US20200130926A1

US20200130926A1 - Bulk container with improved reinforcement

Info

Publication number: US20200130926A1
Application number: US16/177,023
Authority: US
Inventors: Mark A Wisecarver
Original assignee: International Paper Co
Current assignee: International Paper Co
Priority date: 2018-10-31
Filing date: 2018-10-31
Publication date: 2020-04-30
Also published as: WO2020091940A1

Abstract

A bulk container comprising a plurality of wall panels and a bottom surface and a method of forming the same. The bulk container comprises at least one strip of material extending around an outer perimeter of the bulk container, in which the at least one strip of material comprises a first end and a second end, a portion of the second end overlapping and being adhered to a portion of the first end with an adhesive.

Description

FIELD OF THE INVENTION

This invention relates generally to containers for bulk shipping of products to points of sale. More particularly, the invention relates to a bulk container having one or more strips of material extending around a perimeter to reinforce the bulk container.

BACKGROUND OF THE INVENTION

Bulk containers used in the industry for storing and shipping products typically hold 2,000 pounds or more of the product, including flowable or semi-liquid products such as comminuted poultry. The bulk containers are commonly made of corrugated cardboard and comprise a plurality of wall panels joined together along vertical fold lines. The bottoms of the bulk containers preferably are closed or partially closed by inwardly folded bottom flaps joined to bottom edges of the wall panels along horizontal fold lines.
Bulk containers made of corrugated material are typically manufactured from a single blank that is scored to delineate the wall panels and bottom flaps. The blank is folded and secured at a manufacturer's joint and shipped to the user in a flattened condition. The user then sets the flattened container on end and opens it up into a partially-assembled, expanded tubular configuration. The bottom flaps are then folded and secured to hold the container in its set-up condition. Self-locking bottom flaps facilitate setting up the container from its flattened condition to its fully open, usable condition.
Due to the amount and weight of product held in bulk containers, reinforcement is typically needed to prevent splitting and/or tearing along the vertical and/or horizontal fold lines and loss of containment. For example, the bulk container may be reinforced with strips of sesame tape, pre-straps, and/or a full-depth sleeve. While the sesame tape and pre-straps may be applied automatically during the manufacturing process, they are both relatively narrow in width (typically 0.5 to 0.625 inches), which leaves large sections of the bulk container without reinforcement and prone to splitting or tearing along these sections. In addition, the narrow pre-straps are not secured to the bulk container and may move up or down, allowing product to work its way between the pre-straps and rupture the bulk container. Full-depth sleeves also typically are not attached to the container, and because they are often somewhat loose, the sleeves may slide out of position. Full-depth sleeves generally cannot be installed automatically and often require two people to manually install the sleeve on the container prior to use.

