Note: Descriptions are shown in the official language in which they were submitted.
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BULK CONTAINER
FIELD OF THE INVENTION
100011 The present invention relates generally to containers, and more
particularly to
containers for transporting bulk flowable materials.
BACKGROUND OF THE INVENTION
100021 Flowable materials, such as liquids, granulated solids and the like,
are often shipped or
transported in bulk containers. In some cases, it is desirable to store or
transport flowable
materials in separate containers for later combination at their destination or
place of use. It is
an aim of transporters of such flowable materials to ship such separate
containers in an efficient
and convenient manner, and to ensure that the materials are kept separate
until reaching an
appropriate time and/or place for mixing the materials.
SUMMARY OF THE INVENTION
100031 The present invention provides a bulk container that allows transport
of at least two
flowable materials isolated from one another in a common or unitary package.
The flowable
materials are transported in separate containers, with the separate containers
being nested or
coupled to form a container assembly. The separate flowable materials may then
be mixed at a
later time, such as at a final destination.
100041 In one embodiment of the present invention, a bulk container and method
for storage of
at least two substances includes a first container adapted to contain a first
substance, the first
container having an outer surface with a recess. The bulk container further
includes a second
container adapted to contain a second substance. The second container has a
shape at least
generally corresponding with the recess of the first container. The second
container is coupled
with the recess to form a container assembly, so that the first substance and
the second
substance are kept separate when in their respective containers, such as
during transport or
shipping.
100051 In one aspect, the bulk container may also include a cage for the first
and second
containers. The cage includes a base portion to support a bottom portion of
the first container,
a wall substantially surrounding the first container, and an upper outer
perimeter that extends
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above the first container when the first container is in the cage. The wall
may, for example, be
a four sided wall with a square or rectangular cross section, such as for
defining a substantially
cubic cage.
100061 In another aspect, the upper outer perimeter of the cage may be
substantially open, such
as to allow the first container to be freely lowered into or raised out of the
cage.
100071 In another aspect, the recess in the outer surface of the first
container may be located at
a top portion of the first container, so that the second container is
removable through the
opening at the upper outer perimeter of the cage, such as by lifting the
second container out of
the cage and away from the first container. Thus, placing the recess at the
top portion of the
first container may allow for the second container to be removed from the cage
without
removing the first container.
100081 In yet another aspect, the cage may include a plurality of apertures
passing through the
wall at the upper outer perimeter. Such apertures may be used to tie the cage
to an adjacent
surface or support, such as a pallet. Alternatively, the apertures may be used
to lift the cage,
such as with an overhead crane or forklift or the like.
100091 In still another aspect, the recess in the first container may be
located adjacent to the
wall of the cage when the first container is in the cage, so that the second
container is located
between the outer surface of the first container and the inner surface of the
wall of the cage
when the second container is coupled with the recess. When the recess is so
configured, the
second container is restrained from lateral movement when located in the cage
with the first
container, but is freely laterally removable from the first container when the
first container is
not located in the cage.
100101 In another aspect, the first container may include a drain valve
assembly located at a
bottom portion of the first container. The drain valve assembly may be used
for dispensing the
contents of the first container. Such dispensation may optionally occur when
the first container
is located in the cage, such as through a door or cover in the wall portion of
the cage.
100111 In yet another aspect, the first container may have a capacity of at
least 454 liters, but
not more than 3,000 liters, and the second container may have a capacity of 10
liters. Either the
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first container or the second container or both may be made of an elastomeric
material, such as
polyethylene.
100121 In still another aspect, the first container may include a sealable
aperture at a top portion
of the first container, such as an aperture threadably attached to a cap with
a gasket disposed
between the threaded aperture and the cap. Multiple apertures may be provided,
such as two
small apertures and one large aperture in the top portion of the first
container for rapid and
efficient fluid transfer into or out of the first container.
[00131 In another aspect, the outer perimeter of the first container may have
four corner
portions with a recess being located at each corner portion, so that the first
container has four
recesses. Each of the recesses may then be used for coupling a second
container with the first
container, so that the bulk container includes four second containers each
located in a
respective recess of the first container.
100141 Accordingly, the present invention provides a bulk container adapted to
transport and/or
store more than one flowable material separately in a common package. The
separate flowable
materials are prevented from mixing during transport or storage, but can
easily be mixed when
ready to use. A cage may be provided that protects the container and
facilitates safe, orderly
and efficient movement and/or packing of one or more bulk containers.
