BULK BIN WITH PANEL TO PANEL INTERLOCK FEATURES

Abstract

A collapsible bulk bin container with structures for improved strength is provided. The bulk bin container includes wrap-around portions in the short sidewalls with a horizontal top plate and a horizontal rib proximate the top plate. The bulk bin container also includes ramp structure in the long side sidewall and base for lifting and dropping the sidewall when pivoted upright. The upright sidewall and base include surfaces to inhibit or prevent buckling due to compressive loads. The bin can also include post and pocket interlock structures.

Claims

1. A collapsible bulk bin container comprising: a base having a first side, a second side perpendicular to the first side, a third side parallel to the first side and perpendicular to the second side and a fourth side perpendicular to the first side and parallel to the second side; a first sidewall pivotably connected to the first side of the base; a second sidewall pivotably connected to the second side of the base; a third sidewall pivotably connected to the third side of the base; a fourth sidewall pivotably connected to the fourth side of the base; the first sidewall having an outer surface and an inner surface and a first edge on a first side perpendicular to the outer surface, the first sidewall connected to a first wrap-around portion at the first side of the first sidewall, the first wrap-around portion extending outward beyond the first edge of the first sidewall, the first wrap-around portion further extending toward the third side, the first wrap-around portion having a first horizontal plate at a top portion of the first wrap-around portion extending outward over the first wrap-around portion.

2. The collapsible bulk bin container of claim 1 further comprising the first sidewall having a second edge on a second side perpendicular to the outer surface and a second wrap-around portion at the second side of the first sidewall that contacts a first side portion of the fourth sidewall when the first and fourth sidewalls are pivoted upright, the second wrap-around portion extending outward beyond the second edge of the first sidewall and further extending toward the third side, the second wrap-around portion having a second horizontal plate at a top portion extending outward over the second wrap-around portion.

3. The collapsible bulk bin container of claim 2 further comprising a horizontal rib in the first wrap-around portion positioned below the first horizontal plate proximate the top portion of the first wrap-around portion.

4. The collapsible bulk bin container of claim 3 further comprising a horizontal rib in the second wrap-around portion positioned below the second horizontal plate proximate the top portion of the second wrap-around portion.

5. The collapsible bulk bin container of claim 2 wherein the first wrap-around portion extends at about a 90 angle from the first sidewall.

6. The collapsible bulk bin container of claim 5 wherein the second wrap-around portion extends at about a 90 angle from the first sidewall.

7. The collapsible bulk bin container of claim 1 wherein the first wrap-around portion of the first sidewall includes projections for interlocking with the second sidewall.

8. The collapsible bulk bin container of claim 2 further comprising the third sidewall having a first wrap-around portion at a first side of the third sidewall that contacts a second side portion of the second sidewall when the third and second sidewalls are pivoted upright, the first wrap-around portion of the third sidewall having a third horizontal plate extending outward over the first wrap-around portion at a top portion of the first wrap-around portion.

9. The collapsible bulk bin container of claim 8 further comprising the third sidewall having a second wrap-around portion at a second side of the third sidewall that contacts a second side portion of the fourth sidewall when the third and fourth sidewalls are pivoted upright, the second wrap-around portion of the third sidewall having a fourth horizontal plate extending outward over the second wrap-around portion at a top portion of the second wrap-around portion.

10. The collapsible bulk bin container of claim 9 further comprising a horizontal rib in the first wrap-around portion of the third sidewall positioned below the third horizontal plate proximate the top portion of the first wrap-around portion.

11. The collapsible bulk bin container of claim 10 further comprising a horizontal rib in the second wrap-around portion of the third sidewall positioned below the first horizontal plate proximate the top portion of the second wrap-around portion.

12. The collapsible bulk bin container of claim 1 wherein the first wrap-around portion is configured to contact a projection from a first side portion of the second sidewall when the first and second sidewalls are pivoted upright.

13. The collapsible bulk bin container of claim 2 wherein the second wrap-around portion is configured to contact a projection from a first side portion of the third sidewall when the first and third sidewalls are pivoted upright.

14. The collapsible bulk bin container of claim 1 wherein the first wrap-around portion includes an outer wall connected to the first edge of the first sidewall.