SUMMARY OF THE INVENTION

In accordance with an aspect of the disclosure, a bulk container is provided. The bulk container comprises a plurality of wall panels; a bottom surface; and at least one strip of material extending around an outer perimeter of the bulk container. The at least one strip of material comprises a first end and a second end. A portion of the second end overlaps, and is adhered to, a portion of the first end with an adhesive.
The plurality of wall panels may define a height of the bulk container, and the at least one strip of material may comprise a first strip extending vertically along at least a portion of the height of the bulk container. In some examples, the first strip may extend vertically along at least 25% of the height of the bulk container. In other examples, the first strip may extend vertically along substantially an entirety of the height of the bulk container. The first strip may extend horizontally across at least a portion of the bottom surface. In some examples, the first strip may extend horizontally across about 25% to about 90% of a surface area of the bottom surface.
One or more areas of the at least one strip may be adhered to an outer surface of the bulk container with the adhesive.
The at least one strip of material may comprise a first strip and at least one additional strip.
The bulk container may further comprise at least one strip of material that extends around an inner perimeter of the bulk container and is adhered in one or more areas to an inner surface of the bulk container with an adhesive.
The at least one strip of material may be between 12 inches and 40 inches wide.
In accordance with another aspect of the disclosure, a method of forming a bulk container from a flat blank is provided. The blank may comprise a plurality of wall panels foldably connected along first fold lines and a plurality of bottom flaps connected to one end of the plurality of wall panels along second fold lines. The method comprises providing a partially-assembled blank in which lateral ends of the flat blank are joined; providing a strip of material comprising a first end and a second end; applying the strip to an outer surface of the partially-assembled blank in a direction substantially perpendicular to the first fold lines, in which the strip extends around an outer perimeter of the partially-assembled blank and in which the second end of the strip overlaps a portion of the first end of the strip; and adhering the second end of the strip to the portion of the first end of the strip with an adhesive.
The strip may extend in a longitudinal direction along at least a portion of a longitudinal length of the plurality of wall panels. In some examples, the strip may extend in the longitudinal direction along at least 25% of the longitudinal length of the plurality of wall panels. In other examples, the strip may extend in the longitudinal direction along substantially an entirety of the longitudinal length of the plurality of wall panels. The strip may extend in the longitudinal direction along at least a portion of a longitudinal length of the plurality of bottom flaps. In some examples, the strip may extend horizontally across at least 25% of the longitudinal length of the plurality of bottom flaps.
The method may further comprise adhering one or more areas of the strip to an outer surface of the bulk container with the adhesive.
The strip of material may be between 12 inches and 40 inches wide.
The method may further comprise providing at least one additional strip of material comprising a first end and a second end; applying the at least one additional strip to the outer surface of the partially-assembled blank in the direction substantially perpendicular to the first fold lines, in which the at least one additional strip extends around the outer perimeter of the partially-assembled blank and in which the second end of the at least one additional strip overlaps a portion of the first end of the at least one additional strip; and adhering, with an adhesive, the second end of the at least one additional strip to the portion of the first end of the at least one additional strip.
The partially-assembled blank may further comprise at least one additional strip of material extending around an inner perimeter of the partially-assembled blank in the direction substantially perpendicular to the first fold lines, in which one or more areas of the at least one additional strip are adhered to an inner surface of the partially-assembled blank with an adhesive.

BRIEF DESCRIPTION OF THE DRAWINGS

While the specification concludes with claims particularly pointing out and distinctly claiming the present invention, it is believed that the present invention will be better understood from the following description in conjunction with the accompanying Drawing Figures, in which like reference numerals identify like elements, and wherein:

FIG. 1 is a plan view of a blank for forming a bulk container, in accordance with the present disclosure;

FIG. 2 is a plan view of the blank of FIG. 1 that has been partially assembled and folded in half into a flattened condition;

FIG. 3A is a plan view of the partially-assembled blank of FIG. 2 comprising a strip of material;

FIG. 3B is a plan view of the partially-assembled blank of FIG. 2 comprising two strips of material;

FIG. 3C is an enlarged fragmentary plan view of a portion of FIG. 3B;

FIG. 3D is an enlarged fragmentary plan view of a portion of FIG. 3C;

FIG. 4 is a perspective view of a fully-assembled bulk container, in accordance with the present disclosure;

FIG. 5 is a top, plan view of a footprint of the partially-assembled blank of FIG. 2 and the bulk container of FIG. 4;

FIG. 6 is a perspective view of a bottom surface of the bulk container of FIG. 4;

FIG. 7 is a perspective view of an interior of the bulk container comprising one or more strips of material; and

FIGS. 8 and 9 are flowcharts illustrating methods of forming a bulk container, in accordance with the present disclosure.

