US20110017731A1

US20110017731A1 - Recyclable container

Info

Publication number: US20110017731A1
Application number: US12/616,401
Authority: US
Inventors: Philip Taravella; Edward Blair; Roger Kevin Burchett
Original assignee: Anchor Bay Packaging Corp
Current assignee: Anchor Bay Packaging Corp
Priority date: 2009-07-22
Filing date: 2009-11-11
Publication date: 2011-01-27

Abstract

A container is provided comprising a polygonal shaped external wall with integral floor tabs folded upon one another to form a floor of the container. Concentrically disposed within, and immediately adjacent an interior wall of the polygonal shaped external wall is a complementary shaped internal wall. Disposed within the confines of the internal wall and resting upon the floor of the container is a tray assembly for retaining a package containing the contents to be transported within the container. Provision may be made through a portion of the tray and the complementary walls for emptying of the package within the container. Reinforcement of the walls of the container is obtained by a one or more reinforcement provisions made along the upper edges of the container walls and the container may be closed and covered by a removable cap assembly. Once the container is used, the materials forming the container may easily be recycled or reduced in size for disposal.

Description

CROSS REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. provisional patent application Ser. No. 61/227,503 filed Jul. 22, 2009 pursuant to 35 U.S.C. § 119, the contents of which are incorporated herein by reference in its entirety to provide continuity of disclosure.

BACKGROUND OF THE INVENTION

1. Field of the Invention
This invention relates generally to containers, and more specifically to container made from a recyclable material used to transport bulk amorphous materials such as liquids and/or powders that exert substantial lateral forces on containers sidewalls while in transit.
2. Description of the Related Art
Historically bulk products such as liquids, powders, and other amorphous materials have been transported in large metal containers or drums. The metal containers or drums traditionally provided the greatest strength to withstand the lateral forces exerted by the flow of the contents when in transit. Metal containers have in large part been replaced part by containers and drums made from rigid polymeric resins. Flexible bladders have also been used to hold the contents, but were unsuitable for shipment alone because of their inability to remain rigid. More rigid external shells had to be used to constrain the bladders. The more rigid containers such as metal or plastic gaylords present a problem in terms of cost since most are shipped back empty to the source or origin. With the overall trend to greener technologies and recycling, metal and plastic containers present an environmental and cost issue.
The instant invention greatly reduces the cost associated with shipping containers. The instant invention is also easily recyclable, thus reducing the need to return empty containers to a point of origin. A better understanding of the invention and the different embodiments may be obtained from a reading of the following detailed description taken in combination with the attached drawing figures.

