Note: Descriptions are shown in the official language in which they were submitted.
CA 02432288 2003-06-13
COLLAPSIBLE BULK MATERIAL CONTAINER
Field of the Invention
This invention relates generally to shipping and storage containers,
and more particularly to a container for bulk, liquid and granular materials,
which is
collapsible and/or reusable or recyclable.
Background of the Invention
Effective, reliable, safe and economical packaging of bulk products
for handling, transport and storage has been a concern for many years. Bulk
products requiring such packaging vary widely from semi-solids such as meat
and
other such food items; to granular materials such as beans, peas, grains,
rice, salt,
flour, sugar, dry chemicals, dry cementious products, animal feeds,
fertilizers, etc.;
to liquid materials such as syrups, milk, juices, glues, inks, resins, paints,
chemicals,
and the like. Since such materials have a tendency to move or flow,
containment of
them for shipment, handling and storage raises many challenges. It is
desirable to
package such materials in containers that can be readily transported by truck,
rail or
ship and that can be easily handled during transport and at a final
destination such as
at a processing facility by readily available equipment such as fork lifts,
cranes and
the like. The flowable nature of such products presents unique packaging
issues for
the container. Movement or shifting of the materials during transport can
cause
deformation of the container that can result in load shifting and instability
and
bursting containers, often with enough force to damage or destroy the
container. The
result is loss or damage to the container contents and undue cleanup and
environmental concerns. The containers must even be more stable if stacked on
top
of each other.
The packaging industry has, to date, generally used two primary
containment approaches: (1) corrugated bulk box containers (both plastic and
paper); and (2) large bulk bags of woven fabric generally referred to as
flexible
intermediate bulk containers (FIBCs). Both approaches use various
configurations
of liners, typically made of polyethylene or polypropylene, that fit within
the
corrugated bulk box or within the FIBC for preventing contamination of the
product
being shipped and, in the case of a liquid product, to contain the liquid.
Both
CA 02432288 2003-06-13
packaging approaches use containers typically configured to be supported by
and
carned on pallets.
Utilizing the corrugated bulk box approach, the container strength
needed to handle the wide variety of weight and product consistency
requirements is
addressed by using different strength grades of corrugated board materials
and/or by
increasing the wall thickness of the boxes by gluing corrugated sheets
together or by
inserting a corrugated sleeve into the box. Another approach for strengthening
the
box container is to wrap a number of plastic or steel straps around the
outside
periphery of the box. Both techniques suffer shortcomings. The price of the
bulk
box significantly increases with increased wall thickness and/or higher
quality
corrugated materials. If the box board wall strength and/or thickness is
reduced in
order to cut costs, and a number of external support straps or bands are used,
product
pressure against the thinner box walls generally causes the box to bulge
outwardly
between the straps, resulting in a container having marginal safety factor and
leading
to numerous costly box failures in shipment.
The FIBCs utilize various fabrics (such as woven polypropylene and
PVC coated fabrics) and various fabric weights and sewing methods, depending
on
the necessary strength of the bag and its desired factor of safety. Such bags
vary in
size to generally hold from 5 to 120 cubic feet of material and up to about
5,000
pounds of product. They generally can be designed with various shaped tops
suitable for filling, can have a solid bottom or a sewn-in discharge spout
configuration, and have lifting handles. For dry or fluidized products that
require a
more rigid bag for stability, solid support inserts may be placed inside the
bag, and
between the outer bag surface and a liner (if one is used) to provide the
bag's
sidewalls with more rigidity. Because of the cost of the manufacturing sewing
operations and the cost of the rigidity enhancing inserts used in the FIBCs,
they
typically result in a more expensive container than their corrugated box with
strapping counterparts. If used without significant rigidity supports to store
liquid
materials, the FIBC bag will act like a large water balloon; thereby making
the
FIBCs more practical for use in shipping and storing dry bulk products instead
of
liquid or semi-liquid materials. Further, the inserts that are typically
placed within
the FIBCs to provide sidewall rigidity are typically joined/hinged at their
corners to
fold down flat when not in use, and do not have bottoms. Without rigid
bottoms, the
2
CA 02432288 2003-06-13
inserts are susceptible to significant deformation from their intended
footprint
configuration during loading of the FIBC, resulting in a misshaped containment
system that is unstable before and during shipment. To address this problem,
collapsible metal grid cages have been configured to externally support the
FIBC,
further adding to the cost and use inflexibility of such systems for
containing liquids
or semi-liquid materials.
The present invention addresses the problems and shortcomings of
both the prior corrugated box and the FIBC containment systems. The present
invention combines the strength of woven polypropylene materials used in the
FIBC
technology with unique configurations of forming members and inserts using
corrugated box technology, to create a very strong container that is easy to
set up,
generally maintains its shape for stacking, which is significantly more cost
effective,
and which is safer and more reliable than heretofore known packaging methods.
Summary of the Invention
This invention uses existing industry accepted packaging materials to
form a unique bulk container system that is universally applicable to the
packaging
of solid, semi-solid, granular or liquid materials. The bulk container system
of this
invention combines the advantageous features of known packaging techniques in
a
unique manner without suffering their respective shortcomings. A forming
member
of relatively inexpensive lightweight corrugated material is used to define an
internal
geometric volumetric shape of the container in a manner that provides shape to
the
container and structural support for enabling stacking of loaded/filled
containers.
The forming member is collapsible for storage and transport and is easily
erected by
folding to an operable box-like configuration. The forming member has a unique
bottom design that when assembled, squares-up and locks the forming member
sidewalls in predetermined positions to define a desired geometric volume. The
forming member is designed to be placed on and carned by a pallet.
An outer tubular sleeve, that can be configured without stitching or
seams, is sized to surround and snugly engage the entire outer peripheral
sidewall
areas of the forming member, and assumes the defined geometric shape of the
outer
surface of the forming member. The sleeve, preferably of woven polypropylene
material, provides the necessary strength for containing the bulk material
within the
3
CA 02432288 2003-06-13
forming member, while the forming member provides the desired rigidity and
shape
to the system. Additional layers of the woven polypropylene may be used around
the
forming member to provide additional strength. The forming member and the
outer
sleeve(s), together, form a stable, multi-purpose and universal container
system
configuration that is less expensive than either corrugated or FIBC known
container
configurations. As an option, additional layers of corrugated material or
woven
polypropylene material or their combination may be used as inserts engaging
the
inner peripheral sidewall areas of the forming member to provide additional
strength. All the forming member, sleeve, and insert components of the
container
system can be collapsed for reuse depending on the particular use application
and
sanitation requirements, and are completely recyclable. A standard bag/liner
can be
and typically is placed within the forming member or within the insert to
protect the
contents from contamination or the environment and/or to retain liquids.
The forming member, the outer sleeve, and the inserts can be
configured to any desired shape, as dictated by the intended use of the
container
system. The size of the container and the weight of its contents will dictate
the
strength of the outer sleeve or the inner insert, if of woven polypropylene
material,
which will be of a food grade fabric for food containment applications. The
invention also includes forming member and inner insert configurations that
allow
relative movement between cooperating portions thereof, such that the forming
member or the insert can expand and contract with the contained contents of
the
system. Another feature of the invention is a forming member or inner insert
design
that maintains a given footprint configuration of the container, but which
allows the
upper portion of the container to reconfigure along predetermined expansion
lines to
reduce stress across the forming member or insert sidewalls.