DETAILED DESCRIPTION OF THE INVENTION

In the following detailed description of the preferred embodiments, reference is made to the accompanying drawings that form a part hereof, and in which is shown by way of illustration, and not by way of limitation, specific preferred embodiments in which the invention may be practiced. It is to be understood that other embodiments may be utilized and that changes may be made without departing from the spirit and scope of the present invention.
The present description is directed to a container construction comprising a one-piece blank that is folded to form a bulk container. One or more strips of material may be applied to an outer surface of the bulk container to reinforce the bulk container. Examples of bulk containers and blanks for forming the same are disclosed in applicant's U.S. Pat. Nos. 7,654,440 and 8,998,070, the disclosures of which are herein incorporated by reference in their entirety.
With reference to FIG. 1, a blank B for making a bulk container 10 (see FIG. 4) is shown. The blank B may comprise a single, unitary piece of a material, such as a continuous sheet of conventional corrugated cardboard. The blank B is cut along its outer margins to form its specific shape. The blank B illustrated in FIG. 1 is a planar piece of material in which an outer surface 50 is shown facing out of the page and an inner surface (not visible) is facing an opposite direction from the outer surface 50. The blank B extends in a longitudinal direction between first and second longitudinal edges, generally designated 52 and 54, respectively, along line L₁, which defines a longitudinal axis of the blank B. The line L₁also defines a longitudinal axis of the assembled bulk container 10 (see FIG. 4). The blank B extends in a lateral direction between first and second lateral edges, generally designated 56 and 58, respectively, along line L₂, which defines a lateral axis of the blank B.
The blank B comprises a plurality of wall panels 11-17, 18A, 18B connected along vertical fold lines 20 (also referred to herein collectively as first fold lines). The wall panels comprise sidewalls 11 and 12, end walls 13 and 14, and corner panels 15-17, 18A, 18B. The sidewall 11 may have a same width in the lateral direction as the sidewall 12, and the end walls 13, 14 may have a same width as the corner panels 15-17, 18A, 18B. Parabolic creases 21 may be formed in the sidewalls 11, 12 to obtain predictable and controlled buckling of the sidewalls 11, 12 when internal pressure is applied to the sidewalls 11, 12 by the contents of the assembled bulk container 10 (see FIG. 4). The creases 21 may be formed by a score line bordered by crushing on both sides. The operation of the creases 21 is more fully explained in applicant's U.S. Pat. No. 6,783,058, which is herein incorporated by reference in its entirety.
Major bottom flaps 22, 23 are foldably joined to bottom edges of respective sidewalls 11, 12 along horizontal fold lines 24 extending perpendicular to the vertical fold lines 20; minor bottom flaps 25, 26 are foldably joined to bottom edges of respective end walls 13, 14 along horizontal fold lines 27; and diagonal bottom flaps 28-30, 31A, 31B are joined to respective corner panels 15, 16, 17, 18A, 18B along horizontal fold lines 32 (fold lines 24, 27, and 32 are also referred to herein collectively as second fold lines). The upper edges of the wall panels 11-17, 18A, 18B define the first longitudinal edge 52 of the blank B, and bottom edges of major, minor, and diagonal bottom flaps 22, 23, 25, 26, 28-30, 31A, 31B define the second longitudinal edge 54 of the blank B. Outer edges of the corner panel 18A and the diagonal bottom flap 31A define the first lateral edge 56 of the blank B, and outer edges of the corner panel 18B and the diagonal bottom flap 31B define the second lateral edge 58 of the blank B.