SUMMARY OF THE INVENTION

An object of the invention is to overcome the disadvantages of the prior containers by providing a recyclable container of sufficient dimension to handle products in bulk quantities and with sufficient strength and attributes to constrain the contents while providing an easy and inexpensive manner for dispensing the contents. The containers can be shipped one way and recycled at the destination, thus reducing the cost for return shipping. This invention also provides the added benefit of reusing the containers without contamination by simply replacing the protective container lining.
According to one form of the invention, the invention comprises a floor assembly, a multi-faceted rigid exterior sidewall integrally connected to and extending upwardly from the floor assembly defining an upper edge. A tray assembly is disposed within the multi-faceted rigid exterior sidewall and rest upon the floor assembly. A disposable protective bladder is disposed upon the tray assembly to contain the contents to be transported. The protective bladder includes an outlet valve assembly that extends through a hole formed in the multi-faceted rigid exterior sidewall. A cap assembly closes the top of the container enabling stacking of the containers.
According to another form of the invention, the container comprises at least one channel member disposed over the upper edge of the multi-faceted exterior sidewall for reinforcing the sidewall. The channel member may include a first and a second leg, where the first leg may be substantially longer than the second leg to provide stability to the sidewall. If desired the first leg immediately adjacent the sidewall may be adhered to an interior surface of multi-faceted rigid exterior sidewall. A plurality of tabs may extend from the upper edge of the multi-faceted rigid exterior sidewall for folding inwardly into the container to provide reinforcement for the rigid exterior sidewall. The tray may include a plurality of sidewalls configured to lie adjacent an interior of the multi-faceted rigid sidewall. At least one of the sidewalls of the tray preferably includes a port for receiving there through the outlet valve assembly of the bladder. The multi-faceted rigid exterior sidewall may be comprised of a plurality of laminated sheets of corrugated paper. A first plurality of the laminated sheets of corrugated paper may have at least one edge overlapping and compressed against an edge of a second plurality of the laminated sheets of corrugated paper to form a stepped joint. The floor assembly may be comprised of a plurality of folding tabs, each integral with and extending from a lower edge of an opposing facet of the multi-faceted rigid sidewall, each of the folding tabs including a plurality of end tabs configured to interweave with and interlock with a corresponding plurality of end tabs on an opposing folding tab.
In yet another form of the invention, a recyclable container is provided for transporting bulk materials. The recyclable container comprises a primary panel assembly having an upper edge, a lower edge, and opposing ends, the opposing ends interconnected together along a staggered joint to form a plurality of interconnected sidewall panels. Extending from the lower edge of the primary panel and integrally connecting opposing ones of the plurality of sidewall panels are a plurality of tabs. The tabs are foldable toward one another and interlock with an opposing one of the tabs to form a floor assembly for the container. Portions of two opposing tabs extend beyond a perimeter of the sidewall panels to provide a platform for the container. A tray assembly is disposed within the recyclable container upon the floor assembly and includes a plurality of sidewalls for nesting against the interior of the recyclable container. One of the sidewalls of the tray assembly includes a port that is aligned with a port formed in one of the sidewall panels of the container. A protective bladder is disposed upon the tray assembly and includes a nozzle that extends through the ports formed in the tray assembly and the sidewall panel to allow removal of the contents of the bladder. At least one channel reinforces the upper edge of the primary panel. The channel may include one leg that extending along and lies immediately adjacent the sidewall panels to provide additional strength. A cap assembly closes the container by resting upon the upper edge of the sidewalls.
In another form of the invention, the container includes a rigid carrier upon which the container floor assembly rests. The primary panel assembly may be comprised of a plurality of layers of corrugated paper, overlapping at staggered intervals with an opposite end of the primary panel assembly to disperse the forces acting upon the seam. The many tabs extending from the lower edge of the primary panel may further include a plurality of end tabs configured to interleave with a corresponding end tab on the opposing tab for holding the floor assembly in place. Portions of the many tabs extend beyond the perimeter of the sidewall to provide a more rigid base for the container.
In yet another form of the invention, the channels used to reinforce the upper edge of the sidewall may be substituted by a plurality of tabs integral with and extending from the upper edge of the primary panel and foldable to lie substantially adjacent the primary panel.
In still another form of the invention, the shape of the container may be polygonal ranging from an octagon to substantially a cylinder. The preferred shape evenly distributes the outwardly acting forces of the contents about the exterior sidewall.
In yet another form of the invention, a recyclable bulk container is provided comprising a sidewall, a floor assembly integrally connected to a lower edge of the sidewall, the floor assembly including tabs extending outwardly beyond a perimeter of the sidewall for supporting the container; a tray assembly disposed within the sidewall and upon the floor assembly; and a cap assembly closing an upper end of the sidewall. A bladder may be disposed within the sidewall of the container and upon the tray assembly. A spout, port, nozzle or other means may be attached to the bladder and extend through the container sidewall for emptying the contents from the container upon reaching its destination.
The advantages provided by the invention include a lightweight disposable “green” container that is recyclable once it has reached its destination or end of life. The materials used to manufacture the container can be reused to produce other products at a minimal cost. The disposable and recyclable nature of the container makes it less expensive to manufacture and reduces shipping costs or returning of containers for later use. These and other advantages of the invention will become readily apparent from a reading of the detailed description and reference to the associated drawing figures.