[00151 These and other objects, advantages, purposes and features of the
present invention will
become apparent upon review of the following specification in conjunction with
the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
100161 FIG. 1 is a perspective view of a bulk container in accordance with the
present
invention;
[00171 FIG. 2 is an enlarged view of a portion of the bulk container shown in
FIG. 1,
illustrating a container; and
100181 FIG. 3 is an enlarged view of a portion of the bulk container shown in
FIG. 1,
illustrating a drain valve assembly.
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DESCRIPTION OF THE PREFERRED EMBODIMENTS
100191 Referring now specifically to the drawings and the illustrative
embodiments depicted
therein, a bulk container 10 for storage of at least two substances includes
at least two
containers, such as a first or main container 12 and one or more second or
secondary containers
14. Secondary containers 14 nest or couple with a recess or bay or depression
16 formed in
first container 12 to form a container assembly that is storable and/or
transportable as a single
unit while holding two or more flowable materials separately from one another.
[00201 The first or main container 12 has a closed body shape forming a cavity
therein. The
first container wall has generally vertical parallel wall portions 12a with
generally horizontal
top portion 20 and bottom portion 12b. In the illustrated embodiment, the top
portion 20 has a
slight convex curvature, such as for structural rigidity and to leave a gap or
space between the
inside or lower surface of the top portion and the material contained by the
container when the
container is filled to near-capacity. Transitions between the bottom, top and
wall portions of
first container 12 are radiused to provide rounded corners and edges to
facilitate handling of
first container 12 and to reduce stress concentration created by pressure on
such corners and
edges. For example, the radius between the bottom portion and the wall may be
larger than the
radius between top portion and the wall to accommodate the pressure exerted by
the weight of
contained materials on the bottom portion.
100211 In the illustrated embodiment, first container 12 has a generally cubic
shape with each
of four rounded vertical corners having a recess 16 formed in a top portion 20
of the first
container 12 for coupling with up to four second containers 14. However, it
will be apparent to
one skilled in the art that the first container may take other shapes, such as
a cylindrical or
hemispherical shape, without departing from the spirit and scope of the
present invention.
100221 Offset portions in the wall of first container 12 define recesses 16.
The recesses have a
horizontal platform 16a offset from the bottom portion 12b and a plurality of
vertical wall
portions 16b offset inwardly from the outermost wall of the first container.
For example,
recesses 16 have three vertical walls, made up of two mutually opposed wall
portions 16b
offset from the adjacent outer wall portions 12a of the first container 12,
and a middle wall
portion 16c offset from the corner defined by such adjacent wall portions. The
mutually
opposed end wall portions 16b of the recess 16 may be at generally right
angles with respect to
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one another, with the middle wall portion 16c being at a 45-degree angle with
respect to each
adjacent end wall portion 16b.
100231 Second container 14 is shaped and sized to couple or nest with recesses
16. In the
illustrated embodiment, recesses 16 extend sufficiently far into the outer
surface of first
container 12 to allow second containers 14 to complete a substantially cubic
outer profile of the
container assembly when coupled with first container 12. Such a profile
corresponds with a
substantially cubic inner cavity of a cage 18 for a secure fit, as discussed
in detail below.
However, it will be apparent to one of ordinary skill in the art that other
shapes and profiles of
the recesses in the first container may be employed without departing from the
spirit and scope
of the present invention. For example, the recess may be configured to prevent
lateral
movement of the second container even when the first container is not in the
cage, such as by
forming the recess as a cavity in the top portion of the container or by
forming a retaining wall
around the perimeter of the recess to form a cavity, with the second container
being lowered in
to the cavity to couple with the first container.
100241 Second container 14 has a closed body shape forming a cavity therein.
The second
container wall has generally vertical parallel wall portions with a generally
horizontal bottom
portion corresponding with horizontal platform 16a of first container 12
(discussed above).
The top portion of the second container 14 has sloping sides and a handle
portion 14b integrally
formed as part of the container. Adjacent the handle at the top portion is a
cap 15 adapted to
attach to the container and substantially seal any contents inside the
container. In the illustrated
embodiment, second container 14 has a generally rectangular shape, though the
container may
take other shapes without departing from the spirit and scope of the present
invention.
100251 The first or main container includes multiple sealable apertures at its
top portion 20. In
the illustrated embodiment, first container 12 includes a primary or central
aperture 22, with a
secondary aperture 24 and a tertiary aperture 26 located at opposite ends of
primary aperture 22
(see FIG. 2). Primary aperture 22 includes a threaded exterior portion 28
adapted to threadably
couple with a cap 30, with a gasket 32 being optionally interposed between cap
30 and primary
aperture 22 to facilitate sealing of the primary aperture. Cap 30 may include
a venting device
34 attached at a central portion of cap 30 to prevent or relieve any pressure
differential between
the interior cavity of the first container and the atmosphere around the
container.