According to one aspect of the invention, there is provided a
container for bulk materials comprising: (a) a forming member comprising a
plurality of sidewalls extending between upper and lower edges and
interconnected
to cooperatively form an outer surface and to encircle an internal cavity for
receiving
bulk materials; and a locking assembly cooperatively engaging the sidewalk to
define and fix predetermined relative positions there among; and (b) a sleeve
of
continuous, woven material sized to snugly engage and to overlie substantially
the
entire said outer surface of said sidewalls between said upper and lower
edges,
4
CA 02432288 2003-06-13
wherein said sleeve is configured with a fold extending from the lower edges
of the
sidewalls towards said internal cavity. According to a further aspect of the
invention, the forming member comprises a single piece of material and may
have
sidewalls of corrugated construction and may be collapsible when said locking
assembly is not operable to fix the positions of said sidewalls. According to
yet a
further aspect of the invention, the sleeve can be operatively positioned
overlying
said forming member by sliding the sleeve over the sidewalk, from either their
said
upper or lower edges. According to yet a further aspect of the invention the
sleeve is
tubular in shape and of substantially the same cross-sectional dimension
across its
entire length and may be of polypropylene material. According to yet a further
aspect of the invention the sleeve is further folded back upon itself adjacent
said
lower edge of the sidewalk to provide additional strength to the sleeve
adjacent the
lower edge. According to yet a further aspect of the invention the sidewalk
include
foldable tabs alongside some of said upper edges of said sidewalls to enhance
stacking and are configured to slidably engage one another to provide for
limited
relative movement thereof. According to yet a further aspect of the invention
at least
two of said sidewalls may be glued to each other, either by use of a
releasable glue
allowing relative sliding movement between the sidewalls under sufficient
sheer
forces, or by conventional glue techniques. According to yet a further aspect
of the
invention, the container may include a liner of impervious material, sized,
and
configured for placement within the internal cavity, and the container may
have
forming member sidewalls wherein the lower edges are configured to be
supported
by a pallet.
According to yet a further aspect of the invention there is provided a
kit for a bulk material container, comprising: (a) a forming member comprising
a
plurality of sidewalls extending between first and second edges and
interconnectable
to cooperatively form an outer surface and to encircle an internal cavity for
receiving
bulk materials, and a locking assembly configured to cooperatively engage the
sidewalls to define and fix predetermined relative positions there among; and
(b) a
sleeve of continuous material sized to snugly engage and to overlie
substantially the
entire said outer surface of said sidewalk.
According to yet a further aspect of the invention there is provided a
container for bulk materials comprising (a) a forming member, comprising a
5
CA 02432288 2003-06-13
plurality of sidewalls extending between upper and lower edges and
interconnected
to cooperatively form an outer surface and to encircle an internal cavity for
receiving
bulk materials, and a locking assembly cooperatively engaging the sidewalls to
define and fix predetermined relative positions there among; (b) a sleeve of
continuous material sized to snugly slidably engage and to overlie
substantially the
entire said outer surface of said sidewalk between said upper and lower edges,
wherein said sleeve is configured to retain the upright shape of said forming
member
outer surface as bulk materials are loaded into said internal cavity; and (c)
an insert
member sized and configured for placement within said internal cavity.
According to yet a further aspect of the invention the insert member
comprises corrugated material. According to yet a further aspect of the
invention the
insert member comprises a plurality of sidewalls extending between upper and
lower
edges and slidably interconnected to cooperatively encircle an internal cavity
for
receiving bulk materials. According to yet a further aspect of the invention
the insert
member comprises a locking assembly cooperatively engaging the sidewalk to
define and fix predetermined positions of the sidewalls relative to one
another, while
permitting limited movement of said sidewalls relative to each other and to
the
locking assembly. According to yet a further aspect of the invention the
insert
member is collapsible when the locking assembly is not operable to fix the
positions
of said sidewalls. According to yet a further aspect of the invention there is
provided
the locking assembly that engages said sidewalk along said lower edges and may
form a bottom of the insert member and extending across the internal cavity.
According to yet a further aspect of the invention the insert member comprises
continuous, woven material. According to yet a further aspect of the invention
the
insert member is slidably disposed relative to said forming member. According
to
yet a further aspect of the invention the insert member is tubular in shape
and of
substantially the same cross-sectional dimension across its entire length and
may
comprise polypropylene material.
According to yet a further aspect of the invention the sleeve
comprises woven material. According to yet a further aspect of the invention
the
sleeve can be operatively positioned overlying said forming member by sliding
the
sleeve over the sidewalls, from either their said upper or lower edges.
According to
yet a further aspect of the invention the sleeve is tubular in shape and of
substantially
6
CA 02432288 2003-06-13
the same cross-sectional dimension across its entire length and may comprise
polypropylene material. According to yet a further aspect of the invention the
sleeve
is configured with a fold extending upward from the lower edges of the
sidewalk to
provide multiple strength resistance to forces directed outwardly from the
internal
cavity. According to yet a further aspect of the invention, the sleeve is
configured
with a fold extending from the lower edges of the sidewalk towards said
internal
cavity to provide strength resistance to forces directed outwardly and
downwardly
from the internal cavity adjacent the lower edges of said sidewalk. According
to yet
a further aspect of the invention, the sleeve is further folded back upon
itself
adjacent said lower edge of the sidewalk to provide additional strength to
said sleeve
adjacent the lower edge. According to yet a further aspect of the invention
the
container may include a liner of impervious material, sized and configured for
placement within said insert.
According to yet a further aspect of the invention there is provided a
kit for a bulk material container, further comprising an insert member sized
and
configured for placement within said internal cavity.
According to yet a further aspect of the invention, there is provided a
method of configuring a container for bulk materials, comprising the steps of
(a)
providing a forming member of the type having a plurality of sidewalk
extending
between first and second edges; (b) arranging said sidewalls in a closed
manner
such that they collectively define an internal cavity longitudinally extending
between
planes defined by the first and second edges; (c) providing a locking
assembly; (d)
engaging the locking assembly with the sidewalk to fix the geometric shape of
the
internal cavity defined thereby; (e) providing a circumferentially continuous
length
of tubular sleeve material; and (fj snugly engaging the tubular sleeve around
the
outer periphery of the sidewalk such that the sleeve engages substantially the
entire
outer surface area of said sidewalk. According to yet a further aspect of the
invention, the forming member sidewalk are provided with a releasable glue
that
allows for relative sliding movement of said sidewalls under appropriate
loading
force conditions.
These and other features of the invention will become apparent upon
a more detailed description of preferred embodiment of the invention as
described
below.