BRIEF DESCRIPTION OF THE DRAWING FIGURES

FIG. 1 is an isometric view of a bulk liquid-pack embodying one form of the invention;

FIG. 2 is an isometric exploded view of the invention shown in FIG. 1;

FIG. 3 is a isometric elevation cross-section view of the invention shown in FIG. 1 taken along line III-III;

FIG. 4 is a plan view of a sheet of material used to form the bottom and sides of the invention shown in FIGS. 1 and 2;

FIG. 5 is an isometric view of the sheet shown in FIG. 4 partially assembled;

FIG. 6 is a plan view of a reinforcing wall shown in FIG. 2;

FIG. 7 is a plan view of a tray shown in FIG. 2 prior to assembly;

FIG. 8 is an isometric view of the tray and bladder shown in FIG. 2;

FIG. 9 is a plan view of a blank used to form the cap shown in FIGS. 1 and 2;

FIG. 10 is an isometric view of a partially assembled cap blank;

FIG. 11 is an isometric view of another embodiment of a wall support;

FIG. 12 is a plan view of another embodiment of a sheet of material to be used in forming the bottom and sidewalls prior to assembly; and

FIG. 13 is an isometric exploded view of an alternate embodiment of the invention.

DESCRIPTION OF THE DIFFERENT EMBODIMENTS

For purposes of the following description, the terms “upper,” “lower,” “left,” “rear,” “front,” “vertical,” “horizontal” and derivatives of such terms shall relate to the invention as oriented in FIG. 5. However, it is to be understood that the invention may assume various alternative orientations and configuration, except where expressly specified to the contrary. It is also to be understood that the devices and processes illustrated in the attached drawings, and described in the following specification are simply exemplary embodiments of the inventive concepts defined in the inventive concepts of this invention. Specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting unless expressly stated otherwise.
FIGS. 1 through 3 illustrate a first embodiment of a container assembly 20 that may be used to contain product such as liquids, powders or the like. Although the invention is shown in a size supported by a rigid carrier such as a pallet 22, the invention may be of substantially any size. Generally the container assembly 20 includes a multi-faceted exterior sidewall 24 integrally connected to a floor assembly 26. An interior sidewall assembly 28 is disposed concentrically within the exterior sidewall 24 and is adapted to receive a tray assembly 30 therein and resting upon the floor assembly 26. The tray assembly 30 receives a bladder or liner 32 therein for containing the contents to be transported. Closing the container is a removable cap assembly 34. To aid in the removal of the contents from the bladder/liner 32, provision is made through the sidewalls 24, and a portion of the tray 30 for the passage of an outlet, valve, or spout 36 through port 38.
In the embodiment shown in FIGS. 1-3, the exterior and interior wall assembly may be interconnected and reinforced by two or more reinforcing members 39 received over the upper edges of the exterior and interior sidewalls 24, 28. In the embodiment shown, it is preferred that the container assembly 20 be manufactured from recyclable materials such as craft paper, laminated paper, corrugated paper products, wood, fiberboard, and mixtures thereof. It is further contemplated that the container 20 may also be formed from other recyclable materials such as polymers in the form of sheets, laminated sheets, corrugated sheets and the like. It is also anticipated that paper and polymeric material may be combined to create the structure represented by container 20. Regardless of the materials used, the intent is to produce a lightweight yet rigid structure capable of containing liquids and powders within the footprint of the bottom of the container 20.
