- an elongate, rectangularly shaped piece of paperboard having a plurality of spaced apart, parallel, transverse fold scores defining a plurality of adjacent, foldably interconnected wall panels having top and bottom edges, and including sidewall panels and end wall panels interposed between the sidewall panels;
- a major bottom flap foldably connected to a bottom edge of each sidewall panel;
- a minor bottom flap foldably connected to a bottom edge of each end wall panel; and
- a connecting web foldably connected between adjacent side edges of each major bottom flap and an adjacent minor bottom flap.
16. A blank as claimed in claim 15, wherein:
- there are two spaced apart said sidewall panels and a said end wall panel on each side of each said sidewall panel.
17. A blank as claimed in claim 16, wherein:
- an end wall panel is at one end of the blank, followed by one of said sidewall panels, followed by two adjacent said end wall panels, followed by a second said sidewall panel, followed by another said end wall panel, followed by another end wall panel at a second end of the blank.
18. A blank as claimed in claim 17, wherein:
- adjacent edges of adjacent minor bottom flaps on adjacent end wall panels are separated by a cut.
19. A blank as claimed in claim 18, wherein:
- a glue flap is on one of said minor bottom flaps of each pair of adjacent end wall panels, adjacent said cut.
20. A blank as claimed in claim 19, wherein:
- said end wall panels at opposite ends of the blank comprise partial end wall panels.
21. A blank as claimed in claim 20, wherein:
- said sidewall and end wall panels and said major bottom flaps are generally rectangularly shaped, said minor bottom flaps are generally trapezoidally shaped, and said connecting webs and glue flaps are generally triangularly shaped.
22. A blank as claimed in claim 21, wherein:
- said major and minor bottom flaps each have a free edge opposite their folded connection with a respective sidewall or end wall panel, and the width of the major bottom flaps between their folded connection and free edge is greater than the width of the minor bottom flaps between their folded connection and free edge.
23. A blank as claimed in claim 22, wherein:
- said connecting webs and glue flaps each have two sides converging to substantially a point at the folded connections between respective adjacent major and minor bottom flaps and their associated wall panels.
24. A blank as claimed in claim 15, wherein:
- said major bottom flaps are foldably interconnected with adjacent minor bottom flaps by connecting webs; and
- said minor bottom flaps are foldably interconnected with adjacent minor bottom flaps by connecting webs.
25. A process for setting up a bin from a flattened configuration to an erected configuration, comprising the steps of:
- providing a bin in a flattened configuration lying on a surface, wherein said bin, when erected, has opposed sidewalls and opposed end walls, a top end, and a bottom end with major and minor bottom flaps connected to the sidewalls and end walls, respectively, along a crease forming a fold line;
- elevating the top end of the flattened bin, with the flaps resting on the surface;
- causing the flaps to bend about said crease;
- moving the sidewalls and end walls to open up the bin to an expanded tubular configuration;
- rocking the bin back and forth on the major flaps to cause the major flaps to begin folding inwardly;
- pressing the minor flaps inwardly; and
- pushing down on the bin to cause the major and minor bottom flaps to fold to their fully closed positions.
Type: Application
Filed: Dec 13, 2005
Publication Date: Jun 15, 2006
Inventors: Benjamin Quaintance (Germantown, TN), Mark Wisecarver (Morristown, TN)
Application Number: 11/301,438
International Classification: B65D 5/08 (20060101); B65D 5/10 (20060101);