7
CA 02432288 2003-06-13
Brief Description of the Drawing
Refernng to the Drawing, wherein like numerals represent like parts
throughout the several views:
Fig. 1 is an exploded perspective view of a bulk material container
assembly containing a forming member, an outer sleeve member and an optional
bag/liner of impervious material;
Fig. 2 is a perspective view of the container assembly of Fig. 1,
illustrated as it would appear assembled;
Fig. 3 is a sectional view generally taken along the Line 3-3 of Fig. 2;
Fig. 4A is a view illustrating on a planar sheet the cut and fold pattern
of a first embodiment of a corrugated forming member portion of the container
assembly of Fig. 1;
Figs. 4B-4D illustrate bottom perspective views of the corrugated
forming member of Fig. 4A, showing progressive stages of folding of its
various
segments to derive an operative closed bottom configuration of the first
embodiment
forming member;
Fig. 5A is a view illustrating on a planar sheet the cut and fold
patterns of a second embodiment of a corrugated forming member portion of the
container assembly of Fig. 1;
Figs. SB-SD illustrate bottom perspective views of the corrugated
forming member of Fig. 5A showing progressive stages of folding of its various
segments to derive an operative closed bottom configuration of the second
embodiment forming member;
Fig. 6A is a view illustrating on a planar sheet the cut and fold pattern
of a third embodiment of a corrugating forming member portion of the container
assembly of Fig. l;
Figs. 6B-6D illustrate bottom perspective views of the corrugating
forming member of Fig. 6A showing progressive stages of folding of its various
segments, to derive an operative closed bottom configuration of the third
embodiment forming member;
Fig. 6E is a partial top perspective view of an inside upper corner of
the third embodiment of the corrugating forming member of Figs. 6A-6D,
8
CA 02432288 2003-06-13
illustrating how the corner changes shape along the upper predetermined score
lines
as pressure is applied to the inner sidewalls of the forming member; and
Fig. 7 is a diagrammatic perspective view illustrating a plurality of
the bulk material containers of the present invention cooperatively positioned
on a
pallet;
Fig. 8 is a bottom perspective view illustrating how the outer sleeve
member may be folded under the forming member and tucked into the gaps formed
at the bottom of the forming member when it is fully assembled;
Fig. 9 is a sectional view generally taken along the Line 9-9 of Fig. 8;
Fig. 10 is a sectional view similar to that of Fig. 9 illustrating a first
method of folding the sleeve material against itself before .folding the
sleeve under
the forming member;
Fig. 11 is a sectional view similar to that of Fig. 9 illustrating a
second method of folding the sleeve material against itself before folding the
sleeve
under the forming member;
Fig. 12 is an exploded perspective view of a bulk material container
assembly containing an outer sleeve, a forming member, and a one-piece insert;
Fig. 13 is a view illustrating on a planar sheet the cut and fold pattern
of a first embodiment of a corrugated one-piece insert portion of the
container
assembly of Fig. 12;
Fig. 14 is a view illustrating on a planar sheet the cut and fold pattern
of a second embodiment of a corrugated one-piece insert portion of the
container
assembly of Fig. 12;
Fig. 15 is a perspective view of an embodiment of a one-piece insert
constructed of woven polypropylene material;
Fig. 16 is a top view of an assembled bulk material container
assembly of the type illustrated i.n Fig. 12, containing an outer sleeve, a
forming
member, and a one-piece insert constructed of corrugated material, where the
insert
is sized slightly smaller in circumference than the forming member to fit
snugly into
the forming member;
Fig. 17 is a top view of an assembled bulk material container
assembly of the type illustrated in Fig. 12, containing an outer sleeve, a
forming
member, and a one-piece insert constructed of corrugated material, where the
insert,
9
CA 02432288 2003-06-13
having a substantially smaller circumference than the forming member, is
placed in
an offset fashion;
Fig. 18 is an exploded perspective view of a bulk material container
assembly containing an outer sleeve, a forming member, and a two-piece insert,
where the outer piece of the two-piece insert is constructed of woven
polypropylene
material and the inner piece is constructed of corrugated material;
Fig. 19 is a top view of a bulk material container assembly containing
an outer sleeve, a forming member, and a two-piece insert, where both of the
insert
pieces are constructed of corrugated material and are placed in an offset
fashion
relative to each other; and
Fig. 20 is an exploded perspective view of a bulk material container
assembly containing an outer sleeve, a forming member, and a three-piece
insert,
where the outermost piece of the three-piece insert is constructed of
corrugated
material, the middle piece is of woven polypropylene material, and the
innermost
piece is constructed of corrugated material.
Detailed Description of the Preferred Embodiment
A preferred embodiment of a container system incorporating the
principles of this invention is generally illustrated at 10 in Figs. 1 and 2.
The two
basic components of the container system are a forming member, generally
indicated
at 12 and an outer support sleeve member 14. The forming member 12 provides
defined geometric shape and structure to the container system while the sleeve
member 14 is sized to cooperatively and snugly engage and circumferentially
surround substantially the entire sidewall portions of the forming member 12,
as
hereinafter discussed in more detail. An optional bag/liner, well-known in the
art
generally indicated at 16 can be and generally is placed within the forming
member
12, to protect the container contents from contamination and/or to retain
liquid
contents.
The forming member 12 is preferably configured of a relatively light-
weight corrugated material which can be either of cellulose or plastic
construction.
When collapsed, the forming member 12 can be configured as a single planar
sheet,
or, depending upon the particular construction, folded over on itself in a
collapsed
manner. When erected in operative manner, the forming member 12 includes a
CA 02432288 2003-06-13
bottom construction that provides a predetermined two-dimensional geometric
configuration to the bottom of the forming member. The sidewalls 12b of the
forming member extend upwardly and generally perpendicular to the plane of the
bottom 12a and collectively define with the bottom an internal geometric
volume
that represents the storage portion of the container system. The forming
member 12
is configured to lie upon and be carried by a pallet of a type well-known in
the
shipping industry. Depending upon the size of the forming member, one or more
of
such forming members may lie on the same pallet. The thickness and strength of
the
corrugated material of the forming member 12 is a matter of engineering design
and
will vary depending on the shape and size of the container and upon the type
and
weight of the materials to be contained thereby. However, the thickness and
strength
thereof can be significantly reduced as compared to standard corrugated
containers,
since the wall portions of the forming member do not have to provide the
containment strength of the container system. Their function is to simply
provide
structural shape to the outer wall areas of the container, so as to provide a
measure of
rigidity and stability to the container system. The height, size, shape and
dimensions
of the forming member can also vary, as desired or dictated by the use to
which the
container system will be put. When used to replace FIBC containers, the
forming
member could be sized to accommodate a typical pallet grid unit which would
enable shippers and users of the container system to handle the system with
existing
in-plant equipment such as fork lifts, overhead cranes or jib cranes. As with
prior
containers, the container system of this invention can be tailored in size and
shape to
fit each customer's needs. For example, the container systems could be
configured
to accommodate packaging needs as small as five cubic feet for handling high
bulk
density weight products or could be configured to handle much larger sizes up
to, for
example, 120 cubic feet.
While a preferred construction of the forming member is one in
which the entire forming member is configured from a single planar sheet or
blank
of corrugated material, the invention does not require a one-piece
construction. For
example, the sidewall 12b portions of the forming member could be formed from
a
single sheet of material; whereas the bottom 12a could be formed from a
second,
separable piece of material. The important aspect of the forming member 12 is
that
it contain a bottom or similar structure that gives initial predetermined
fixed
11
CA 02432288 2003-06-13
geometric definition to the sidewall portions of the forming member, and
particularly
to the lower base portions thereof. It is preferable that the bottom portion
12b of the
forming member be secured to the sidewalk 12a in a manner that will prevent
the
sidewalk from riding or sliding upward, away from the bottom of the forming
S member during filling of the container. Further, while the preferred
embodiment
will be described with respect to forming members that are constructed from
the
same corrugated material, the invention does not require the same material to
be
used for both the sidewall 12b and bottom or shape defining portions 12a of
the
forming member.