FIGS. 4 and 5 more clearly illustrate the form of construction of the exterior sidewall 24 and integral floor assembly 26 shown in FIGS. 1-3. Exterior sidewall 24, in a preferred form of the invention, is formed from one or more sheets, preferably corrugated paper. From a sheet of corrugated paper, a blank 40 may be cut, preferably with the aid of a die, to produce the form 40 shown in FIG. 4. The blank 40 includes a primary panel 42 having a dimension sufficient to form the complete exterior of the container 20 and wrap back upon itself to close the sidewall 24. Multiple plies or laminations of corrugated paper may build up the primary panel 42. The primary panel 42 includes an upper edge 44, opposing ends 46, 48, and a lower margin or edge 50. The opposing ends 46, 48 of each layer, ply or lamination of corrugated paper may be staggered to provide a step-like feature at each end for reasons that will become more apparent below. Thus, when the ends are fastened together the joint is not concentrated in one particular point, but displaced over an annual arc.
Depending from lower edge 50 yet integrally connected to primary panel 42 are a plurality of flaps 52, 54, 56, and 58, each configured to fold along a hinge line, fold line, or crease 60 coincident with the lower margin or edge 50 to form the integral floor assembly 26 when folded together. Primary panel 42 may contain a plurality of creases, hinge lines, or fold lines formed therein by compression of the corrugated material to aid in the forming of the different sidewall elements. In a preferred embodiment of the invention, vertical creases, or hinges 62, 64, 66, 68, 70, 72, 74, 76, and 78 may be formed in the primary panel substantially perpendicular to upper edge 44 and lower margin 50 where it is desired to form the sidewall facets or panels 82, 84, 86, 88, 90, 92, 94, and 96. Sidewall panel facets 88 and 96 are intended to have the same width as do bottom panels 54 and 58. Bottom panels 52 and 54 are separated from panel 42 along cuts 98, 100, 102, and 104 which extend inwardly from the edges of the bottom panels 52 and 54 up to crease lines 64, 66, 72 and 74, respectively. When multiple plies, layers, or laminations of corrugated paper are used, it is preferred that the many flaps align even though the plies at the ends are staggered.
When exterior sidewall blank 40 is folded along fold lines 62, 64, 66, 68, 70, 72, 74, 76, and 78, and when bottom panels 52, 54, 56 and 58 are folded inwardly toward the interior of the container 20 along hinge line 60, an multi-panel sidewall is formed to create the interior confines of the container 20 and the floor assembly 26. Portions of the bottom panels 52 and 56 extend beyond the octagonal shape created by the panels 82, 84, 86, 88, 90, 92, 94 and 96 as a result of cuts 98, 100, 102 and 104 as shown in FIG. 5. As a result all of the sidewalls of the container rest upon and are supported atop other laminated sheets. None of the sheared ends of the panel come into direct contact with ground or other surface when folded and in the upright position. The disposition of the floor assembly beneath all of the edges of the multi-faceted sidewall provides a buffer to any abrasive forces and extends the life of the container. Moreover, the portions extending beyond the perimeter of the container sidewalls also provide a means for anchoring the container to a more rigid substrate such as the pallet described above.
In a preferred embodiment of the invention, each of the bottom panels 52, 54, 56 and 58 include a set of tabs intended to cooperate and interlock with corresponding tabs in an opposing panel when the bottom is folded into position. Referring again to FIGS. 4 and 5, the reader will appreciate the formation of three tabs along each panel formed by die cuts and crease lines formed in the material. More specifically, panels 52 and 56 each contain three interlocking tabs generally designated by reference numerals 106, 108 and 110 formed by generally V-shaped cuts 112, 114, and angles crease lines 116 and 118. In a like manner, each of panels 54 and 58 each contain three interlocking tabs 120, 122 and 124 defined by generally V-shaped die cuts 126, 128. It is intended that each of the tabs formed at the ends of the bottom panels overlap in alternating sequence and interlock with a corresponding tab extending from an opposing panel when folded into position to help keep the panels 52, 54, 56 and 58 folded into position to form the bottom of the container 20. Portions of tabs 52 and 56, when folded into position, extend beyond the shorter width octagonal panels 82, 86, 90 and 94 and lie substantially flat. Those portions of the tabs 52 and 56 may be used to help anchor the container 20 to any transport bed such as the pallet 22, either with the aid of staples, pins, or the like.