With continued reference to FIG. 1, the major bottom flaps 22, 23 each have opposing sides defined by creases 35, 36 that align with the vertical fold lines 20 delineating a respective associated wall panel 11, 12. The major bottom flaps 22, 23 are of a substantially equal width in the lateral direction between respective creases 35, 36 that corresponds to a width of the respective associated wall panel 11, 12. The minor bottom flaps 25, 26 each have opposing side edges 33, 34 aligned with the vertical fold lines 20 delineating a respective associated wall panel 13, 14. The minor bottom flaps 25, 26 are of a substantially equal width in the lateral direction between the opposing side edges 33, 34 that corresponds to a width of the respective associated wall panel 13, 14. In some examples, the width of the sidewalls 11, 12 may be greater than the width of the end walls 13, 14, such that the major bottom flaps 22, 23 are wider than the minor bottom flaps 25, 26. In other examples (not shown), the width of the sidewalls 11, 12 may be substantially equal to the width of the end walls 13, 14, such that the major and minor bottom flaps 22, 23, 25, 26 are substantially equal in width.
The major bottom flaps 22, 23 each have trapezoidally-shaped extensions or wings 37, 38 projecting laterally from the creases 35, 36 at opposite side edges of the major bottom flaps 22, 23. The extensions 37, 38 are separated from respective adjacent diagonal flaps 28-30, 31A/31B by cuts 39 extending at about a 45° angle from a point near the intersection of the fold lines 24 with a respective crease 35, 36 to a point about midway along opposite side edges 40, 41 of the extensions 37, 38; and by shaped cutouts 42 that space the side edges 40, 41 of the extensions 37, 38 from adjacent side edges 33, 34 of the minor bottom flaps 25, 26. The extensions 37, 38 therefore include edge portions 43, 44 that extend at about a 45° angle relative to the vertical fold lines 20 and edge portions 40, 41 that extend parallel to the vertical fold lines 20.
As shown in FIG. 1, each cutout 42 terminates at a longitudinally inner end 42A in a curvilinear configuration that delineates an end edge of a respective diagonal bottom flap 28-30, 31A/31B, and the angled cut 39 delineates one side edge (not separately labeled) of the diagonal bottom flap 28-30, 31B. The other side edge (not separately labeled) of the diagonal bottom flap 28-30, 31A is integrally connected to the adjacent minor bottom flap 25, 26 along a fold score (not separately labeled) that is in alignment with the vertical fold line 20 joining the associated wall panels 13-17, 18A. A second fold score (not separately labeled) extends at an angle of about 22.5° relative to the first fold score from a point on the first fold score near, but spaced from the fold line 27, to an apex of the curved end edge of the diagonal bottom flap 28-30, 31A. The first and second fold scores define a substantially triangular web (not separately labeled) that connects the diagonal bottom flap 28-30, 31A with the respective adjacent minor bottom flap 25, 26. It should be noted that joining of the lateral edges 56, 58 of the blank B brings flaps 31A and 31B together to form a structure similar to that depicted with respect to the diagonal bottom flaps 28-30.
A self-locking structure for holding the bottom flaps 22, 23, 25, 26 in a closed position is defined by a pair of triangularly shaped notches 60, 61 in a free, bottom edge of each of the minor bottom flaps 25, 26 and a pair of angled slots 64, 65 formed in the major bottom flaps 22, 23 near a respective free, bottom edge. The notches 60, 61 define a pair of locking tabs 62, 63 on the corners of the minor bottom flaps 25, 26 that are received in the angled slots 64, 65 when the major and minor bottom flaps 22, 23, 25, 26 are folded inwardly, as described below.
With reference to FIGS. 1 and 2, a partially-assembled blank B′ is formed by folding the lateral edges 56, 58 of the blank B toward each other and joining the lateral edges 56, 58 to form a manufacturer's joint, in which wall panel 18A is joined to wall panel 18B (hereinafter referred to collectively with reference numeral 18), and diagonal bottom flap 31A is joined to diagonal bottom flap 31B (hereinafter referred to collectively with reference numeral 31). Following joining of the lateral edges 56, 58, the partially-assembled blank B′ is substantially tubular and open at both ends. The partially-assembled blank B′ may be folded in half and flattened, as shown in FIG. 2, for shipping to a customer. In the example shown in FIG. 2, the partially-assembled blank B′ has been folded along the vertical fold lines 20 between wall panels 13, 15 and 14, 17, with portions of panels 23 and 25 and slot 64 being visible in the cutouts 42.
