Bulk Container

The present invention relates to bulk containers for flowable materials including, but not limited to, fluids. More particularly, this invention relates to a unique flexible bulk container system which is stackable both in use and in storage and is collapsible to facilitate more compact storage.

Handling flowable or fluent materials in bulk is difficult because of the weight of the material and the bulk of the container. Warehouse and in-transit storage space is often scarce and expensive. Various containers have been developed to address this handling problem. For instance, many existing container systems utilize a rigid frame, a drum, or a rigid frame with a flexible, fluid impervious liner. Some of these rigid containers can even be stacked to save space. However, these container systems are bulky, requiring considerable storage space whether they are full or empty. Such container systems are also quite heavy, whether full or empty. In an effort to reduce weight and cost, some container manufacturers have tried corrugated cardboard container walls, but the cardboard walls are not strong enough to withstand the high compression loads of stacking. Furthermore, the cardboard deteriorates if exposed to moisture.

Therefore, a primary objective of the present invention is the provision of an improved bulk container system.

Another objective of this invention is the provision of a container system that is collapsible when not in use.

Another objective of this invention is the provision of a container system with an outer body or frame that includes some flexible side walls and some rigid side walls, such that the outer body foldingly collapses for storage.

Another objective of this invention is the provision of a container system that can be stored on or incorporated with a standard wooden shipping pallet.

Another objective of this invention is the provision of a container system that is lightweight, strong, waterproof, durable and yet stackable.

Another objective of this invention is the provision of a container system that utilizes rigid support walls removably disposed in pockets in some, but not all, sides the outer body.

Another objective of this invention is the provision of a container system that is shaped like an octagon in a horizontal plane so as to allow a relatively large volume of material to be stored in a given space, utilizing a round of cylindrical liner.

Another objective of this invention is the provision of a container system that is economical to produce, easy to use and repair, and reliable.

These and other objectives will be apparent from the drawings, as well as the description and claims which follow.

The present invention relates to a container for fluent material. The container includes a flexible liner for holding the fluent material, a plurality of substantially vertical support walls spaced around the periphery of the liner, and a flexible skin interconnecting the walls and encircling the liner so as to laterally constrain and support it when fluent material is added.

The container can include a bottom wall under the liner and connected to some of the support walls. Furthermore, a top platform can be removably secured over the liner so as to rest on top of the support walls. This provides the strength and rigidity to make the container system stackable. The support walls can be removably disposed in pockets or a sleeve in the flexible skin.

The container system of this invention is flexible and lightweight. The container can be removably secured to a standard wooden pallet, and the resulting unit can be stacked for more efficient use of storage space. The unit easily breaks down, with the container being foldingly collapsible, even with the support walls in place.

FIG. 1 is a perspective view of bulk container system of this invention.

FIG. 2 is a perspective view illustrating the construction of the bottom container shown in FIG. 1. The other container(s) stacked thereon share the same common structure as shown in FIG. 2.

FIG. 3 is a sectional view of the outer body of the container taken along line 3--3 in FIG. 2.

FIG. 4 is a front elevation view of the outer body of the container of FIG. 3 in a folded condition for storage or transport when the container is empty. The vertical spacing is exaggerated slightly to better show the flexible sides or sections interconnecting the support walls.

FIG. 1 shows two container systems 10, 12 of this invention stacked on top of each other for storage or transport. FIG. 2 shows the construction of the container 14 which is the main component of the flexible stackable container system 10, 12. The container 14 includes a removable flexible liner 16 having an inlet opening with a top cap 18 and a drain or outlet opening with a threaded plug 20 therein. Of course, the liner 16 is empty when first inserted into the outer body skin 22. However, when filled it has a horizontal periphery. Polyethylene liners are known to perform well in holding nonhazardous fluent materials. As best seen in FIG. 3, the container 14 further includes a bottom 24 joined along a seam 26 with an outer skin 28. The outer skin 28 includes a top flap 30 which overlaps an inner skin 32 that is joined to the bottom 24 and the outer skin 28 along seam 26. This forms a sleeve with an upwardly directed opening therein 34 between the inner and outer skins 28, 32. In addition to the substantially horizontal seam 26, vertical seams can be added so that the sleeve 34 comprises a plurality of pockets. A woven polypropylene fabric-like material is preferred for the bottom 24, as well as for inner and outer skins 28, 32. At least the outer skin 28 should be coated to waterproof the skin so the container can be stored indoors or outdoors.

