SELF-STANDING FOLDABLE CONTAINER APPARATUSES AND METHODS OF USING THE SAME

Abstract

A self-standing foldable composite container apparatus comprises, preferably, a vertical cuboid body, namely having the shape of a square prism, rectangular prism, or cube. The container apparatus may be made from one or a plurality of layers of woven polymeric material, further having plastic inserts therein to maintain the shape thereof, reinforce the sides thereof, and further allow the containers to self-stand. The top and bottom of the container apparatus may comprise covers that may be relatively flat, the top cover having a flap openable by one or more zippers and having at least a pair of lifting loops for lifting the same with a forklift or other like lifting mechanism. Methods of using the same are further provided.

Claims

1. A container apparatus comprising: a body having a tubular configuration formed from a plurality of flexible layers and having a plurality of side walls, the body having a plurality of corners, each corner forming a vertex of the plurality of side walls thereby forming a cuboid shape, the body further having a top cover and a bottom cover thereby forming an interior space within the body; a flap disposed in the top cover configured to open forming an opening in the top cover to access the interior space; an inner liner bag disposed within the interior space; and first and second flat panel inserts within first and second pockets, respectively, within each of the plurality of side walls forming a fold line between the first and second flat panel inserts within each of the side walls.

2. The container apparatus of claim 1 wherein the layers are made from woven polypropylene.

3. The container apparatus of claim 1 wherein each of the corners is rounded.

4. The container apparatus of claim 1 wherein the flap comprises a zipper around a periphery thereof for closing to and opening from the top cover.

5. The container apparatus of claim 1 wherein the inner liner bag is adhered to an inner wall of the body.

6. The container apparatus of claim 1 further comprising: a tab extending from an inner wall of the body, wherein the inner liner bag is affixed to the tab.

7. The container apparatus of claim 1 further comprising: a spout disposed through the inner liner bag configured to open and allow material to fill the space within the inner liner bag or remove the material from the inner liner bag.

8. The container apparatus of claim 1 further comprising: a first strap connected to a first corner of the body and a second corner of the body forming a first loop.

9. The container apparatus of claim 8 wherein the first corner and the second corner are adjacent to each other.

10. The container apparatus of claim 8 further comprising: a second strap connected to a third corner of the body and a fourth corner of the body forming a second loop.

11. The container apparatus of claim 10 wherein the first and second corners are adjacent to each other and the third and fourth corners are adjacent to each other.

12. The container apparatus of claim 1 wherein the inner liner bag comprises a neck that is configured to extend through opening in the top cover.

13. A method of using a container apparatus comprising the steps of: providing a container apparatus comprising a body having a tubular configuration formed from a plurality of flexible layers and having a plurality of side walls, the body having a plurality of corners, each corner forming a vertex of the plurality of side walls thereby forming a cuboid shape, the body further having a top cover and a bottom cover thereby forming an interior space within the body, and first and second flat panel inserts within first and second pockets, respectively, within each of the plurality of side walls forming a fold line between the first and second flat panel inserts within each of the side walls, wherein the container apparatus is in a folded state; unfolding a first sidewall via a first fold line between the first and second panel inserts within the first sidewall; unfolding a second sidewall via a second fold line between the first and second panel inserts within the second sidewall; and standing the body upright with each of the sidewalls in an unfolded configuration.

14. The method of claim 13 further comprising the steps of: providing a flap disposed in the top cover configured to open forming an opening in the top cover to access the interior space; opening the flap and forming the opening in the top cover; and accessing the interior space of the body.

15. The method of claim 14 wherein the flap comprises a zipper around a periphery thereof and wherein opening the flap is caused by unzipping the zipper around the periphery of the flap.

16. The method of claim 14 further comprising the steps of: providing an inner liner bag within the body having an opening accessible through the opening in the top cover; and opening the inner liner bag and accessing an interior of the inner liner bag.

17. The method of claim 16 wherein the inner liner bag comprises a neck that is configured to extend through the opening in the top cover, and further comprising the step of: extending the neck of the inner liner bag through the opening prior to opening the inner liner bag and accessing the interior of the inner liner bag.

18. A method of using a container apparatus comprising the steps of: providing a container apparatus comprising a body having a tubular configuration formed from a plurality of layers and having a plurality of side walls without any vertical seams, the body having a plurality of corners, each corner forming a vertex of the plurality of side walls thereby forming a cuboid shape, the body further having a top cover and a bottom cover thereby forming an interior space within the body, and first and second flat panel inserts within first and second pockets, respectively, within each of the plurality of side walls forming a fold line between the first and second flat panel inserts within each of the side walls; and folding a first sidewall at the fold line between the first and second flat panel inserts within the first sidewall inwardly toward the interior space.