To finish constructing the bulk container 10 as shown in FIG. 4, the partially-assembled blank B′ is opened up from its flattened configuration and placed in an inverted position with the bottom flaps 22, 23, 25, 26, 28-31 pointing up. The major bottom flaps 22, 23 are folded inwardly along fold lines 24 toward an interior space 66 of the bulk container 10, followed by inward folding of the minor bottom flaps 25, 26 along fold lines 27. The diagonal bottom flaps 28-31 and portions of the minor bottom flaps 25, 26 are crushed in a predetermined pattern to provide clearance for the major and minor flaps 22, 23, 25, 26, as described in detail in applicant's U.S. Pat. Nos. 7,654,440 and 8,998,070. The minor bottom flaps 25, 26 are pressed downwardly against the major bottom flaps 22, 23, causing the major bottom flaps 22, 23 to move downward slightly into the interior space 66 and bringing the locking tabs 62, 63 into aligned registry with the angled slots 64, 65. When downward pressure is released, the major and minor bottom flaps 22, 23, 25, 26 spring back upward, with the locking tabs 62, 63 extending into the angled slots 64, 65 to interlock the major and minor bottom flaps 22, 23, 25, 26 in a generally horizontal position. Interlocking of the major and minor bottom flaps 22, 23, 25, 26 closes one end of the bulk container 10 and forms a bottom surface 46, as shown in FIG. 6. Inward folding of the major bottom flaps 22, 23 is easily accomplished because they are free of connection with adjacent flaps, and inward folding of the minor bottom flaps 25, 26 causes the diagonal bottom flaps 28-31 to automatically fold inwardly so that they are sandwiched between the major and minor bottom flaps 22, 23, 25, 26 in the fully-assembled container 10. The folding sequence is described in greater detail in applicant's U.S. Pat. Nos. 7,654,440 and 8,998,070.
FIG. 4 depicts an octagonal bulk container 10 formed from the blank B of FIG. 1 comprising wall panels 11-18, in which sidewalls 11 and 12 are opposite each other; end walls 13 and 14 are opposite each other; and the corner panels 15, 16, 17, 18 are interposed between respective side and end walls, with corner panels 16, 18 being diagonal from each other and corner panels 15, 17 being diagonal from each other. The diagonal corner panels 15-18 may have substantially the same width as the end walls 13, 14, and parabolic creases (not shown; see FIG. 1) may be formed in the sidewalls 11, 12. FIG. 5 is a top view of a footprint of the bulk container 10 of FIG. 4 in which it can be seen that a perimeter of bulk container 10 defines an octagonal shape. An outer perimeter P_10-1is defined along the outside of the bulk container 10, and an inner perimeter P_10-2is defined along the inside of the bulk container 10. A plastic bag liner 120 may be placed in the interior space 66 of the bulk container 10. It is understood that bulk containers having shapes other than an octagonal shape, such as a rectangular shape or a cylindrical drum, with or without bag liners, may also be used.
The bulk container 10 may comprise at least one strip of material 200, 210 that extends around the outer perimeter P_10-1of the bulk container 10 in a direction that is substantially perpendicular to the fold lines 20 connecting the wall panels 11-18. The strip(s) 200, 201 reinforce the bulk container 10 and help prevent splitting and/or tearing of the bulk container 10, e.g., along one or more of the first fold lines 20 between the wall panels 11-18 and/or along the second fold lines (not shown; see FIG. 1) between the wall panels 11-18 and bottom flaps 22, 23, 25, 26, 28-31. As described in detail herein, respective ends of each strip 200, 210 are adhered together with adhesive to form a closed band that extends around the outer perimeter P_10-1of the bulk container 10, and one or more areas of the strips 200, 210 may optionally be adhered to an outer surface 68 of the bulk container 10 with adhesive.