15. The collapsible bulk bin container of claim 14 wherein the outer wall of the first wrap-around portion is perpendicular to the first edge of the first sidewall.

16. A plastic collapsible bulk bin container comprising: a rectangular base portion having a first side, a second side, a third side and a fourth side; a rectangular first sidewall extending upward from the first side, the first sidewall having an outer surface and an inner surface, a first planar edge perpendicular to the outer surface and inner surface on a first side of the first sidewall and a second planar edge perpendicular to the outer surface and inner surface on a second side of the first side wall; a second sidewall pivotally mounted to the second side of the base portion; a third sidewall extending upward form the third side of the base portion; a fourth sidewall pivotally mounted to the fourth side of the base portion; a first wrap-around portion extending laterally outward from the first edge of the first sidewall, the first wrap-around portion having a top plate and a pocket below the top plate for receiving a first portion of the second sidewall.

17. The plastic collapsible bulk bin container of claim 16 wherein the first wrap-around portion extends toward the third sidewall.

18. The plastic collapsible bulk bin container of claim 16 further comprising a second wrap-around portion extending laterally outward from the second edge of the first sidewall, the second wrap-around portion having a top plate and a pocket below the top plate for receiving a first portion of the fourth sidewall.

19. The plastic collapsible bulk bin container of claim 18 wherein the second wrap-around portion extends toward the third sidewall.

20. The plastic collapsible bulk bin container of claim 18 further comprising a first wrap-around portion extending laterally outward from a first edge of the third sidewall, the first wrap-around portion extending from the third sidewall having a top plate and a pocket below the top plate for receiving a second portion of the second sidewall and a second wrap-around portion extending laterally outward from a second edge of the third sidewall, the second wrap-around portion extending from the third sidewall having a top plate and a pocket below the top plate for receiving a second portion of the fourth sidewall.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0024] To understand the present invention, it will now be described by way of example, with reference to the accompanying drawings in which:

[0025] FIG. 1 is a perspective view of bulk bin container having a horizontal wrap-around plate in accordance with one aspect of the present invention;

[0026] FIG. 2 is an enlarged perspective view of a corner portion of the bulk bin container of FIG. 1;

[0027] FIG. 3 is a cross-sectional view of bulk bin container with a sidewall ramp and bottom ramp in accordance with another aspect of the present invention;

[0028] FIG. 4 is an enlarged cross-sectional view of a corner portion of the bulk bin container of FIG. 3;

[0029] FIG. 5 is a cross-sectional view of the bulk bin container with a sidewall partially lowered;

[0030] FIG. 6 is an enlarged cross-sectional view of a corner portion of the bulk bin container of FIG. 5; and,

[0031] FIG. 7 is a perspective view of a corner of the bulk bin container showing the bottom ramp with a partially collapsed sidewall.

DETAILED DESCRIPTION

[0032] While this invention is susceptible of embodiments in many different forms, there is shown in the drawings, and will herein be described in detail preferred embodiments of the invention with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the broad aspect of the invention to the embodiments illustrated.

[0033] In accordance with a first aspect of the present invention, a collapsible bulk bin container is provided with an improvement to features utilized for interlocking the sidewalls. Specifically, the bulk bin container is provided with an upper, horizontal plate to the wrap-around sections of the short sidewalls. This increases the strength of the container, and in particular, the corner portions of the container when the sidewalls are in an upright and locked position.

[0034] Referring to FIG. 1, a bulk bin container 10 is shown having a base 12 and four collapsible sidewalls (also sometimes referred to as panels) 14, 15. Three of the sidewalls 14 are shown in an upright position and a fourth sidewall 15 is shown just prior to being upright.

[0035] The bulk bin container 10 is configured so that two of the sidewalls 14 include projections or wrap-around portions 18 on both sides of the sidewall that allow the sidewall 14 to interlock with adjacent sidewalls. Referring to the enlarged corner view of FIG. 2, the wrap-around portion 18 extends at approximately a right angle (i.e., 90) to the sidewall. The wrap-around portion 18 forms an inwardly facing pocket and includes a plurality of projections that mate with projections on the edge of the adjacent sidewall to interlock the two sidewalls in the upright position. The interlocking features can be, for example, a post-and-pocket structure or a lift-and-lock structure.