As shown in FIG. 2, a plurality of rigid support walls 36 are inserted into the sleeve 34 or pockets at spaced intervals circumferentially around the liner 16. The support walls 36 include a pair of horizontally spaced upright members 38, 40 and a substantially rigid wall member 42 which extends between the upright members 38, 40 and is attached to them. The wall member 42 and the upright members 38, 40 are made of wood, but other strong and lightweight materials cold be used without detracting significantly from the invention. To store up to 200-400 gallons in the container, a one-half inch thick particle board wall member 42 and 1 inch by 4 inch pine upright members 38, 40 will suffice.

In the preferred embodiment, an octagonal outer body skin 22 is formed around the liner 16 by inserting the support walls 36 into the sleeve 34 or pockets on the odd numbered sides 1, 3, 5 and 7. The flap 30 is folded over the support walls 36 until it overlaps the inner skin 32. Folds, seams or slits 44 are provided along the flap 30 to allow it to lay flat. The seams 44 may extend all the way to the bottom 24. Along the even-numbered flexible sides 2, 4, 6 and 8, the flap 30 can be secured to the inner skin 32 along a seam 46 by glue, stitching, or other suitable means of securement.

FIG. 4 illustrates that the container 14 can be collapsed when the liner 16 is empty or removed. The user merely folds the sides of the container 14 inwardly upon each other until the compact rectilinear structure shown results. This structure is compact, lightweight, and easily storable or transportable. Other methods of folding the container 14, with or without the rigid support walls being removed, are contemplated and would be obvious to those skilled in the art after studying the drawings and this description.

It is contemplated that the bottom 24 may not be necessary, as the container 14 can be placed on a sufficiently supportive pallet 50 prior to inserting and filling the liner 16.

As best seen in FIG. 1, a conventional wooden pallet 50 can be positioned in supporting or load bearing relation under the liner 16 of the container 14. Thus, the outer body skin 22 and the support walls 36 contained therein rest on the pallet 50. A substantially rigid top platform 52 is placed on top of the container 14. The platform 52 rests on at least some of the vertical support walls 36. Corner protectors 54 (preferably made of cardboard) mount on some edges of the platform 52 as shown, preferably over the support walls 36. Then the user can secure the top 52 to the container 14 and the container 14 to the pallet 50 with a plurality of flexible strapping bands 56, 58, 60 and 62. Once the bands 56-62 are tightened and locked, the container 14 and pallet 50 move as an integrated unit. Thus, the units can be stacked on top of each other as shown in FIG. 1. FIG. 1 shows the containers 10, 12 stacked two units high; however, it is possible that the units could be stacked even higher. It is important that the support walls 36 be positioned directly over each other for optimum results. The upright members 38, 40 carry the bulk of the compressive load. Advantageously, the force or pressure of the flowable material in the liner pushes outwardly with substantially equal force on all of the support walls 36. Thus, the filled liner 16 actually hydraulically stabilizes or "hydrostabilizes" the support walls 36, keeping them vertical and rigid for stacking purposes.

In use, the collapsed container 14 is unfolded from the storage position shown in FIG. 4. The container 14 is placed on a supporting surface, such as the pallet 50 and arranged in its octagonal configuration, as shown in FIG. 2. The empty liner 16 is placed inside the loop of the outer body skin 22 with the inlet opening or top cap 18 up and the drain opening plug 20 registered with the aperture 23 provided in the outer body skin 22. Next the user fills the liner 16 with the fluent material, then replaces the top cap 18. If the container 14 is to be stacked, the user will apply the top platform 52 and the bands 56-62, but these items are optional in non-stacking applications.

Of course, the width of the flexible sides 2, 4, 6 and 8 can be varied. However, the widths of sides 2, 4, 6 and 8 should be at least as great as the widths of the corresponding adjacent sides 1, 3, 5 and 7 to provide the greatest collapsibility. It is contemplated that one or two flexible sides of sufficient width would still allow the container sides to be folded and collapsed for more compact storage.

The bulk container of this invention efficiently stores and facilitates handling of nonhazardous liquids, including, but not limited to, tomato paste, purees, and concentrates. One person can assemble the container system in about a minute. The container is hydrostabilized so no horizontal banding is required. Furthermore, this container system weighs 70 percent less than similar conventional bins. This container system also saves freight costs whether the container is full or empty (broken down).

Therefore, the present invention at least achieves its stated objectives.

In the drawings and specification there has been set forth a preferred embodiment of the invention, and although specific terms are employed, these are used in a generic and descriptive sense only and not for purposes of limitation. Changes in the form and the proportion of parts as well as in the substitution of equivalents are contemplated as circumstances may suggest or render expedient without departing from the spirit or scope of the invention as further defined in the following claims.