VOLUMINOUS CONTAINER BOX WITH SIDE SUPPORT BEAMS
FIELD OF THE INVENTION The present invention relates to bulky containers and in particular, to bulky square or rectangular containers made of rigid packaging material having vertical side support beams to prevent warping of the container when loaded with flowable materials. BACKGROUND OF THE INVENTION Containers have been developed for shipping, storing and transporting flowable materials such as grains, chemicals, fertilizers and minerals of medium or intermediate volume. These containers are often designed in square or rectangular form and constructed of a rigid material, such as corrugated cardboard. The containers have a high density capacity of approximately 453 to 1.359 kg. or more of bulky material and due to its economical design, they are easily stacked to store and transport at high density. As a result of the inherent properties of the flowable or bulky material, the bulky material exerts a lateral force around the side wall panels of the bulky containers. The shape similar to a container box does not allow the uniform distribution of lateral forces. Therefore, the warping of the container may result. Warping is an undesired effect as it distorts containers causing loss of storage space when containers are stacked together. The extreme warping may cause the containers to rupture and the contents of the container to be scattered. This is especially undesirable when the contents are a composition of chemical products. To compensate for the lateral forces exerted by the flowable materials, the rigid bulky containers (that is the box) square or rectangular are made of durable material (eg reinforced corrugated cardboard) that is able to withstand lateral forces. Said durable material is more expensive than normal packaging material. In addition, the manufacture of rigid containers is more complex as a result of construction techniques designed to add resistance to containers to compensate for lateral forces. Each of U.S. Patent Nos. 3,543,991 and 3,715,072 discloses a bulky, rigid container of rectangular shape. Three individual cells of corrugated cardboard are formed and may contain both upper and lower closing flaps. The cells are placed in a side-by-side relationship and interconnected through the junction of the respective adjacent panels. The reinforcing side panels can be placed on top of the outer side panel of the first and third cells. A drawer down and a drawer can be placed around the respective upper and lower ends of the container. U.S. Patent No. 3,715,072 further describes the adhesion of reinforcing sheets between the side walls adjacent to the individual cells to increase the resistance to warping and to evenly distribute the tension along the side walls adjacent to the cells The rigid rectangular bulky intermediate containers of the type described in U.S. Patent Nos. 3,543,991 and 3,715,072 are more expensive as a result of manufacturing costs due to the composition of the containers that are needed by the square or rectangular design. rectangular (which does not evenly distribute the lateral forces exerted by the flowable material) and the overall complexity of the configured containers. In addition, these containers are still susceptible to warping, despite their construction. As an alternative, bulky hybrid containers have been developed that combine square or rectangular rigid containers and bulky flexible circular containers. Each of the United States Patent Titles Nos. 4,834,255; 4,901,885; 4,927,037;
,052,579; 5,071,025; 5,282,544; 5,289,937; and 5,407,090 describe a bulky container having an external rigid container of rectangular design and a flexible internal circular container. The internal circular flexible container has the function of diverting the lateral forces exerted by the flowable materials (which are contained mainly inside the flexible container) and release the warping pressure, which in a normal rigid container could have been exerted against the walls side of the container. Again, this configuration suffers from the disadvantages of increased and complex costs. It is therefore an object of the present invention to overcome the drawbacks associated with warping of bulky rectangular or square rigid containers under load. This object is achieved through the use of vertical side beams 5 placed around the side wall panels of the bulky container. SUMMARY OF THE INVENTION The object of the present invention is achieved by providing a bulky rectangular or square Q rigid container having vertically placed rigid lateral beams located around the panels of the side walls of the container. The side beams are connected in the upper and lower part of the container in such a way that the lateral beams support the lateral forces of the flowable materials that are contained and transfer these forces vertically to the upper and lower part of the container as well as horizontally. to the side wall panels. The rigid side beams can be shaped in a variety of ways and can be composed of various materials. However, the shape and composition of the rigid side beams must work to transfer the force longitudinally with a relatively small deviation. A preferred form for rigid side beams is that of a profile of a triangular or V shape according to the material which makes the strength ratio in this way economically feasible. An angle of 45 degrees at the apex is preferred, with the vertex preferably pointing towards the center of the container. A product known commercially available as "angled board" or "edge board" could be suitable for building the side beams. This profile has a V shape and is made of paper or plastic fiber. The side beams can be clamped in place by a variety of clamping mechanisms. The use of an adhesive to fix the side beams to the panels of the side wall of the container can be used. Additionally, the side wall panels may contain liners or pockets that receive the side beams and hold them in position around the sidewall panel. It is also possible to laminate the side beams of the side wall panels. Perhaps more feasible is a modality in which the side beams are folded into the same panels of the side wall or are folded into an internal covering that fits inside the container. The spacing and the number of lateral beams depends on the characteristics of the flowable material that is to be contained. Ideally, the spacing and the number of side beams will result in the bending or the lateral force being equally divided. This is often accomplished by using eight pairs of side beams in sets of two that separate at or near the center of each sidewall panel. The side beams act to transfer the lateral bending forces away from the panels of the side walls and to the top of the container. This is accomplished by connecting the top ends of the side beams to or near the top panel of the container. BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is an isometric view of a first embodiment of the bulky container box showing the side beams placed on the inner surface of the side wall panels.