The cellulose corrugated material used in a preferred embodiment of
the invention for the forming member 12 may be obtained from any corrugated
material supplier such as from Menasha Corp. of Lakeville, Minnesota or from
the
Packaging Corporation of America. Plastic corrugated materials could also be
obtained from any number of different suppliers such as Menasha Corp. or
Liberty
Carton of St. Louis Park, Minnesota. As mentioned above, the weight and
strength
of the corrugated material depends on the application to which the container
system
will be put, and the method of use of the container. In general, this
invention allows
use of a relatively inexpensive material, since the primary containment
strength of
the container system will not depend on the strength of the forming member
material, but rather on the strength of the outer sleeve 14. For example, for
smaller
containers a single weight 175 1b. C flute material might be adequate; whereas
for
even larger containers that might hold up to 2,000 pounds of material, a
relatively
low weight corrugation in the 200 1b. to 275 1b. C flute material range may
suffice.
In contrast, for the same application, a prior art total cardboard corrugation
construction may require several layers of double wall 400 1b. to 500 1b.
weight
materials to achieve the same purpose. Often, the prior art corrugated
materials also
would require the insertion of filament tape between the flutes to provide
additional
support andlor cross fluted configurations and gluing of the respective
corrugated
layers to one another to form a strengthened laminated configuration.
A first embodiment of the forming member, constructed from
corrugated cellulose (cardboard) material, is illustrated at 20 in Figs. 4A-
4D. In the
preferred embodiment, the forming member 20 is configured from a single piece
of
corrugated material that is scored and patterned for folding, as illustrated
in Fig. 4A.
12
CA 02432288 2003-06-13
Referring thereto, the forming member 20 has eight sidewall portions 20a-20h
consecutively connected and defined by intervening fold lines 21a-21h
respectively,
which eventually define the eight "corners" of the forming member. A
connecting
wall member 22 is contiguous with sidewall 20a and extends outwardly from fold
line 21a. Connector wall 22 has a pair of arcuate tabs 22a cut into the wall
and
projecting back from the side edge 25a back to fold lines 22b. The forming
member
20 also has an upper edge 23, a lower edge fold line 24 and oppositely
disposed side
edges 25a and 25b. Each of the sidewalls 20a-20h has a tab 26 projecting
upwardly
therefrom that folds along the upper edge 23 of the forming member. The ends
of
the tabs 26 are cut at a taper from the respective fold lines 21a-21h and the
end 25b
so as to minimize interference with one another when folded in toward the
center of
the structure.
The forming member 20 also has a plurality of downwardly
depending tab portions 27a-27h which collectively define the bottom 28 of the
forming member 20, as hereinafter described. End wall 20h includes a pair of
vertically aligned slots S1 and S2 for cooperatively receiving the arcuate
tabs 22a of
the connector wall 22. Bottom tab 27g also has an extended key member,
generally
designated at T. Bottom tab 27h has a horizontal slot S3 cooperatively sized
for
accepting the extended key member T of bottom tab 27g.
The forming member patterned blank material of Fig. 4A is
progressively folded as illustrated in Figs. 4B-4D, until a box-like octagonal
receptacle is configured, with bottom 28 is defined, as illustrated in Fig.
4D. To
form the box-like receptacle configuration, the material illustrated in the
Fig. 4A
pattern is folded along the wall fold lines 21 so that the side edges 25a and
25b move
toward one another (illustrated by "X"), and until the side edge 25a engages
the slots
S l and S2 of sidewall 20h such that the arcuate tab members 22a are slidably
received within the slots S 1 and S2. The upper tabs 26 are folded inward,
along the
upper edge 23. In this position, the connecting wall 22 overlies the end
sidewall 20h
and is connected thereto by means of the tabs 22a and slots S 1 and S2
combination.
At this stage, the forming member 20 would appear as illustrated in Fig. 4B.
At this
point, the structure is still foldable upon itself and can be folded into a
collapsed
position, since the bottom 28 has not yet been formed.
13
CA 02432288 2003-06-13
The bottom 28 of the forming member 20 is defined by folding in the
lower tab extensions 27, toward the center of the enclosed cavity defined by
the
connected sidewalls 20. The angled tabs 27a, 27b, 27c and 27d are folded in
first,
followed by tabs 27e and 27f, and finally by tabs 27g and 27h. The distal key
end
(T) of bottom tab 27g is received by and retained within the slot S3 of tab
27h, in
interlocking manner, to complete and hold the bottom assembly 28 in place, as
illustrated in Fig. 4D. Such bottom configuration 28 not only defines but
locks in
the positions of the sidewalls. The inner sidewalk and boiaom portions of the
assembled forming member 20 collectively define an internal geometric solid
shaped
cavity as established and maintained by the outer peripheral edge shape or
"footprint" of the plane of the bottom 28. According to a preferred
configuration of
the Fig. 4 structure, each of the sidewalk is 17.875 inches wide, providing a
diameter footprint of 43 x 43 inches and a circumference o.f 143 inches.
According
to the preferred embodiment, the height of the container from the bottom edge
24 to
the upper edge 23 is 44 inches.
It will be noted that in this illustrated embodiment of a forming
member, the tab members 22a are slidable within the slots S 1 and S2. Such
sliding
construction provides for limited relative movement of the sidewall
configuration to
accommodate expansion and contraction of the material being contained by the
container assembly. Such movement prevents rupturing of the forming member
within the outer sleeve that might otherwise occur if the forming member ends
were
fixedly glued together. Also, such expansion feature accommodates any
tolerance
differences between the circumferences of the outer surface of the forming
member
and the inner surface of the tubular sleeve.
Although the preferred embodiment of the forming member includes
a sidewall construction wherein the sidewalls are slidably expandable as above-
described, the sidewalk may be fixedly secured for no movement relative to one
another. For example, the connecting wall 22 can be glued in standard fashion
to the
end sidewall 20h to provide for further structural integrity and rigidity,
especially for
stacking purposes. In such embodiment, even if the forming member were to
subsequently rupture, since the outer sleeve 14 will continue to withstand the
loading
pressure, the containment system would still serve its purpose. Gluing of the
corrugated forming member sidewalls is always an option whenever there is an
14
CA 02432288 2003-06-13
accompanying outer sleeve member constructed of woven polypropylene material
surrounding the forming member. Gluing of the forming member sidewalls may be
attractive to some container manufacturers since the material blank member
from
which the forming member is configured can be made from less material than
might
otherwise be used if an expandable slot/tab configuration is used to
accommodate a
slidable sidewall configuration such as described with respect to Fig. 4.
Gluing
would also eliminate the need for a container manufacturing step of assembling
the
forming member (such as described in Figs 4B-4D) before use thereof in the
container system. Gluing of the forming member may also provide additional
rigidity to the containment system structure when an insert (hereinafter
described in
more detail) is used in combination with the forming member and an outer
sleeve.
Gluing, although not necessary, provides more rigidity for stacking purposes.
Traditional gluing of the forming member sidewalls, although reducing the
accommodation of expansion or contraction of the material being contained by
the
corrugated member, does not defeat the purpose of the invention since all the
container loading pressure is still absorbed by the surrounding sleeve member
in
case of rupturing of the corrugated member.