FIG. 6 generally illustrates in plan view an interior sidewall blank 130 prior to assembly. Interior sidewall blank 130 may be corrugated paper in a length sufficient to wrap upon itself to form the interior sidewall 28 within the confines of the exterior sidewall 24. Sidewall blank 130 includes an upper edge 132, a lower edge 134, and opposing ends 136, 138. Multiple panels facets 140 142, 144, 146, 148, 150, 152 and 154 are defined when the blank 130 is folded along crease lines 156, 158, 160, 162, 164, 166, 168 and 170. The dimensions between the different crease or hinge lines are such that the interior sidewall 28 slides concentrically within the interior of exterior sidewall 24 and immediately adjacent thereto to provide a double wall thickness of material for the sidewalls of the container 20. Just as with the primary panel 42, sidewall blank 130 may also be formed from multiple plies, sheets, layers or laminations of corrugated paper with fastened ends of the many plies staggered or stepped to displace any forces over a greater annular segment rather than at one point. In a preferred embodiment, the joints of the exterior sidewall 24 and the inner sidewall 28 are also staggered and preferably located in different panel segments to provide greater strength.
A better understanding of the form and construction of the tray assembly 30 shown in FIGS. 1-3 is obtained by referring to FIGS. 7 and 8. A tray blank 170 is used to form tray 30 shown in FIG. 8. Generally tray blank 172 is cut from one or more sheets of corrugated paper or other desired material to create a central, generally octagonal panel 174 having exterior dimensions that parrot the internal dimensions created by the interior of sidewall assembly 28 when concentrically disposed within exterior sidewall 24. Such shape is generally represented by die cut edges 176, 178, 180 and 182 and hinge lines 184, 186, 188 and .190. Integrally formed tabs 192, 194, 196 and 198 are disposed outboard of hinge lines 184, 186, 188 and 190. Tabs 192, 194, 196 and 198 are intended to be folded upwardly at approximately a right angle about hinge lines 184, 186, 188 and 190 to form the sides of the tray 30. Tab 196 may be reinforced by an integrally attached tab 200 generally having a mirror image profile to that of tab 196 that may be folded down adjacent tab 196 about hinge line 202. Additional strength may be provided to central panel 174 with the aid of a crimp 204 defined by hinges 206 and 208. As briefly mentioned above, a port or opening may be provided in the container to allow the contents of the container to be emptied through a spout, valve or the like extending through the walls of the container. Illustrated in FIG. 8, an opening 209 is formed is formed in a portion of tab 196 and central panel 174. Retention of the spout, outlet or valve by tab 196 is aided by the tab 200 folded back over onto tab 196 such that a notch 211 engages the nozzle of the bladder described below.
In a preferred embodiment of the invention, the thickness of the corrugated paper panel used to make tray 30 may be thicker than the material used to make the other components. Alternatively, tray 30 may be formed from a paper/polymer laminated composite material to obtain the desired strength. A polymer external coating may be applied to an upper surface of the tray to prevent absorption of liquids such as may leak from the bladder, form as a result of condensation, or be deposited as a result of weather.
The intent of this invention is to provide a recyclable container for carrying bulk items such as liquids, powders, granular material or the like. Although the container is suitable for carrying substantially any type of goods or materials including parts and the like, a preferred embodiment of the invention is to transport fluid materials or materials that behave as a fluid such as liquids, powders or granular materials including palletized plastic or grain. For liquid materials or fine powder or granular material it may be desired to use a liner or bladder such as generally referenced by numeral 32 to hold the contents without leaking through the container floor. One option of the invention is that the contents may be contained simply