19. The method of claim 18 further comprising the steps of: folding a second sidewall at the fold line between the first and second flat panel inserts within the second sidewall inwardly toward the interior space; and flattening the body of the container apparatus.

20. The method of claim 18 further comprising the steps of: providing a third panel insert within the bottom cover of the container apparatus, wherein the third panel insert is foldable.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0044] The drawing figures depict one or more implementations in accord with the present concepts, by way of example only, not by way of limitations. In the figures, like reference numerals refer to the same or similar elements.

[0045] FIG. 1 illustrates a perspective view of a self-standing foldable container apparatus with a closed top in an embodiment of the present invention.

[0046] FIG. 2 illustrates a close-up perspective view of a lower corner of a self-standing foldable container apparatus in an embodiment of the present invention.

[0047] FIG. 3 illustrates a perspective view of a self-standing foldable container apparatus with an open top in an embodiment of the present invention.

[0048] FIG. 4 illustrates a top view of a self-standing foldable container apparatus in an embodiment of the present invention.

[0049] FIG. 5 illustrates a side view of a self-standing foldable container apparatus showing a closed inner liner and an open top in an embodiment of the present invention.

[0050] FIG. 6 illustrates a top perspective view of a self-standing foldable container apparatus showing an open top flap and a pour spout in an embodiment of the present invention.

[0051] FIG. 7 illustrates a front view of a self-standing foldable container apparatus having a bottom pour spout in an embodiment of the present invention.

[0052] FIG. 8 illustrates an internal view of a bottom pour spout in a self-standing foldable container apparatus in an embodiment of the present invention.

[0053] FIG. 9 illustrates a top view of a self-standing foldable container apparatus with a closed top in an embodiment of the present invention.

[0054] FIGS. 10A-10D illustrate a step-by-step methodology for collapsing and folding a self-standing foldable container apparatus in an embodiment of the present invention.

[0055] FIG. 11 illustrates a foldable bottom panel insert in an embodiment of the present invention.

[0056] FIG. 12 illustrates a bottom perspective view of a self-standing foldable container apparatus with a foldable bottom panel insert disposed therein in an embodiment of the present invention.

DETAILED DESCRIPTION OF THE PRESENTLY PREFERRED EMBODIMENTS

[0057] The present invention relates to self-standing foldable composite container apparatuses. Specifically, the self-standing composite container apparatuses comprises, preferably, a vertical cuboid body, namely roughly having the shape of a square prism, a rectangular prism, or cube. The container apparatuses are made from one or a plurality of layers of woven polymeric material, further having plastic inserts therein to maintain the shape thereof, reinforce the sides thereof, and allow the containers to self-stand. The top and bottom of the container apparatus comprise covers that may be relatively flat, the top cover having a flap openable by one or more zippers and having at least a pair of lifting loops for lifting the same with a forklift or other like lifting mechanism. Methods of using the same are further provided.

[0058] Referring now to FIG. 1, a self-standing foldable composite container apparatus 10 is illustrated. The container apparatus 10 comprises a flexible body 12 forming four walls in a rectangular prism or cuboid shape. The body 12 is preferably made from a single or a plurality of flexible polymeric layers, such as, for example, woven polypropylene layers, that are adhered or otherwise fused together and formed in a cuboid tubular shape. In a preferred embodiment, the single or plurality of flexible polymeric layers formed into a cuboid tubular shape may have seams to weaken the body thereof Alternatively, a vertical seam may be provided after two sides of a flat polymeric material or plurality of layers thereof are formed together. The seam may be formed by aligning and folding the ends over each other and stitching the same to provide reinforcement of the same at the seam. Corners 14 may be formed thereby forming the cuboid or rectangular prism shape by running vertical reinforcement stitching at particular locations where corners are desired.

[0059] Preferably, the corners 14 may be rounded and formed by several layers folded back and forth on itself and stitched together, providing a relatively high amount of strength in the corners. Preferably, the body 12 is formed from a plurality of flexible woven polypropylene layers that are adhered or otherwise fused together to form a strong and resilient outer shell. FIG. 2 illustrates an exemplary corner 14 of the present invention showing the layers of material folded upon itself and stitched together to form a rounded corner, whereby the folding of material over itself and stitched together, in the manner shown in FIG. 2, may reinforce the corners and provide further strength and resiliency thereof.

[0060] As illustrated in FIG. 3, the body 12 may have a plurality of inserts 16, formed preferably from sheets of corrugated polypropylene, preferably 5 mil in thickness, although the inserts 16 may be any material and/or thickness apparent to one of ordinary skill in the art, that may run roughly the vertical length of the body 12. Preferably, each wall 15 of the body 12 between corners 14 may have a pair of inserts 16 disposed in side-by-side positions with a space therebetween that may form a fold line 50. The inserts 16 may be disposed within a pocket between layers of the woven polypropylene layers, thereby providing rigidity and strength to the container apparatus 10 and may further allow the container apparatus 10 to be free-standing. Moreover, the inserts 16 may be sewn in place within the pocket between the layers of the woven polypropylene, thereby ensuring that the inserts 16 do not shift when in use, storage, or transport.