Another embodiment of a forming member construction that
accommodates both the desire fo.r use of a smaller blank of forming member
material and the advantages of slidably movable sidewalk is to configure the
forming member in the same manner as one would when permanently gluing the
sidewalls to one another, but to use a glue that is "releasable" in nature
when
subjected to a predetermined sheer force that is less than the sheer rupture
parameter
of the material to which the glue i.s applied. With the use of such releasable
glue, the
glue would have enough bonding strength to affix the sidewalls together for
handling
and transportation purposes, as though the forming member sidewalls were
permanently glued to one another. However, the releasable glue would be
applied in
a manner and selected for properties such that as the container is being
filled and
pressure is being applied by the load to the forming member sidewalls, the
glue in
the sidewall joint will release the sidewalls at the joint from one another,
enabling
the sidewalls at the joint to move/slide in expansion manner relative to one
another,
before the load pressure applied to the sidewalls is large enough to cause the
sidewall material to rupture. When the expansion force that provides the
release
CA 02432288 2003-06-13
sheer forces on the glue has subsided, the releasable glue will once again
form a
bond between the sidewalk at the "glued" joint. Therefore, this configuration
provides the advantages of both an expandable, slidable forming member that
also
acts as a glued structure when harmful expansion forces are not present. Those
skilled in the art can select the proper glue and application techniques for
accomplishing the described configuration. Releasable glues that have been
found to
be acceptable for these purposes are sold by H.B. Fuller Company under its
PD0661
and AP6903 labels. Such glue can be applied by standard glue application
techniques such as by extrusion or spraying. Alternatively, hot melt glue
applications could be used that would provide the aforementioned desired glued
joint slip/release properties. By using such slip/release glued sidewall joint
technique, it has been found that a sidewall overlap of from 4 to 5 inches at
the glue
joint is adequate to provide the desired slip joint tolerance and forming
member
rigidity parameters, which is generally less than the amount of forming member
overlap material required to form a non-glued slip joint.
A second octagonal embodiment of a forming member 20' is
illustrated in Figs. SA-SD. The general function and folding pattern of the
corrugated sheet defining the forming member 20' is basically the same as that
of the
forming member 20 with the following changes: (1) the uniform width dimension
of the sidewalls has been changed to an irregular width pattern; (2) the upper
individual tabs 26 of the forming member 20 have been replaced by a pair of
elongate tabs 26' having fold score marks 26a replacing the notched cuts of
the
forming member 20 pattern; and (3) the slot S3 of bottom tab 27h has been
deleted
in bottom tab 27h' of the second forming member, and the lower edge of bottom
27g'
has been reconfigured to include three tabs T1, T2 and T3, separated by a pair
of
notches. When assembled as illustrated in Fig. SD, the second embodiment
forming
member 20' provides a more elongated octagonal structure than the regular
octagonal
structure of the Fig. 4 forming member.
A third embodiment of a forming member is illustrated generally at
30 in Figs. 6A-6E. Refernng thereto, the third embodiment of the forming
member
is a four sided container when assembled, with its four primary sidewalls
represented
by the panels 31a-31d. The corners of the sidewalls 31a-31d are defined by the
vertical fold lines 32a-32d. The forming member includes a connector wall
16
CA 02432288 2003-06-13
extension 33 having an upper arcuate connecting tab 33a and a lower connecting
tab
33b, both terminating at a first edge 34a of the forming member. The opposite
vertical edge of the forming member 34b defines one edge of the sidewall 31 d.
The
upper edge of the forming member is designated at 35, and the lower edge of
the
sidewalls is defined by the first horizontal fold line 36. The forming member
includes two additional horizontal fold lines 37 and 38 extending the full
width of
the pattern. The vertical distance between the fold lines 36 and 37 is the
same as
that between fold lines 37 and 38. A first horizontal panel 39 is defined and
extends
the entire width of the pattern between the horizontal fold lines 36 and 37. A
second
horizontal panel 40 is defined and extends the entire width of the pattern
between the
horizontal fold lines 37 and 38. The panel 40 includes a cantilevered
extension or
tab 40a (illustrated at the left side of Fig. 6A.) The forming member 30
further
includes four downwardly extending bottom panel members 41 a-41 d respectively
located below the sidewall panel portions 31a-31d. A plurality of horizontal
cuts,
generally designated at C1-CS are formed approximately one fourth of the way
up
the sidewall panels and intersecting the vertical fold lines 32a-32d and
extending
through the oppositely disposed edges 34a and 34b.
This embodiment of the forming member includes a stress relief
feature associated with each of the corners 32a-32d of the forming member. As
the
container assembly is filled, causing pressure to be applied to the sidewalls
31a-31d
of the forming member, there is a natural tendency for the upper portion of
the
forming member to deform to a circular cross-sectional configuration. Such
deformation tendency places stress on the forming member sidewalls that is
greater
in a rectangular container configuration where the corners between sidewalk
are at
90° angles. In order to relieve such stress, and to allow for
controlled sidewall
deformation, the sidewalk are vertically scored adjacent and on either side of
the
corners 32a-32d, as indicated by the dashed score lines SOa-SOd in Fig. 6A.
Each of
the score line pairs vertically extends on either side of a respective corner,
in parallel
manner, from the upper edge 35 and downwardly to the edges of the cuts Cl-C5.
It
will be noted that the score line pair SOa is partially on sidewall 31 a and
partially on
31 d, since these two sidewalls will be contiguous to one another in the
assembled
structure. Each pair of the stress relief score lines converge toward one
another, in
V-shaped manner, slightly below the cuts C1-CS and meet at the fold line 36
that
17
CA 02432288 2003-06-13
will represent the bottom of the respective sidewalls. As illustrated in more
detail in
Fig. 6E, the cuts C 1-CS allow the portions of the sidewalls above the cuts to
outwardly deform to a greater extent than that portion of the sidewalls
located below
the cuts, without placing undue stress to the lower corners of the forming
member.
Fig. 6E has been illustrated with respect to corner 32b and is a view taken
from the
inside of the forming member corner. The resultant deformation of the forming
member 30 allowed during loading of the container, effectively changes the
cross-
sectional shape of the forming member from a rectangular configuration to a
nearly
circular twelve-sided configuration.
The forming member patterned blank material of Fig. 6A is
progressively folded as illustrated in Figs. 6B-6D, until a box-like
rectangular
receptacle is configured with bottom 45 as defined, as illustrated in 6D. To
form the
box-like receptacle configuration, the pattern material illustrated in Fig. 6A
is first
folded along the fold line 36 such that the horizontal panel 39 and 40 and the
lower
bottom panels 41 are folded outwardly at an angle of 180° about the
fold line 36 and
lie in engagement with the sidewall members 31. Next, the pattern is folded
along
the horizontal fold line 37, such that the bottom tab panels 41 are again
disposed in a
downwardly depending position and the "inner" surfaces of horizontal panel
portions
39 and 40 cooperatively engage one another. The horizontal panels 39 and 40
define
a circumferentially extending strengthening band of material around the lower
portion of the container, as illustrated in Figs. 6B-6D. The left most end of
the
folded panels 39 and 40 (as configured in Fig. 6A) defines a receptor pocket
for
receiving the tab 40a of panel 40. The pattern is then folded along the corner
fold
lines 32a-32d to define a box-like internal cavity as illustrated in Fig. 6B
such that
side edges 34a and 34b move toward one another, and until the side edge 34a
engages the slot S4 and the side edge 34b. At this position, the tab 40a will
be
slidably received by the pocket formed between panel members 39 and 40, the
lower
connecting tab 33b will slide behind the sidewall 31 d, and the upper arcuate
tab 33a
will be slidably received by the slot S4. Further movement of the panels will
form
the configuration illustrated in Fig. 6C. At this stage, the forming member 30
is still
foldable on itself, and can be folded into a collapsed position, since the
bottom 45
has not yet been formed.