within a liner or bag disposed within and constrained by the sidewalls. The bag or liner may substantially fill the interior of the container 20 and hold the contents, to be emptied either by a vacuum or other conveyance from the top opening of the container. However, in a preferred embodiment of the invention, the container would be used to transport bulk liquids or powders contained within the bladder 32. A spout, valve, or closeable opening 36 is provided toward the bottom of the bladder such that it can extend through the port 38 formed through the sidewalls, and by opening 209 formed in the tray tab 196. The volume to be held by the bladder 32 may be substantial as provision has been made for the sidewalls to withstand substantially outward radial forces. The size of the bladder 32 may be such as to fill the entire cavity within the sidewalls. Substantially any suitable impermeable material may be used for bladder 32 including commonly recyclable polymers.
Cap assembly 34 is preferably cut from a single sheet of corrugated paper material commonly known in the art, although it is anticipated that polymer coated corrugated paper may also be used as the cap assembly may have greater exposure to the elements that other components of the assembly. Polymeric layers or exterior coats, or wax impregnation of the material should inhibit absorption of moisture or other liquids. As best illustrated in FIGS. 9 and 10, the blank 210 for cap assembly 34 may be generally rectangular in plan form defined by external edges 212, 214, 216 and 218. Tabs 220, 222, 224 and 226 may be formed at the corners of the blank 210 by wedge shaped, cuts at each corner identified by reference numerals 228 and 230. The inner extent of each angular cut 228, 230 terminates at a substantially continuous inner hinge line generally identified by reference numeral 232 sequentially intersecting subsequent cuts 228, 230. The inner hinge line 232, in cooperation with the angular cuts 228, 230 define an opposing end tabs 234, 236, and opposing edge tabs 238, 240. The end tabs 234, 236 and edge tabs 238, 240 are intended to fold inwardly ninety degrees so as to be generally perpendicular to central panel 242. The end portions of each tab 234, 236, 238 and 240 are intended to fold vertically about hinge lines generally identified by reference numeral 244 which extends from the innermost end of cuts 228, 230 out to the peripheral edges of the cap so they are oriented at a right angle. Tabs 220, 222, 224 and 226 each include an intermediate hinge line 246 such that each tab 220, 222, 224 and 226 can fold vertically about hinge line 232 and once again about hinge line 246 such that the end of the tab wraps around the ends of the end and edge tabs, and is received in slot 248 piercing central panel 242 to lock in place.
Briefly mentioned above, it may be desired to reinforce the upper edges 44 and 132 of the exterior and interior sidewalls 24, 28 with reinforcement members 39 to protect them against crushing impacts and the radial forces exerted by the contents of the container. The reinforcement of the sidewalls 24 and 26 at the upper edges 44 and 132 also serve to strengthen the intermediate portions of the sidewalls furthest from the crease or hinge lines from the forces exerted from the interior of the container 20 by the contents. According to one aspect of the invention, suitable reinforcement may be obtained by a U-shaped corrugated channel 250 such as shown in FIG. 11. The U-shaped channel 250 may be formed from laminated paper, a combination of laminated paper and corrugated paper, as well as a wide range of polymeric materials well known in the industry. It is contemplated that channels, each having a dimension equal to or approximating the width of the larger panels and fixed in position over the upper edges by an adhesive. It is further contemplated, but not shown that the downward extension of the legs 252, 254 of the U-shaped channel may be different in length so as to extend downwardly over the reaches of the panels for added strength. That is to say than one leg 252 of the U-shaped channel depending from central web 256 may be different from that of the opposing leg 254 and extend along one of the outer or interior sidewalls to bolster the structure.