Figure 2 is a schematic view of the first embodiment of the bulky container box showing the placement of a plastic inner liner in the container chamber. Figure 3 is a schematic top view of a second embodiment of the bulky container box showing the placement within the container chamber of a rigid inner liner containing bends that form the side beams. Figure 4 is an isometric view of a third embodiment of the bulky container box showing the side beams placed around the outer surface of the sidewall panels through the liners. Figure 5 is an isometric view of the third embodiment of the bulky container box showing the side beams placed around the outer surface of the sidewall panels through the pockets. Figure 6 is an isometric view of the third embodiment of the bulky container box showing the side beams placed around the outer surface of the sidewall panels through a lamination sheet.
Figure 7 is an isometric view of a fifth embodiment of the bulky container box showing the interconnection of the upper and lower ends of the side beams through the clamps. Figure 8 is an isometric section view of the fifth embodiment of the bulky container showing the interconnection of the upper and lower ends of the side beams through the upper and lower covers. DETD DESCRIPTION OF THE PREFERRED MODALITIES With reference to the figures in which like elements have been provided according to the numerical designation to facilitate an understanding of the present invention, and particularly with reference to the embodiment of the bulky container of the present invention illustrated in Figure 1, the bulky container can be constructed as a box made of a material for substantially rigid packing. The box 10 can have a top panel 11 and a bottom panel 12 interconnected by four side wall panels 13 defining a chamber 14 for bulky flowable materials. Preferably, at least one side beam 15 extends in a substantially vertical direction around each of the four panels of the side walls 13 in a separate relationship. Various materials for rigid packaging can be used to construct the box 10. For example, the box 10 can be made of corrugated cardboard, plastic or metal. Preferably, the box 10 is made of corrugated cardboard. As seen in Figure 2 the box 10 can also be formed of several layers. For example, the box 10 may be composed of a layer 23 of relatively rigid permeable material, such as cardboard, and a relatively impermeable layer of material 24. The relatively impermeable material can be an internal or external coating. Preferably, the layer 24 of relatively rigid impervious material is a synthetic film material. Examples of synthetic film materials include polyethylene, polypropylene, polyvinyl chloride, polyurethane, nylon and polyester. The layer 24 of the relatively impermeable material can also be in the form of a separate plastic inner liner 25 which is placed inside the chamber 14 of the box 10. The construction of the box 10 can be achieved using standard techniques known to skilled artisans. Various methods can be used to join the ends of the four panels 13 of the side walls as well as the upper and lower interconnected panels 11, 12 to the side wall panels 13. The construction techniques employed to construct the box 10 can depend on the type of rigid packaging material used to form the box 10. For example, in a mode wherein the box 10 is made of metal, welding can be used to join the panels of the side walls 13 and the top and bottom panels 11, 12. Furthermore, the box 10 can be preformed and require only the folding of the various panels to form the box 10. This type of construction has application in the situation where the box 10 is made of cardboard or plastic. With reference to Figure 1, if two lateral beams 15 are preferred they extend substantially vertically around each of the panels of the side walls 13. Figure 1 shows the side beams 15 placed around the internal surface 17 of the panels of the side walls 13, However, it should be understood that the side beams 15 can also be placed around the external surfaces 31 of the panels of the side walls 13. In addition, more than one side beam 15 can be placed around each side wall panel 13. For example, each panel of side wall 13 can have from two to five side beams 15 placed therewith. The number of side walls 15 placed on each side wall 13 depends on the load factors that will be further described herein. Furthermore, it is not necessary that each side wall panel 13 contain the same number of side beams 15.
