Corner Lock Bulk Bin

1. Field of the Invention

The subject invention relates to a new and improved paperboard bulk bin, and more particularly to a rigidified paperboard bulk bin of octagon shape.

2. Description of the Prior Art

The subject invention is particularly concerned with a bin for relatively heavy, palletized loads, for example, large quantities of fresh meat, which are to be moved from place to place. In a centralized meat cutting operation involving the mechanized cutting, packaging, and shipment of large quantities of fresh meat, heavy duty bulk bins are required, and preferably heavy duty bulk bins that can be easily erected by a workman in a minimum amount of time. The resulting bulk bin should be rugged enough to withstand abuse during the handling and moving of the bin from place to place on pallets, and must be of sufficient strength to insure that it will not break apart or split when being transported.

In U.S. Ser. No. 829,625, filed Sep. 1, 1977 and assigned to the same assignee as the present application, a new and improved paperboard bulk bin, which is preferably octagon-shaped and includes an upstanding side wall formed from first and second opposed pairs of side panels, and two pairs of corner panels, is disclosed. Each corner panel is disposed between one of the panels of each first and second pair of side panels, and foldably connected to each side and corner panel is a bottom flap portion. The four flaps extending from the corner panels are folded inwardly, preferably to an overlapped relationship. The flaps extending from the first pair of opposed side panels are substantially rectangular in configuration, while the flaps extending from the second pair of side panels are slotted, with the respective slots in said flaps being aligned to accept therebetween the flaps extending from the first pair of side panels. The interengagement of the flaps extending from the side panels, as well as the overlapping of the flaps from the corner panels provide a substantially more rigid bottom wall for the bulk bin, as contrasted e.g., with the bin construction illustrated in U.S. Pat. No. 3,945,558. In this patent, a bottom wall is press-fitted into the bin interior and under heavy loads can buckle causing the bin container to come apart.

The subject bulk bin is made as in U.S. Pat. No. 3,945,558 from a two-piece construction but includes a similar interengagement feature as in U.S. Ser. No. 829,625 wherein corner panels on the side walls of the bin have flaps received in locking engagement with a separate complementary shaped bottom sheet. When the bin is assembled, the corners of the bin meet the corners of the bottom sheet. Thus, the bin becomes rigid and will not buckle when turned upright. Because of the substantial enclosure of the entire bottom of the bin, the weight of the product is distributed over the entire area thereof in a more uniform manner than heretofore as the applied pressure of the product bears against an enclosed bottom. This results in a sturdier construction and one not subject to bursting of the bottom and collapse of the container. Furthermore, because of the two-piece construction described, once a corner flap is inserted in a slot in the bottom sheet, it locks the two pieces together wherein the bottom sheet can be used as a jig or guide for the assembly of the bin side walls .

Further objects and advantages of the invention will become apparent from the following specification and claims, and from the accompanying drawings, wherein:

FIG. 1 is a top perspective view of the assembled bulk bin of the present invention;

FIG. 2 is a plan view of a blank used to form the side wall of the bulk bin of FIG. 1.

FIG. 3 is a plan view of a die cut sheet used to form the bottom of the bulk bin of FIG. 1; and

FIG. 4 is a bottom perspective view of the assembled bulk bin of FIG. 1.

Referring now to the drawing in detail, wherein like numerals indicate like elements throughout the several views, the bulk bin of the subject invention is designated by the numeral 10, and is preferably made of a paperboard material, such as single wall or double wall corrugated board.

The bulk bin is formed of a single blank 11 which is slotted and scored, and a die cut octagonal sheet 11a, as more fully described hereinafter. The bulk bin 10 includes an upstanding side wall 12 formed from blank 11 and a bottom wall 13, formed from sheet 11a. The upstanding side wall 12 is of generally octagon configuration and basically comprises a first pair of opposed side panels 14, 14a, a second pair or opposed side panels 16, 16a, a first pair of opposed corner panels 18, 18a and a second pair of opposed corner panels 20, 20a. Each side and corner panel is substantially rectangular in configuration, with the side panel 16a being formed by two side wall portions 16c and 16b which are bonded along seam 16d. Portions 16c and 16b are bonded by means of a suitable adhesive, or alternatively, may be stapled together in order to complete the upstanding side wall 12 of the bulk bin 10.

As shown in FIG. 2, each corner panel is disposed between one of the side panels so that the side panels and corner panels are alternatively arranged. Furthermore, the respective side and corner panels are hingedly connected along hinge lines designated by the numerals 22 through 36 inclusive. Extending from each side panel and corner panel and hingedly connected along fold line 41 thereto is a flap. More particularly, as shown in FIG. 2, extending from the corner panels 18 and 18a are flaps 19 and 19a, respectively. Likewise, extending from the corner panels 20 and 20a are flaps 21 and 21a. Flaps 19, 19a and 21, 21a are generally rectangular in configuration, and in the erected condition of the bulk bin 10 are disposed generally horizontally.

Foldably connected to the lower edge of the first pair of opposed side panels 14 and 14a are rectangular flaps 15 and 15a. Foldably connected to the side panel 16 of the second pair of opposed side panels is a flap 17. In like manner, each side panel portion 16c and 16b includes a foldably connected bottom flap 17c and 17d, respectively. As also shown in FIG. 2, a single score line 50 extends across all of the flaps, closer to the free edge thereof.

In the erection of the subject bulk bin, the blank 11 is first folded about the fold lines 22 through 36, and side wall panels 16c and 16b are bonded along seem 16d, forming the octagonal side wall 12. Then, the flaps 15, 15a, 17 and 17c-17d are folded about the fold line 41 into horizontal planes; the flaps 17 and 17c-17d overlapping flaps 15, 15a and the interior of bin 10. The four flaps 21, 19, 21a, 19a extending from the corner panels are then folded inwardly about score line 41 and their free ends folded about score line 50. Die cut sheet 11a which is octagonal in plan and dimensioned to complement the interior dimensions of the bottom of bin 10 is inserted between flaps 21, 19, 21a, 19a and the horizontal flaps 17 and 17c-17d. The free ends 52 of flaps 21, 19, 21a and 19a are inserted through aligned apertures 54-60, respectively in die cut sheet 11a so as to lock the sheet 11a to the side wall 12 of the bulk bin 10 to form a completely closed bottom which is interlocked with the side wall 12.

Alternatively, one of the corner flaps 21, 19, 21a or 19a can be first inserted in an appropriate slot 54-60, and the sheet 11a used as a jig about which the side wall 12 of the bin 10 can be formed. Furthermore, where the weight of the product to be shipped allows the bins to be stacked on top of each other, similar flaps 15-21 can be added to the other end of the bin blank 11 to be connected to a second sheet 11a as a cover.

The subject invention, and many of its intended advantages will be understood from the foregoing description, and it will be apparent that various changes may be made in the form and construction of the subject bulk bin without departing from the spirit and scope of the invention as defined by the following claims.