18
CA 02432288 2003-06-13
The bottom 45 of the forming member 30 is defined by folding in the
lower panel extensions 41 toward the center of the enclosed cavity defined by
the
connected sidewalls 31. As illustrated in Figs. 6C and 6D, the lower panels
41b and
41 d are folded in first, followed by lower panels 41 a and 41 c. Such bottom
S configuration 45 defines and locks in the positions of the sidewalk and
collectively
defines an internal geometric solid shaped cavity having an initial
rectangular or
square cross-sectional shape. As described above, as bulk material is added to
the
internal cavity of the forming member, the resultant pressure applied by the
bulk
material to the sidewalls of the forming member will cause the sidewalls to
deform
along the score lines 50 adjacent the corners 32 to provide stress relief to
the
container assembly, while retaining the underlying stability of the container
assembly that is provided by the forming member.
While several configurations of forming member have been described
with respect to specific preferred embodiments of the invention, those skilled
in the
art will readily recognize that many other configurations of such forming
members
can be designed within the scope of this invention. Further, while specific
corrugated materials have been described for use in association with
constructing the
forming members, those skilled in the art will readily recognize that other
materials
can be employed.
The outer containment sleeve 14 is preferably constructed of the same
types of materials, well-known in the art, that are used for making flexible
intermediate bulk containers (FIBCs). The sleeve is preferably configured from
a
flexible woven fiber material, preferably woven polyethylene material which
are
known for their strength and light weight. Such fabrics come in various
weights,
which would be selected in accordance with the necessary strength and safety
factors
required by the container. As with fabrics used in the FIBC industry, the
sleeve
material could be coated, as for example with polyethylene, or remain
breathable,
could be treated for ultra violet retardation, could be configured for weather
resistance, or could, for example, be of a fabric that complies with the Food
and
Drug Administration criteria for foods, pharmaceuticals and edibles, and the
like.
Those skilled in the art will readily recognize these and other options for
appropriate
materials that could be used for the containment sleeve. The sleeve provides
the
containment strength of the container system, and must be of a strength
suitable for
19
CA 02432288 2003-06-13
supporting the forces applied by the contained material against the inner
surfaces of
the forming member sidewalls 12b. The sleeve is preferably of tubular and
seamless
construction, requiring no sewing or stitching. For assembly purposes, the
sleeve
material could simply be cut to a desired length by a sheer or laser or by a
hot knife
technique that also conditions the woven material to prevent unraveling
thereof. The
sleeve 14 is sized to snugly engage and cover virtually the entire outer
peripheral
surface area of sidewalls. The sleeve 14 extends from the upper edges of the
sidewalls 12b of the forming member to their lower edges.
In one embodiment of the outer sleeve, as illustrated in Figs. 1,2, and
3 the length or height of the sleeve 14 is cut longer than the vertical height
of the
sidewall portions of the forming member 12, such that the lower portion of the
sleeve 14 can be folded back upon itself (as illustrated at 15 in Figs. 1,2,
and 3) and
extends upwards along the lower portions of the sidewalk to provide additional
strength along the surface area portions of the sidewalls, where the pressure
caused
by weight of the contained material is the greatest. While it can extend along
the
entire height of the sidewalk, the folded over sleeve portion 15 preferably
extends
from about 20% to 50% of the height of the sidewalls 12b, and more preferably
from
about 20% to 30% of the height of the sidewalk.
In another embodiment of the outer sleeve, the sleeve 14 extends past
the lower edges 17 of the sidewalls 12b of the forming member and is folded
along
the lower edges 17 of the sidewalls 12b towards the internal cavity formed by
the
forming member (as illustrated at 19 in Figs. 8 and 9). Once folded, the
folded
portion 19 of the sleeve may be tucked into the gaps formed at the bottom of
the
forming member when it is fully assembled (as illustrated at 19a). Liquids and
semi-
liquids, such as meat, have a high tendency to flow during shipment. Such
movement increases the pressure against the sidewalk of the forming member
that
the flow and movement are directed against. Tucking the sleeve under the
forming
member in this manner counteracts the increased pressure and provides extra
strength to the container system. It also provides stability to the sleeve
member and
prevents unwanted movement of the sleeve member, such as rising up of the
sleeve
along the sidewalk 12b. The weight of the container content when loaded into
it
holds the tucked sleeve member 19a in place during shipment. Since the sleeve
14
does not have a closed bottom as is the case with an FIBC, significant
manufacturing
CA 02432288 2003-06-13
costs are saved as compared to the FIBC manufacturing process, by eliminating
all
stitching and sewing operations.
In yet another embodiment of the outer sleeve 14', as illustrated in
Fig. 10, the length or height of the sleeve 14' may be cut longer than the
vertical
height of the sidewall portions 12b of the forming member 12, such that the
lower
portion of the sleeve can be folded back upon itself (as illustrated at 15')
after being
folded along the lower edges 17 of the sidewalls 12b towards the center of the
bottom 12a of the forming member 12 (as illustrated at 19'). The sleeve
portion
remaining past the lower edges 17 of the sidewalk 12b is tucked into the gaps
formed at the bottom of the forming member when it is fully assembled, as
mentioned above, to provide strength, stability and prevent unwanted movement
(as
illustrated at 19a'). The folded up sleeve portion 15' preferably extends from
about
20% to 50% of the height of the sidewalk 12b, and more preferably from about
20%
to 30% of the height of the sidewalk. This configuration provides a double
layer of
sleeve material that extends upwards along the lower portions of the sidewalk
to
provide additional strength to the surfaces of the sidewalk.
In yet another embodiment of the outer sleeve 14", as illustrated in
Fig. 11, the lower portion of the sleeve can be folded back upon itself first
(as
illustrated at 15") and then folded back down upon itself and folded at the
lower
edges 17 of the sidewalk 12b towards the center of the bottom of the forming
member (as illustrated at 19"). Once folded, the folded portion 19" of the
sleeve may
be tucked into the gaps formed at the bottom of the forming member when it is
fully
assembled, as mentioned above, to provide strength, stability to the sleeve
member
and prevent unwanted movement (as illustrated at 19a"). The folded up sleeve
portion 15" preferably extends from about 20% to SO% of the height of the
sidewalk
12b, and more preferably from about 20% to 30% of the height of the sidewalk.
This configuration provides a triple layer of sleeve material that extends
upwards
along the lower portions of the sidewalk to provide additional strength along
the
bottom surface area portions of the sidewalls, where the pressure caused by
weight
of the contained material is the greatest.
Those skilled in the art can envision yet other methods for selectively
increasing the strength of the outer sleeve by using folding techniques.
Alternatively
and/or additionally, extra layers of outer sleeve 14 may be used around the
forming
21
CA 02432288 2003-06-13
member 12 to provide additional strength. Each layer may be non-folded or
folded
according to any of the embodiments discussed above depending upon the
intended
use of the container system and the additional strength needed.
The woven tubular material forming the outer sleeve 14 can be
readily purchased from any supplier of FIBCs such as from B.A.G. Corp. of
Dallas,
Texas or from other distributors or suppliers such as Tech Packaging Group of
Joplin, Missouri or National Paperboard Group, Inc. of Burnsville, Minnesota.