As shown in FIG. 4, the bulk container 10 comprises a height H_Bthat is defined by the wall panels 11-18, and the strip(s) 200, 210 extend vertically along at least a portion of the height H_Bof the bulk container 10. One strip of material 200 may be adjacent to the bottom surface 46 (see FIG. 6) of the bulk container 10 and may extend vertically along a portion, e.g., H_B-200, of the height H_Bof the bulk container 10. In some examples, the strip 200 may extend vertically along about 25% or more of the height H_Bof the bulk container 10. In other examples, the strip 200 may extend vertically along substantially an entirety of the height H_Bof the bulk container 10 (not shown; see FIG. 3A). The strip 200 may also extend horizontally across a portion of the bottom surface 46 of the bulk container 10, as shown in FIG. 6 and described below in more detail.
Alternatively, or in addition, the bulk container 10 may comprise a strip of material 210 that extends vertically along a portion, e.g., H_B-210, of the height H_Bof the bulk container 10. The strip 210 may be spaced apart from the bottom surface 46 of the bulk container 10. In some examples in which the bulk container 10 comprises both strips 200 and 210, the strip 210 may be spaced apart from the strip 200, as shown in FIG. 4, and in some particular examples, the strip 210 may be located at approximately a midsection of the bulk container 10. In other examples, one or more sections of the strips 200, 210 may overlap (not shown; see FIG. 3B). In further examples, the strip 210 may extend across substantially an entirety of the height H_Bof the bulk container 10 spanning between the strip 200 and the upper edges of the wall panels 11-18 (not shown; see FIG. 3B). Although not shown, it is understood that the bulk container 10 may comprise three strips, four strips, etc. and that these strips may be spaced apart from each other and/or overlapping.
With reference to FIGS. 2 and 3A-3D, the one or more strips of material 200, 210 may be applied while the bulk container 10 is in a partially-assembled state. FIG. 3A depicts a partially-assembled blank B′ with one strip of material 200, and FIG. 3B depicts a partially-assembled blank B′ with two strips of material 200, 210. FIG. 3C is an enlarged view of the two strips 200, 210 of FIG. 3B, and FIG. 3D is an enlarged view of respective first and second ends 200A, 200B and 210A, 210B of the strips 200, 210.
As shown in FIG. 2, the wall panels 11-18 (only panels 11 and 14-16 are visible) comprise a longitudinal length L_WPextending in the longitudinal direction, as indicated by line L₁, between the second fold lines 24, 27, 32 and the first longitudinal edge 52 of the partially-assembled blank B′. The bottom flaps 22, 23, 25, 26, 28-31 (only flaps 22, 26, 28, and 29 are visible) comprise a longitudinal length L_BFextending in the longitudinal direction between the second fold lines 24, 27, 32 and the second longitudinal edge 54 of the blank B′. With reference to FIGS. 3A and 5, the strip of material 200 (also referred to herein as the first strip) is applied to the outer surface 50 of blank B′ such that the strip 200 extends around an outer perimeter P_B′-1of the blank B′ in a direction that is substantially perpendicular to the fold lines 20. The strip 200 may comprise a discrete, one-piece strip or band of material. The material may comprise one or more polymeric materials, such as polypropylene and polyester; one or more non-polymeric materials, such as solid fiber sheets; or mixtures thereof, such as fabric-reinforced films. The material may comprise a woven or a nonwoven material. In some particular examples, the material may comprise a woven polypropylene material. In all cases, the strip 200 preferably comprises a recycled and/or recyclable material. The strip 200 may comprise any desired width W₂₀₀, as shown in FIG. 3C. In some examples, the width W₂₀₀of the strip 200 may be between about 12 inches and about 40 inches.
With reference to FIGS. 2 and 3A, the strip 200 extends in the longitudinal direction along at least a portion of the longitudinal length L_WPof the wall panels 11-18, in which the portion is measured between the second fold lines 24, 27, 32 and a first outer edge 200-1 of the strip 200, i.e., the edge 200-1 located toward the first longitudinal edge 52 of the blank B′. In some examples, the strip 200 may extend along a portion L_W-200of the longitudinal length L_WPof the wall panels 11-18. In other examples, the strip 200 may extend along about 25% or more of the longitudinal length L_WPof the wall panels 11-18. In further examples, the strip 200 may extend along substantially an entirety L_W-200′ of the longitudinal length L_WPof the wall panels 11-18, such that the outer edge 200-1′ of the strip 200 is located at or near the first longitudinal edge 52 of the blank B′.