[0036] The bulk bin container 10 includes two larger opposing sidewalls and two shorter opposing sidewalls. The wrap-around portions 18 are typically located on the shorter sidewalls (however, the present invention can be utilized if the longer sidewalls include the wrap around portions, or for containers having equal sidewalls).

[0037] The wrap-around portions 18 (one of which is shown in FIG. 2) include a horizontal plate 20 positioned at the top of the wrap-around portion 18. A horizontal rib 22 is positioned just below the horizontal plate 20 proximate the top of the wrap-around portion 18.

[0038] As illustrated in FIGS. 3-6, the bulk bin container 10 also includes features which lift the long sidewall 15 as it is pivoted upward. In particular, the container 10 is provided with ramps having ramp surfaces, molded into the panel and into the base, which cooperate to lift the panel approximately 0.75 inches upward as the panel is moved into an upright position. Once the panel is upright or nearly upright, it can then be forced downward and locked. This allows interlocking structure on the edge of the panel to engage corresponding structure of a wrap-around section of an adjacent panel as discussed above. The ramps are located above the hinge rotation centerlines. While near the edge, the ramps are moved inward from the exterior edge or surface of the bulk bin container 10 (i.e., towards the center of the base). This inward location provides an additional benefit of counteracting buckling of the panel when the bulk bin container 10 is subjected to compressive loads from stacking. The resistance against buckling is accomplished by a vertical surface on the ramp in the base which contacts a parallel vertical surface on the panel.

[0039] Referring to FIGS. 4 and 6, the base 12 includes a first upward projection 30 along a side of the base 12 aligned with the long side sidewall 15. The first upward projection includes a first upper edge portion 31. The first long side sidewall 15 has a first lower edge portion 32 with a first lower ramp surface 34. The first lower ramp surface 34 is positioned to engage a second ramp surface 36 positioned at a top of the first upper edge portion 31. The first ramp surface 34 and the second ramp 36 surface are preferably curved.

[0040] The first ramp surface 34 and second ramp surface 36 are designed to engage during pivoting of the sidewall 15 and cause the sidewall to lift upward. The sidewall 15 is provided with a floating hinge (not shown) to accommodate the upward movement of the sidewall 15.

[0041] As the sidewall 15 is moved more upright, the first ramp surface 34 passes the second ramp surface 36 and then moves downward. This allows a vertical surface 38 (connected to the second ramp surface 36) in the first upper edge portion 31 to engage a vertical surface 40 in the first lower edge portion 32 of the long side sidewall 15 as illustrated in FIG. 4. This configuration counteracts inward buckling forces which can arise from vertical compressive loads.

[0042] The first lower edge portion 32 and first upper edge portion 30 can be positioned proximate a corner of the base. Additional upper/lower edge portions with the described ramp surfaces can be formed along the sidewall 15. Moreover, the opposing long sidewall can include such features.

[0043] FIG. 7 shows an embodiment of the bulk bin having a bottom ramp 42 in the base 12 which interacts with a ramp surface in the in the bottom of the sidewall positioned along the side of the sidewall 15. The ramp 42 is positioned to contact the bottom of the sidewall 15 proximate one side of the sidewall 15 (another ramp can be positioned on the base portion 12 proximate the other side of the sidewall 15 to interact with a ramp on the bottom of the sidewall on that side). The ramp 42 includes a vertical surface 38 facing toward the exterior of the container 10. The ramp 42 is preferably molded into the base 12.

[0044] As discussed above, the ramp 42 is preferably located above the hinge rotation centerline of the sidewall 15. Additionally, it is positioned inward from the outer edge or exterior of the base 12 (i.e., toward the interior or center of the base 12). The ramp 42, and in particular the vertical surface 38, provides an additional benefit of reacting to buckling of the sidewall when subjected to compressive loads from stacking (of other bins or objects).

[0045] Again, as discussed above, the ramp 42 is designed to lift the sidewall 15 approximately 0.75 inches as the sidewall 15 is moved to its upright position. Once over the ramp 42 (i.e., nearly upright), the sidewall 12 is forced downward to engage the interlock structure in the wrap-around portions discussed above.

[0046] Many modifications and variations of the present invention are possible in light of the above teachings. It is, therefore, to be understood within the scope of the appended claims the invention may be protected otherwise than as specifically described.