An alternate embodiment of an exterior sidewall blank 260 of the invention is shown in FIG. 12. FIG. 13 illustrates an exploded view of the container folded using the exterior sidewall blank shown in FIG. 12. For the purposes of brevity and clarity, only those portions of the blank 260 that are different from that described above will be described. As evident from the figure, blank 260 includes a plurality of tabs 262, 264, 266 and 268 integrally connected to and extending from the upper edge 270 of the blank 260. Each tab includes a double hinge line 272 generally coincident with the upper edge 270 of the blank to enable tabs 262, 264, 266 and 268 to fold inwardly about the respective hinge lines and over the upper edge of the inner sidewall described in the prior embodiment of the invention. The tabs 262, 264, 266 and 268 are intended to replace the need for the reinforcement U-shaped channels described above in order to provide the structural rigidity to the sidewalls as well as reduce crush impact to the upper edge of the container. This view simply illustrates one difference between the blank used in the formation of the exterior sidewall. It is also envisioned that in the event of the tabs 262, 264, 266 and 268 described above, further benefit may be obtained by overlapping and further strengthening the upper edges by an additional U-shaped channel overlying the tabs 262, 264, 266 and 268.
In operation the various blanks are cut from the desired material. The exterior sidewall assembly 24 is preferably folded about the vertical hinge lines to produce a substantially octagonal cylinder. Portions of panel 84 overlaps with a portion of panel 96 where a suitable adhesive is used to holds the panels together. As mentioned above, portion 84 may have a plurality of stepped or staggered lamination of corrugations that overlaps with the corresponding end to produce a joint where the forces are distributed over an angular arc. Tabs 52, 54, 56 and 58 may be folded inwardly to close the bottom of the exterior sidewall tube. End tabs 106, 108 and 110 may be engaged by one or more tabs 120, 122 and 124 extending from flaps 54 and 58 to aid in holding the bottom of the container closed. Once the exterior sidewall 24 and floor assembly 26 are formed, interior sidewall blank 130 is folded along the identified hinge lines such that end 136 of panel 132 overlaps with and is adhered to panel 154 and forms the octagonal interior sidewall insert 28. It is further contemplated that the exterior of sidewall 28 may be sprayed or have otherwise applied a suitable adhesive such that when interior sidewall 28 is concentrically located within exterior sidewall 24 the adhesive bonds and forms a very rigid octagonal box.
Depending upon the embodiment of the invention selected, the upper edge 44 and 50 of the sidewalls 24 and 28 may be reinforced, either by the application of the U-shaped channels or by the folding over of the tabs 262, 264, 266 and 268 described and shown in FIG. 12. Furthermore, both options may be used depending upon the desire of the builder to help strengthen the upper sidewalls. Either method is an acceptable embodiment of the invention.
With the body of the container substantially complete tray blank 172 is folded and bladder or liner 32 may be disposed thereon such that the spout, valve or outlet 36 is received by the port 209. The tray 30 and bladder 32 are then placed within the container 20 against the floor 26 and the spout or valve 36 is worked through the ports 38 formed in the sidewall. The bladder is then suitable arranged on the tray 30 so that it may be easily accessed from the top opening of the container for filling at a later stage. The top of the container is closed with the folded cap assembly 34. Folding of the cap assembly 34 is rather straight forward and is simply provided to prevent unwanted debris or contaminants access to the interior of the container.
The above description is considered that of the preferred embodiments only. Modifications of the invention will occur to those skilled in the art and to those who make or use the invention. Therefore, it is understood that the embodiments shown in the drawings and described above are merely for illustrative purposes and not intended to limit the scope of the invention.