Figure 1 also exhibits side beams 15 extending substantially vertically around the outer surface 17 of the panels of the side walls 13. Preferably, the side beams 15 can be positioned at an angle in the scale of 10 to 90 degrees in relation to the lower panel 12. More preferably, the side beams 15 can be positioned at an angle in the scale of 45 to 90 degrees relative to the lower panel 12. And even more preferably, the side beams 15 can be placed in a angle of approximately 90 degrees in
0 relationship with the lower panel 12. Preferably, the side beams 15 extend substantially over the entire height of each of the panels of the side walls 13. To effect the distribution of the lateral bending forces, it is preferred that the side beams 15 are formed of a substantially rigid material. The rigid material forming the side beams 15 can be any material that has rigidity so as to achieve the distribution of lateral bending forces. Preferably, said rigid material is cardboard, wood, plastic Q or metal. The side beams 15 can also be designed in a variety of ways. For example, the side beams 15 can be tubular. In addition, the side beams 15 can be triangular or V-shaped in cross section.
The side beams 15 should be placed around the panels of the side wall 13 in order to effect a deviation equal to the lateral bending force. In the bulky square or rectangular container of the present invention, the deviation equal to that of the lateral warping force could occur around the center of each panel of the side wall 13. Hence it is preferred that the position of the side links 15 at or near the center of each side wall panel 13 as shown in Figure 1, especially if only one side beam 15 is placed per panel of the side wall 13. In one embodiment of the present invention wherein two or more side beams 15 are placed by side wall panel 13, it is preferred that side beams 15 be placed outside the center of each side wall panel 13. Side beams 15 can be placed around the side wall panels 13 in different ways. As illustrated in Figure 3, the side beams 15 can be integrated with or form part of a rigid internal sheath 16. The inner sheath 16 can be positioned within the chamber 14, seated adjacent to the inner surface 17 of the panels. the side walls 13. Preferably, the inner liner 16 is a layer of corrugated cardboard and the side beams 15 are formed as bends 18 within the inner liner 16. The inner liner 16 may be a part of a non-removable component of the panels. the side walls 13 in which case it is formed as part of the panels of the side walls 13 or as a unit that is permanently clamped (eg by adhesive or staple) to the inner surface 17 of the side wall panels 13. However, it is preferred that the inner liner 16 be a removable unit that separates from the panels of the side walls 13 and be removable from the chamber 14 or of the box 10. In another embodiment of the bulky container box the side beams 15 can be formed as an integrated part of the panels of the side walls 13. The side beams 15 can be formed in this embodiment by the panels of the sidewalls are bent or pressed or molded 13 in the desired configuration to create the side beams 15. The side beams 15 can be held in position around the side wall panels 13 by various retaining means 22. For example, the beams sides 15 can be attached directly to the panels of the side walls 13 or the side beams 15 can be directly attached to the top panel 11 and the bottom panel 12. The type of retaining elements 22 provided can be separated by the type of material that form the box 10. In the embodiment of the present invention wherein the side beams 15 are fixedly attached to the sidewall panels., the retention elements can be adhesive. In an alternative embodiment of the invention, wherein the box 10 is made of metal the retaining means can be welded. Alternatively, the retaining means 22 can operate to receive and maintain the side beams 15 in a substantially vertical position around the side wall panels 13. Preferably in this embodiment, the retaining means 22 is configured as liners 26. With reference to Figure 4 the liners 26 can be secured to the sidewall panels 13. In one embodiment of the present invention, the liners 26 are placed at the upper end 27 and at the lower end 28 of each of the panels of the side walls 13, whereby the ends of the side beams 15 are fixedly attached to the panels of the side walls 13. The liners 26 can be extended continuously around the panels of the side walls 13 at the upper end 27 and at the lower end 28. However, the liners 26 may also extend non-continuously around the panels of the side walls 13 at the upper end 27 and at the lower end 28. Preferably, the liners 26 are in the form of multiple pockets 29 wherein a series of two pockets 29, one placed at the lower end 28 and the other positioned At the upper end 27, they individually receive and maintain the side beams 15 in a substantially vertical position around the panels of the side walls 13, as shown in Figure 5. The liner 26 can be secured to the wall panels side 13 by conventional means depending on the material forming the liner 26. For example, the liner 26 can be made of a non-elastic, flexible material, preferably, a synthetic material, a polypropylene material, or a polyethylene material. The liner 26 made of a flexible, non-elastic material can be