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[0026[ Secondary aperture 24 is sealed with a second venting device 36, also
operable to
prevent or relieve pressure differentials, such as during pouring or draining
of the contents of
first container 12. Tertiary aperture 26 is closed or sealed by a plug 38,
such as a two inch
buttress plug, which may be removed for pouring the contents of first
container 12 through
tertiary aperture 26. For example, if the contents of first container 12 are
poured through
tertiary aperture 26, venting device 34 and/or second venting device 36 may be
opened to allow
ambient air to flow into the container. As the contents of the container are
discharged through
tertiary aperture 26, the air admitted by venting devices 34, 36 smoothly
displaces the poured
contents as they flow out of first container 12. Although the illustrated
embodiment includes
three aligned apertures, it will be apparent to one of ordinary skill in the
art that other
combinations or configurations of apertures through the container may be
employed without
departing from the spirit and scope of the present invention.
100271 Bulk container 10 includes a cage 18 that provides protection for
containers 12, 14 and
promotes safe and efficient transport and storage of the substances contained
therein. As best
seen in FIG. 1, cage 18 includes a base or bottom portion 40 that supports
first container 12 and
provides a stable foundation for bulk container 10. A wall 46 extends upwardly
from base 40
to form a cavity 48 adapted to enclose the container or containers. Ribs 50
extend downwardly
from base portion 40 to form legs 42 and upwardly from base portion 40 to form
an upper outer
perimeter 52 of wall 46. Legs 42 are extend below the lower face of cavity 48
with channels 44
extending between legs 42 across the width of cage 18. Channels 44 may, for
example, allow a
lifting device such as the forks of a forklift to pass therethrough to
facilitate lifting bulk
container 10 from the bottom. At the base portion 40, wall 46 curves inwardly
to define the
lower surface of cavity 48 that supports first container 12. In the central
portion of the
inwardly curved surfaces, protrusions 51 extend downwardly to support, for
example, forks of a
forklift as discussed above. Depressions 50a are formed between ribs 50 with
radiused
transitions for enhanced strength and rigidity of cage 18.
100281 In the illustrated embodiment, cavity 48 is adapted to receive first
container 12 and
second containers 14 by having a substantially cubic shape corresponding with
the substantially
cubic shape of the container assembly (as discussed above), although the
containers and cage
may be formed in other shapes. Depressions 50a gradually flare outwardly as
they approach
upper outer perimeter 52 (see FIG. 1) to provide an oversize opening at the
top of cavity 48 to
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facilitate alignment of containers 12, 14 with cavity 48 as the containers are
lowered in to cage
18, as discussed in detail below. As containers 12, 14 move down in to cavity
48, the inner
perimeter of the central and lower portions of wall 46 contracts to hold
containers 12, 14
securely with little or no clearance for lateral movement of the containers.
100291 When the containers 12, 14 are placed in cage 18, upper outer perimeter
52 of cage 18
extends above the upper surfaces of the containers for protection and to allow
stacking of
multiple bulk containers (as discussed below). Upper outer perimeter 52 is
substantially open
to allow ingress and egress of containers 12, 14 by lifting or lowering the
containers in to or out
of the cage.
100301 Optionally, cage 18 may include apertures 54 passing through wall 46 at
upper outer
perimeter 52 (see FIG. 1). Apertures 54 may be used to secure bulk container
10 to a lower or
supporting surface, such as a pallet or truck bed. Apertures 54 may also be
used to lift or
support bulk container 10 from above, such as with a forklift or overhead
crane. For example,
forks of a forklift may be passed through apertures 54 to securely couple bulk
container 10 with
the forklift for safe and efficient transport of the bulk container.
100311 At least two substances may be stored and transported using bulk
container 10. The
first substance is transferred to first container 12 through an aperture in
upper surface 20
(discussed above), such as through primary aperture 22. Graduation markings 56
may be
provided at the exterior portion of first container 12 to aid in accurately
transferring a desired
amount of the first substance to the first container. First container 12 is
then closed and sealed
using cap 30, venting devices 34, 36 and plug 38, as discussed above. A second
substance is
transferred to a second container 14, and second container 14 is then closed
and sealed with cap
15. First container 12 is then lowered into the cavity 48 of cage 18. Once
first container 12 is
firmly seated in cavity 48, and in contact with the upper interior surface of
lower portion 40,
second container 14 is lowered into recess 16 to couple therewith, securing
second container 14
between the outer surface of first container 12 and the inner surface of wall
46 and thereby
forming a substantially unitary bulk container 10. Other substances or
additional quantities of
the second substance may be transferred to subsequent second containers 14 as
necessary, and
additional second containers 14 are similarly coupled with respective recesses
16.