Claims

We claim as our invention:

1. A container, comprising: a floor assembly; a multi-faceted exterior sidewall integrally connected to and extending upwardly from the floor assembly defining an upper edge; a tray assembly disposed within the multi-faceted exterior sidewall and resting upon the floor assembly; a bladder disposed upon the tray assembly for containing the contents to be transported within the container; an outlet valve assembly attached to said bladder and extending through a hole formed in said multi-faceted exterior sidewall; and a cap assembly disposed atop and closing said multi-faceted exterior sidewall.

2. The container as defined in claim 1, further comprising at least one channel member disposed over said upper edge of said multi-faceted exterior sidewall for reinforcing said multi-faceted exterior sidewall.

3. The container as defined in claim 1, further comprising a plurality of tabs extending from an upper edge of said multi-faceted exterior sidewall for folding inwardly and reinforcing said exterior sidewall.

4. The container as defined in claim 2, wherein said at least one channel member includes a first and a second leg, said first leg being substantially longer than said second leg.

5. The container as defined in claim 4, wherein said first leg is immediately adjacent and adhered to an interior of said multi-faceted exterior sidewall.

6. The container as defined in claim 4, wherein said tray includes a plurality of sidewalls configured to lie adjacent an interior of said multi-faceted sidewall, at least one of said sidewalls of said tray having a port for receiving there through said outlet valve assembly.

7. The container as defined in claim 5, wherein said multi-faceted exterior sidewall is comprised of a plurality of laminated sheets of corrugated paper, a first plurality of said laminated sheets of corrugated paper having at least one edge overlapping and compressed against an edge of a second plurality of said laminated sheets of corrugated paper.

8. The container as defined in claim 5, wherein said floor assembly is comprised of a plurality of folding tabs, each integral with and extending from a lower edge of an opposing facet of said multi-faceted exterior sidewall, each of said plurality of folding tabs including a plurality of end tabs configured to interweave with and interlock with a corresponding plurality of end tabs on an opposing folding tab.

9. A recyclable container for use in transporting bulk materials, comprising a primary panel assembly having an upper edge, a lower edge, and opposing ends, said opposing ends interconnected together along a staggered joint to form a plurality of interconnected sidewall panels; a plurality of tabs extending from said lower edge of said primary panel and integrally connected to opposing ones of said plurality of sidewall panels, said plurality of tabs foldable toward one another and interlocking with an opposing one of said plurality of tabs to form a floor assembly, portions of at least two opposing tabs extending beyond a perimeter of said interconnected sidewall panels; at least one of said plurality of interconnected sidewall panels having a port formed therein; a tray assembly disposed within the recyclable container upon said floor assembly and having a plurality of sidewalls for nesting within the recyclable container, at least one sidewall of said tray assembly having a port aligned with said at least one port formed in one of said plurality of interconnected sidewall panels; a bladder disposed upon said tray assembly and having a nozzle extendable through said port formed in said tray assembly and through said at least one port formed in one of said plurality of interconnected sidewall panels to allow contents of said bladder to exit through said nozzle; at least one channel received over and reinforcing said upper edge of said primary panel, said at least one channel having at least one leg extending along and lying immediately adjacent one of said plurality of sidewall panels; and a cap assembly for closing said an upper end of said recyclable container.

10. The recyclable container as defined in claim 9, further comprising a rigid carrier upon which said floor assembly rests.

11. The recyclable container as defined in claim 9, wherein said primary panel assembly is comprised of a plurality of layers of corrugated paper, overlapping at staggered intervals with an opposite end of said primary panel assembly.

12. The recyclable container as defined in claim 9, wherein said plurality of tabs extending from said lower edge of said primary panel further comprise a plurality of end tabs configured to alternately interleave with a corresponding end tab on the opposing tab for holding the floor assembly in place.

13. The recyclable container as defined in claim 9, further comprising a plurality of tabs extending from an upper edge of said primary panel and foldable to lie substantially adjacent said primary panel for reinforcing the container.

14. The recyclable container as defined in claim 9, wherein said plurality of sidewalls panels form a polygon.

15. The recyclable container as defined in claim 9, wherein said plurality of sidewall panels form an octagon.

16. The recyclable container as defined in claim 9, wherein said plurality of sidewall panels form a cylinder.

17. The recyclable container as defined in claim 10, wherein said portions of at least two opposing tabs extending beyond a perimeter of said interconnected sidewall panels are attached to said rigid carrier.

18. A recyclable bulk container, comprising a sidewall, a floor assembly integrally connected to a lower edge of said sidewall, said floor assembly including tabs extending outwardly beyond a perimeter of said sidewall for supporting the container; a tray assembly disposed within said sidewall and upon said floor assembly; and a cap assembly closing an upper end of said sidewall.

19. The recyclable bulk container as defined in claim 18, further comprising a bladder disposed within said sidewall and upon said tray assembly.

20. The recyclable bulk container as defined in claim 18, further comprising a means for emptying contents from said container through at least one port formed in said sidewall.