* secured to the panels of the side walls 13 by conventional fastening means, such as, for example, mechanical fastening. For purposes of illustration, mechanical fastening may be by stapling. In yet another preferred embodiment shown in
Figure 6, the liner 26 may be in the sheet form 30. Preferably, the sheet 30 forms a laminate that substantially covers the panels of the side wall 13 and the beams 15 as they are placed around the panels of the side walls 13. The sheet 30 can be attached to the side wall panel 13 by various conventional means such as adhesive and staples. In addition, the sheet 30 can extend continuously around the panels of the side walls 13 to form the sheet or sheet 30 that can extend continuously around the panels of the side walls 13 to form the laminate. In the last configuration, the sheet 30 may be composed of separate sheets that cover part of the panels of the side walls 13. Figure 7 illustrates another embodiment of the present invention. In another embodiment, the upper force distribution means 19 interconnect the upper ends 20 of the side beams 15. Lower force distribution means 31 are also provided which can interconnect the lower ends 32 of the side beams 15. The means of distribution of upper and lower force 19, 31 function to evenly distribute the lateral forces through the box 10 specifically to all the side beams 15. Preferably, the upper force distribution means 19 connect the adjacent upper ends 20 of the side beams 15. each other, and the upper force distribution means 31 are connected together adjacent to the lower ends 32 of the side beams 15. The upper and lower force distribution means 19, 31, can be any device that provides the interconnection of the side beams 15 and work to distribute the lateral forces as mentioned before. Examples may include wires and other rigid preformed materials. Preferably, the upper and lower force distribution means 19, 31 are in the form of staples 21 made of a non-elastic material. In the embodiment only the retaining means 22 is described which can also place or join side beams 15 to the panels of the side walls 13. The upper and lower force distribution means 19, 31, can also be in the form of caps upper and lower 33 of the container as shown in Figure 8. The upper and lower covers 33 could rest against the respective upper and lower ends 20, 32 of the side beams 15 and hold the side beams 15 in place around the panels of the side wall 13. The side beams 15 can be joined or disengaged from the side panels 13. Preferably, the upper and lower covers 33, form the upper and lower panels 11, 12, respectively. The upper and lower force distribution means 19, 31 (e.g., staples 21) cause the side beams 15 to be relatively restricted from movement when the chamber 14 is filled with fluid materials. As a result, an extensive force in any direction around one of the side beams 15 could be opposed by an opposing force caused by the same forces around one or more of the other side beams 15. Therefore, it results in a distribution of equal stabilized forces. In other words, any external force connection exerted around a lateral beam 15 by a force exerted by the force of lateral force bending around the side wall panel 13 is transmitted to the inner upper ends 20, 32 of the side beams 15 and then it is transmitted through the upper and lower force distribution means 19, 31 to other side beams 15. Therefore, the side beams 15 resist and remain in place, the box 10 has a fixed dimensional stability. Preferably, eight side beams are used in this embodiment, and the upper and lower force distribution means 19, 31 could look like an octagon that would connect eight separate geometric side beams 15 at the upper and lower end of the box 10 resulting in a stable condition of resistance against all directional resistance. The bulky container of the present invention can be constructed by providing a rigid top panel 11 and a rigid bottom panel 12. Four panels of the rigid side walls 13 are then connected to the top panel 11 and the bottom panel 12 to create a chamber 14 for materials flowable At least one rigid side beam 15 is placed around each of the panels of the side walls 13, in a substantially vertical position whereby the side beams 15 provide lateral support to the box 10 to prevent bending thereof when the chamber 14 contains flowable materials. The retaining means 22 can be used to achieve the placement of the side beams 15 around the side wall panel 13. Preferably, two side beams 15 are placed substantially vertically around each of the side wall panels. The present invention has utility for a variety of rigid containers. It is anticipated that an application of the present invention will be with rigid intermediate bulky containers. These containers normally contain between 453 and 1,359 kg. of material and are made of cardboard. Preferably, the box 10 can contain about 906 kg of bulky material which equals 0.76 to 2.58 cubic meters. Although the preferred embodiments of the present invention have been described, it will be understood that the embodiments described are illustrative only and that the scope of the invention will be defined only by the appended claims when read carefully according to a full scale of equivalences; Many variations and modifications will naturally occur to those skilled in the art.