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100321 With containers 12, 14 securely stowed in cage 18, the first and second
substances
contained in their respective containers can be safely stored or transported.
When transporting
bulk container 10, containers 12, 14 may be secured against vertical movement
by placing an
obstruction, such as a strap or bar, across upper outer perimeter 52 through
apertures 54.
Alternatively, the bottom portion of a second cage may enclose the cavity 48
when the second
cage is stacked on the first cage (as discussed in detail below). Upon
reaching a destination or
being removed from storage, second container 14 is removed from recess 16 and
the second
substance contained therein is be placed in fluid communication with the first
substance
contained in first container 12 to form a mixture. In the illustrated
embodiment, bulk container
includes four second containers 14, thereby providing for a mixture of up to
five different
substances.
100331 Optionally, the first container may include a drain valve assembly 62
for discharging
the substance contained therein. Referring now to FIG. 3, drain valve assembly
62 of the
illustrated embodiment includes a split ring assembly 64, a coupler 66, and a
valve 68, with 0-
rings 70 interposed between each. Optionally, valve assembly 62 may also
include a dust cap
72. Valve assembly 62 attaches at a bottom portion of first container 12 for
draining the
substance or a mixture of substances contained in the first container. Valve
68 includes a lever
74 which can be rotated between a closed position and an open position, with
the open position
allowing a flowable substance to pass therethrough and the closed position
being substantially
sealed or closed to prevent such passage.
100341 To accommodate drain valve assembly 62, first container 12 may include
a recessed
portion 75, such as a cup-shaped portion (see FIG. 3) in the bottom portion of
the first
container. The recess may be generally semi-cylindrical in shape, with the
axis of the cylinder
being approximately coincidental with the bottom outer surface of the first
container so that the
recess extends upwardly in to the body of the first container, thereby
allowing drain valve
assembly 62 to couple with first container 12 without increasing the footprint
of the container.
The terminal end of the recess is offset from the outer wall of first
container 12 so that the
recess extends a portion of the bottom portion, such as about halfway across.
Ribs 75a may be
included at the inwardly facing surface of recess 75 to add structural support
and reinforcement
to the recess. A spout or protrusion 75b extends into the recessed portion 75
and provides a
port for the first container which is in fluid communication with the interior
cavity of first
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container 12. Drain valve assembly 62 connects to spout 75b to dispense the
contents of first
container 12, as discussed above.
]0035] Cage 18 may include an opening 76 at its bottom portion corresponding
with the
location of drain valve assembly 62 when first container 12 is located in the
cage. Opening 76
eliminates the need for removal of the first container from the cage when
draining the
substance in first container 12 by allowing passage through drain valve
assembly 62 and
opening 76. Optionally, a cover or door 78 may be pivotally coupled to the
cage at opening 76
to conceal and protect the drain valve assembly. A protrusion 80 adjacent one
side of opening
76 provides a stop and prevents further rotation of door 78 when the door is
in the closed
position, while allowing free rotation of the door to the open position.
]0036] Optionally, the cage may include keys 82 at each corner of upper outer
perimeter 52.
Keys 82 fit into corresponding recesses 84 in the outer surface of legs 42.
Thus, a cage with
keys 82 provides for precise and secure stacking of multiple bulk containers
10. The keys
prevent lateral shifting of an upper bulk container stacked on a lower bulk
container. The
upper container is also prevented from falling into the lower container (as
might occur in the
event of a lateral shift of the upper container), enhancing the safety and
security of the
substances contained therein.
100371 Optionally, first or main container 12 includes a recessed area 86 for
placement of text
or symbols or warnings or the like. In addition, the upper surface 20 of first
container 12 may
include a label 88 (see FIG. 2) affixed thereto for information, warnings,
port specifications
related to the destination of the bulk container, or the like.
]0038] Changes and modifications to the specifically described embodiments may
be carried
out without departing from the principles of the present invention, which is
intended to be
limited only by the scope of the appended claims, as interpreted according to
the principles of
patent law including the doctrine of equivalents.
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