[0061] The container apparatus 10 may further have a top cover 18 and a bottom cover 20, generally formed from a square of flexible, woven polypropylene material (in a single or plurality of layers) or other cross-sectional shape of the container apparatus 10, that may be stitched around the perimeter of the top of the body 12 and the bottom thereof, respectively, thereby enclosing a space 22 disposed within the body 12.

[0062] The top cover 18 may have a zippered U-shaped opening flap 24 therein, having a hinged side 26 and a zippered portion 28 for closing over an opening 29. The zippered opening flap 24 may have a pair of zippers 30a, 30b running over the zippered portion 28 for ease of opening and/or closing the same, as further shown in FIG. 7. By opening the flap 24, access to the interior space 22 may be accessed.

[0063] The top cover 18 and the bottom cover 20 may be made from one or more layers of, preferably, woven polypropylene, and the zippered portion 28 may be reinforced with additional material and stitching for additional strength and resiliency. Optionally, a rigid and/or foldable insert panel 60 (as illustrated in FIG. 9) may be disposed within the bottom 20. Specifically, the rigid and/or foldable insert panel 60 may be disposed between layers within a pocket (not shown) of the bottom 20 to provide additional rigidity and strength to the bottom 20 thereof and/or to aid in allowing the container apparatus 10 to be free-standing.

[0064] Disposed within the space 22 of the body 12 may be a flexible plastic liner bag 32 that may be adhered or otherwise disposed on the bottom 20 and/or sides of the body 12 of the container apparatus 10 and may have an extended neck or duffel portion 33 that may be pulled up and out of the body 12 through the opening 29. As illustrated in FIG. 4, the liner bag 32, specifically, the duffel portion 33 thereof, may be folded over sides of the body 12 to create a large opening for adding material or object therein. Once material and/or objects are added, the liner bag 32 may be closed and tied via a tie 34 to hold the material and/or object within the liner bag 32, as illustrated in FIG. 5. As shown in FIG. 7, the zippers 30a, 30b may be used to close the opening 29 with the flap 24 by zippering the flap 24 to the rest of the top cover 18 via the zippered portion 28.

[0065] Preferably, the inside of the body 12 may have one or more tabs 35 (as illustrated in FIG. 3), each of which may form a wing to which the liner bag 32 may be affixed. The tabs 35 or wings may be sewn to the body 12 and adhered to the liner, thereby keeping the liner in place within the body 12. Most preferably, the liner bag 32 may be adhered with glue to both the one or more tabs or wings and the inner wall of the body 12.

[0066] In another embodiment, the liner bag 32 may be hidden within the body 12, wherein another one or more layers of polypropylene (not shown) may be disposed over the liner bag 32 within the body 12. Therefore, the liner bag 32 may be sandwiched between multiple layers of woven polypropylene.

[0067] In an alternate embodiment of the present invention, illustrated in FIG. 6, a sealed and enclosed liner bag 42 may be provided wherein access to an interior of the sealed and enclosed liner bag 42 may be via an inlet spout 44, which may be disposed in a top of the liner bag 42 to allow material, such as fluids, for example, to be added to within the liner bag 42. The inlet spout 44 may have a cap 46 that may be opened and allow the material to be added thereto, wherein the cap 46 may further be closed thereupon, thereby sealing the material within the liner bag 42. In addition, a second bottom discharge spout 70 (illustrated in FIG. 7) may be at or near a bottom of the container apparatus 10 that may be openable to gain access to the interior of the liner bag 42 so that the material may be retrieved, such as via pouring or otherwise discharging out of the liner bag 42. The discharge spout 70 at or near the bottom of the container apparatus 10 may penetrate the outer layers of the container apparatus, as illustrated in FIG. 8. Specifically, FIG. 8 illustrates inner liner bag 42 having the bottom pour spout 70 disposed both through the inner liner bag 42 and the sidewall 15 so that the material contained therein may be accessed and discharged. A reinforcement panel insert 72 may be provided at the location of the bottom pour spout 70 to provide a reinforced attachment of the bottom pour spout 70. The reinforcement panel may preferably be made from corrugated polypropylene, although any other material may be used and the present invention should not be limited.