The
woven polypropylene tubular sleeve material is typically graded by weight. A
preferred weight of material that is acceptable for most applications is a 5.2
oz.
weight. The liner bags 16 can be purchased generally from the same suppliers
that
supply the FIBCs.
Lighter weight materials can be used for the outer sleeve of this
invention as compared with FIBC applications, since the sleeve only needs to
support horizontally applied containment forces. It should be noted that the
maximum bulk material handling weight specifications for materials used in
constructing FIBCs do not generally apply to this invention, since the weakest
feature of FIBC construction relates to the stitching used in the FIBC bag
construction. Generally, the stitching of a FIBC will fail long before the
woven
fabric. Since there is no stitching required for the sleeve of the present
invention,
this invention takes full advantage of the base strength of the woven
material,
enabling the use of relatively lighter weight materials for containing
relatively heavy
parcels of contained materials. Further, due to its woven construction, small
holes or
the like that may be imparted to the sleeve fabric during use will generally
not result
in catastrophic failure or unraveling or rupture of the sleeve that would
reduce its
containment strength as used in this invention. Also, if the woven
polypropylene
sleeve material is coated with polyethylene, the unraveling of the
polypropylene
material is generally prevented by the coating.
Refernng to Fig. 12, an inner insert 62 may be used to provide
additional strength to the containment system. Inner insert 62 may be
comprised of
one, two, three or more pieces, depending upon the intended use of the
container
system and the additional strength needed. When operatively configured within
the
container system, the insert engages the inner peripheral sidewall areas 12b
of the
forming member to provide additional strength. The insert 62 is sized to fit
within
22
CA 02432288 2003-06-13
the internal cavity defined by the forming member. The difference in the
circumference of the insert 62 and the circumference of the forming member 12
allows the volume of the loaded material to expand within the container system
without splitting or bursting the sidewalk 12b of the forming member 12. Use
of an
insert 62, may permit the forming member 12 to be glued if desired, to provide
more
rigidity. In a one-piece insert (as illustrated at 62 in Figs. 12, 1 S, and
17, the insert
can be configured of a relatively lightweight corrugated material (as
illustrated at 62
in Figs. 12 and 17), such as the material used for the forming member 12, or
it can
be constructed of the same type of materials that are used for the outer
sleeve 14 (as
illustrated at 62 in Fig. 15). Also, the thickness and strength of the
corrugated
materials used for the forming member 12 may be significantly reduced as a
result of
the insert 62 providing the additional strength. The insert 62 is an important
feature
of the invention that adds an additional expansion feature, enables the
forming
member 12 to be glued for increased rigidity for stacking, and adds overall
strength
and rigidity to the overall container system. The insert itself, however,
generally
does not have glued sidewall joints.
A first embodiment of a one-piece insert, constructed from corrugated
cellulose (cardboard) material, is illustrated at 64 in Fig. 13. In this
embodiment, the
one-piece insert 64 is configured from a single piece of corrugated material
that is
scored and patterned for folding, as illustrated in Fig. 13. Referring
thereto, the
insert 64 has nine sidewall portions 64a-64i consecutively connected and
defined by
intervening fold lines 65a-65h respectively, which collectively define the
eight
"corners" of an octagonally shaped configuration formed by the insert. The
insert
patterned blank material of Fig. 13 is folded along the scored lines 65a-65h
until an
octagonal tubular insert is configured. Sidewall 64a will overlap sidewall
64i,
resulting in an eight-faced insert. To form the octagonal insert, the material
illustrated in the Fig. 13 pattern is folded along the scored lines 65a-65h so
that side
edges 66a and 66b move toward one another and until the sidewall 64a overlays
sidewall 64i. At this stage, the one-piece insert would appear as illustrated
at 62 in
Fig. 12. At this point, the structure is still foldable upon itself and can be
folded into
a collapsed position. Sidewall 64a would be freely slidable over sidewall 64i
in this
embodiment. The insert would mainly be providing the container system with a
23
CA 02432288 2003-06-13
second layer of corrugated material for extra strength and rigidity for
stacking
purposes.
A second embodiment of the one-piece insert, constructed from
corrugated cellulose (cardboard) material, is illustrated at 64' in Fig. 14.
In this
S embodiment, the one-piece insert is configured from a single piece of
corrugated
material that is scored and patterned for folding, as illustrated in Fig. 14.
Refernng
thereto, the insert 64' has ten sidewall portions 64a'-64j consecutively
connected and
defined by intervening fold lines 65a'-65j respectively, which eventually
define the
eight "corners" of the insert. The insert patterned blank material of Fig. 14
is folded
along the scored lines 65a'-65j until an octagonal tubular insert is
configured. To
form the octagonal insert, the material illustrated in the Fig. 14 pattern is
folded
along the scored lines 65a'-65j so that side edges 66a' and 66b' move toward
one
another. Tab member 67, when the material is folded, will remain on the inner
side
of the formed octagonal tubular insert. Tab member 67 is slidably received
within
slot 68. In this position, the sidewall 64i' overlies sidewall 64a' and
sidewall 64j
overlies sidewall 64b'. At this stage, the one-piece insert would appear as
illustrated
at 62 in Fig. 12. At this point, the structure is still foldable upon itself
and can be
folded into a collapsed position. It will be noted that the tab member 67 is
slidably
within the slot 68. Such sliding construction provides for limited relative
movement
of the sidewall configuration to accommodate expansion and contraction of the
material being contained by the container assembly.
The inserts 64 and 64' described above did not have any "bottoms".
However, a third embodiment of the one-piece insert, constructed from
corrugated
cellulose (cardboard) material, which does have a bottom stmcture, is
illustrated at
20 in Fig. 4A. In this configuration, the embodiment of the forming member,
previously described and illustrated at 20 in Figs. 4A-4D, is used as the one-
piece
insert, which is placed within an outer forming member 12. When so used, the
insert
is sized smaller than the outer forming member in order to fit within the
forming
member 12. This embodiment is configured and folded according to the
directions
given above for the embodiment of the forming member illustrated at 20 in
Figs. 4A-
4D.
The one-piece insert configurations described above are by no means
exhaustive of the configurations that are possible. Depending upon the forming
24
CA 02432288 2003-06-13
member configuration utilized, the insert should be accordingly shaped and
configured to fit within the forming member. While several configurations of
the
one-piece insert have been described with respect to specified preferred
embodiments of the invention, those skilled in the art will readily recognize
that
many other configurations of such inserts can be designed within the scope of
the
invention. Further, while specific corrugated materials have been described
for use
in association with constructing the forming members, those skilled in the art
will
readily recognize that other materials can be employed.
Once configured, the one-piece insert is placed within the forming
member 12 to engage the inner peripheral sidewall areas of the forming member.
The one-piece insert is preferably sized in order to snugly engage the inner
peripheral sidewall areas of the forming member so that, when bulk material is
being
poured inside the cavity formed by the forming member, the insert does not
slide up
along the inner sidewall areas 12b of the forming member 12, as illustrated in
Fig.
16. The insert 62 may also be placed in an offset fashion within the forming
member 12, where each corner of the insert defined by the sidewalls of the
insert
engages each of the inner sidewalls 12b of the forming member generally along
a
vertical centerline of the forming member sidewalls, as illustrated in Fig.