[0068] Referring back to FIGS. 1 and 3, a pair of lifting straps or loops 40a, 40b may extend from the top of the body 12, forming reinforced loops that may be mechanically lifted, such as via a forklift, a crane, or other like mechanism. The straps may be made from flexible woven polypropylene webbing that may be stitched and held to the sides of the body 12. Preferably, the lifting straps 40a, 40b may extend down at or near each top corner of the body 12 to the respective bottom corner of the body 12, thereby providing reinforcement to the body 12 at or near each corner thereof and further reinforcing the lifting straps 40a, 40b, especially when used by lifting mechanisms to lift the same. In addition, one end of one of the lifting straps 40a or 40b may be disposed over a vertical seam that may form the cuboid tubular body 12 thereby hiding and reinforcing the same. Specifically, the end of one of the lifting straps 40a or 40b may be stitched vertically from the top to the bottom of the body over a seam that may be disposed in the same location.

[0069] The container apparatus 10 may preferably be used to store and transport material and objects therein and the features described herein allow the storage and transport with no or minimal risk of leakage or spillage of the objects or materials from within. Preferably, the container apparatus 10 may be utilized for hazardous waste storage and transport, such as material falling in to hazard class 3, 4.1, 4.2, 4.3, 5.1, 6.1, 8, or 9, which may fall into Packing Groups I, II, and/or III, in place of drums or barrels, as authorized to be shipped in lap packs in accordance with 49 CFR 173.12(b), for example. Because the container apparatus 10 stands by itself in an upright configuration, it may be easily loaded and may also easily stack onto pallets or the like for transport of the same. The cuboid shape of the container apparatus 10 allows many to be stacked adjacent each other with maximum spatial efficiency.

[0070] Transporting empty container apparatuses 10, as described herein, may also be accomplished easily, requiring minimal space. When empty, the container apparatus 10 of the present invention may be folded down to a flat configuration, as illustrated in FIGS. 8A-8D. Specifically, FIG. 8A illustrates an empty container apparatus 10 in a self-standing, upright configuration. A fold line 50 may be disposed in each side of the container apparatus 10 between each of the plastic insert panels 16, allowing each side to be folded, as shown in FIG. 8B. Specifically, a first side of the container apparatus 10 may be folded inwardly and a second, opposite side (not shown) may also be folded inwardly, allowing the container apparatus 10 to lie flat, as illustrated in FIG. 8C. The flattened container apparatus shown in FIG. 8C may be folded via further fold lines disposed in the other two sides of the container apparatus 10 to form a folded, flat configuration, as illustrated in FIG. 8D.

[0071] Optionally, as detailed above, the bottom 20 of the container apparatus 10 may have an insert 60, as illustrated in FIGS. 9-10. The insert 60 may be a rigid plastic panel that may have a plurality of fold lines therein, namely 62a, running diagonally from a first corner to a second corner thereof; 62b, running vertically from a first side to a second side thereof; 62c, running from a third side to a fourth side thereof; and 62d, running from a third corner to a fourth corner thereof. The fold lines 62a-62d in the insert panel 60 may allow the bottom 20 to form fold lines 64a, 64b, 64c, 64d, corresponding to the fold lines 62a, 62b, 62c, 62d in the insert panel 60, respectively, and thus may allow the bottom 20 fold together when the container apparatus 10 is folded as described above, as the fold lines 62a-62b may be utilized to fold the bottom thereof along fold lines 64a-64d, as shown in FIG. 10. Thus, the container apparatus 10 may have the rigidity and strength of the reinforcing panel 60 within the bottom 20 thereof while also still allowing the same to be easily foldable and stackable, as described above.

[0072] Thus, the container apparatus 10 may be folded and flattened when not in use, allowing the same to be easily stored and transported, such as a to a user for use thereof or from a user back to the manufacturer for cleaning, reuse, or the like. A plurality of folded and flattened container apparatuses may be stacked upon each other to minimize space constraints.

[0073] While the present invention details a container apparatus 10 having a rectangular or cuboid prism shape, it should be noted that the container apparatus 10 may be any shape and size and should not be limited as described herein. For example, the container apparatus 10 may have a cube shape, wherein each dimension thereof is roughly the same size. In an exemplary embodiment, the container apparatus 10 of the present invention may have width and length dimensions of about 24 each and a height dimension of about 34. Alternatively, the container apparatus 10, having roughly a cube shape thereof, may have width, length, and height dimensions of about 36 each. Of course, the present invention may be any dimensional length and the present invention should be limited as described herein.

[0074] It should be noted that various changes and modifications to the presently preferred embodiments described herein will be apparent to those skilled in the art. Such changes and modifications may be made without departing from the spirit and scope of the present invention and without diminishing its attendant advantages. Further, references throughout the specification to the invention are nonlimiting, and it should be noted that claim limitations presented herein are not meant to describe the invention as a whole. Moreover, the invention illustratively disclosed herein suitably may be practiced in the absence of any element which is not specifically disclosed herein.