17. This
offset configuration (Fig. 17), providing a tight fit, prevents unwanted
movement of
the insert 62 inside the forming member 12 that might tend to collapse the
insert
prior to the container loading or filling operation. Also, offsetting the
insert 62 in
this manner provides additional strength to the container assembly by
distributing
the stress on the sidewalls 12b of the forming member 12 and the insert 62
instead of
placing it all at the weaker fold lines. Typically, an oversized liner 16 is
used with
the container system. The upper portion of the liner is folded over the top
edges of
the forming member and inserts) and down along the outside surfaces of the
forming member sidewalk, such that the liner material overlays and "covers"
the
gaps or spaces between the insert and forming member sidewalls (see Figs. 17
and
19), so that the material being loaded into the container does not fall within
such
gaps or spaces during the loading operation. The insert sidewalk are thus
freely
allowed to expand outwardly toward and into engagement with the forming member
sidewalls during the loading operation.
CA 02432288 2003-06-13
In a one-piece insert, the insert can also be of the same type of
materials that are used for the outer sleeve 14. For assembly purposes, the
sleeve
material could simply be cut to a desired length by, for example, any of the
techniques previously discussed. The sleeve material one-piece insert is sized
to be
placed inside the forming member to provide an additional layer of strength.
The
sleeve material one-piece insert may be folded in any of the combination of
ways
discussed above for the outer sleeve member, when placed inside the forming
member depending upon the intended use and the needed strength of the
containment system. Folding the lower edge of the insert sleeve material
towards
the inside, as illustrated at 69 in Fig. 15, provides the advantage of
preventing
unwanted upward movement of the insert sleeve. When bulk material is being
poured into the containment system, the bulk material weighs down the folded-
in
extended portions 69 of the inner sleeve, preventing the entire sleeve from
rising up
along the surfaces of the inner sidewalk 12b of the forming member 12.
The insert may also be constructed of at least two pieces, the pieces
being configured of any combination of the materials or the shapes discussed
above
for the one-piece insert (as illustrated at 62 in Figs. 18, 19, and 20. The
two-piece
insert may utilize either the relatively lightweight corrugated material, such
as the
material used for the forming member 12, or it can be constructed of the same
type
of materials that are used for the outer sleeve 14, or the two-piece insert
may utilize
a combination of the two types of materials (as illustrated at 62 in Fig. 18).
The
outer piece of the two-piece insert is sized and shaped to slidably engage the
surfaces
of the inner sidewalk 12b of the forming member 12, while the inner piece of
the
two-piece insert is sized and shaped to engage the inner surface of the outer
piece.
Either pieces of the two-piece insert, if of corrugated material, may be
placed in an
offset fashion, as discussed above, to prevent unwanted movement of the pieces
and
to increase strength by distributing the stress on the sidewalls. A
configuration
showing both of the pieces of the two-piece insert being placed in an offset
fashion
relative to each other is shown in Fig 19. In a configuration where the outer
insert
piece of the two-piece insert is of woven polypropylene (sleeve material), the
outer
piece may be folded in a variety of ways as discussed above for the outer
sleeve. In
a configuration, such as the one seen at 62 in Fig. 18, the lower edge of the
sleeve
material of the two-piece insert being folded under the inner corrugated piece
26
CA 02432288 2003-06-13
provides the advantage of preventing the inner corrugated piece from moving
during
the loading of bulk material. This is possible because, as discussed above,
the bulk
material weighs the folded-in extended portions 69 of the sleeve material
down, and
since the sleeve material of the insert is sized to fit snugly around the
inner
corrugated piece of the insert, the corrugated piece is also held down.
Depending on the intended use of the containment system or the
strength needed, three or more pieces can be utilized to make up the inner
insert,
being configured of any of the combination of the materials and the shapes,
discussed above, of the one-piece insert (as illustrated at 62 in Fig. 20).
The optional bag/liner, illustrated at 16 in Figs. 1, 2, and 3, may be of
any appropriate film or sheet of flexible impervious material, preferably
polyethylene or polypropylene, to protect the contents of the container system
andlor
to prevent leakage of liquids or sifting of powders out of the forming member
insert.
Such liners are well-known in the art and have been used in the past for both
corrugated and FIBC packaging. The bag/liner 16 could include a filling spout
and
sealing mechanism at its upper end, as well as a discharge spout at its lower
end.
Such discharge spout would operatively extend through a hole ar opening (not
illustrated) in the sidewalk of the forming member and insert members) as well
as
through the outer sleeve material, for enabling emptying of the contents from
the
liner. The bag/liner 16 could also be made just thin enough to provide an
impervious inner coating or layer to the forming member 12. Often, wherein the
contents of the shipping container are pumped out of the container during
removal,
the bag/liner need only be strong enough to allow lifting of any residual
product left
in the bagJliner following the pumping operation, in order to remove and
reclaim the
residual materials. Similar to the sleeve material 14 used with the forming
member
12 or the insert 62, the baglliners are flexible and collapsible and can be
recycled,
making the entire container system a collapsible and recyclable system.
In a preferred configuration of the invention as used for carrying a
2000-lb. load of liquids or semi-liquids such as meat, the follawing container
system
parameters have been found to provide safe and successful performance: an
elongated octagonal outer forming member of 350 1b. weight and of double-wall
flute corrugation; an outer sleeve of 5.2 oz. polycoated polypropylene having
an
27
CA 02432288 2003-06-13
operative circumference of 144 inches (stretches about 1 inch) and extending
beyond
the lower edge of the sidewalk of the forming member by approximately 8
inches.
In a preferred configuration of the invention as used for carrying a
1200-1400-lb. load of semi-solids such as resin, the following container
system
parameters have been found to provide safe and successful performance: a
regular
octagonal outer forming member of 350 to 500 1b. double wall corrugated
material;
an outer sleeve of 5.2 oz. polycoated polypropylene having an operative
circumference of 144 inches (stretches about 1 inch) and extending beyond the
lower
edge of the sidewalls of the forming member by approximately 8 inches; and an
inner sleeve insert (placed around a corrugated insert of 2?5 1b. C-flute
material) of
5.2 oz. coated polypropylene having an operative circumference of 142 inches
(stretches about 1 inch).
In a preferred configuration of the invention as used for carrying a
3000-lb. load of solids such as sugar, the following container system
parameters
have been found to provide safe and successful performance: a regular
octagonal
outer forming member of 500 1b. weight and of double-wall flute corrugation;
an
outer folded sleeve of 5.2 oz. polycoated polypropylene having an operative
circumference of 144 inches (stretches about 1 inch) and extending beyond the
lower
edge of the sidewalls of the forming member by approximately 8 inches; and an
inner sleeve insert (placed around a corrugated insert) of 5.2 oz. coated
polypropylene having an operative circumference of 142 inches (stretches about
1
inch).
Fig. ? illustrates the fact that the container apparatus of the present
invention can be employed in situations wherein multiple such container
assemblies
are supported by a single pallet. While the container assemblies of Fig. ?
have been
illustrated as being separated from. one another, they could equally well have
been
positioned so as to engage one another for forming a more stabilized pallet
block of
such container assemblies.
The above specification, examples and data provide a complete
description of the manufacture and use of the composition of the invention.
Since
many embodiments of the invention can be made without departing from the
spirit
and scope of the invention, the invention resides in the claims hereinafter
appended.
28