The strip 200 may also overlap the second fold lines 24, 27, 32 and extend in the longitudinal direction along at least a portion of the longitudinal length L_BFof the bottom flaps 22, 23, 25, 26, 28-31, in which the portion is measured between the second fold lines 24, 27, 32 and a second outer edge 200-2 of the strip 200, i.e., the edge 200-2 located toward the second longitudinal edge 54 of the blank B′. In some examples, the strip 200 may extend along a portion L_B-200of the longitudinal length L_BFof the bottom flaps 22, 23, 25, 26, 28-31, such that the second outer edge 200-2 of the strip 200 is located at or near the longitudinally inner end 42A of the cutouts 42. In other examples, the strip 200 may extend along a portion L_B-200′ of the longitudinal length L_BFof the bottom flaps 22, 23, 25, 26, 28-31, such that the second outer edge 200-2′ of the strip 200 is located at or near the angled slots 64, 65 formed in the major bottom flaps 22, 23.
With reference to FIGS. 3A, 4, and 6, when the blank B′ is assembled into the bulk container 10 as described herein, the strip 200 may extend horizontally across at least a portion of the bottom surface 46 of the bulk container 10. When the bottom flaps 22, 23, 25, 26, 28-31 are folded as described herein to form the bottom surface 46, the portions of the strip 200 that are adjacent to and/or adhered to the major and minor bottom flaps 22, 23, 25, 26 are folded along with the flaps 22, 23, 25, 26. Folding of the diagonal bottom flaps 28-31 during closure of the bulk container 10 may cause portions of the strip 200 that are adjacent to and/or adhered to the diagonal bottom flaps 28-31 to become at least partially folded under the flaps 22, 23, 25, 26. The bottom surface 46 comprises a surface area defined by the bottom flaps 22, 23, 25, 26, 28-31. In some examples, the strip 200 extends horizontally across about 25% to about 90% of the surface area of the bottom surface 46.
The strip 200 helps to reinforce the bulk container 10 along the first fold lines 20 between the wall panels 11-18 and along the second fold lines 24, 27, 32 between the wall panels 11-18 and bottom flaps 22, 23, 25, 26, 28-31 to prevent splitting and/or tearing along these fold lines 20, 24, 27, 32 and loss of product containment. These sections of the bulk container 10 are typically subjected to the highest amount of internal pressure when the bulk container 10 is filled with a product. The greater width W₂₀₀of the strip 200 (as compared to conventional straps) may help to resist movement of the strip 200 in the longitudinal direction due to shifting of the product, particularly after a small split or tear in one of the fold lines is initiated. In addition, absorption of environmental moisture and/or liquid leaking into the interior space 66 of the bulk container 10 may weaken the material of the bulk container 10, e.g., cardboard. The strip 200, particularly those portions adjacent to and extending across the bottom surface 46, may help to prevent the bulk container 10 from absorbing liquid when placed in a wet environment and/or to prevent splitting and/or tearing at wet, weakened sections of the bulk container 10.
With reference to FIGS. 2, 3A, and 4, in some examples, a longitudinal length L_WPof the wall panels 11-18 (which corresponds to a height H_Bof the bulk container 10) may be about 36 inches to about 60 inches. In some specific examples, the longitudinal length L_WPof the wall panels 11-18 may be about 40 inches, and the width W₂₀₀of the strip 200 may be 34 inches, with the strip 200 extending in the longitudinal direction about 20 inches onto the wall panels 11-18 and about 14 inches onto the bottom flaps 22, 23, 25, 26, 28-31, i.e., about 14 inches onto the bottom surface 46.
With reference to FIGS. 3B and 5, the blank B′ may optionally comprise an additional strip of material 210 (also referred to herein as the second strip), which is similarly applied to the outer surface 50 of blank B′ such that the strip 210 extends around the outer perimeter P_B′-1of the blank B′ in a direction that is substantially perpendicular to the fold lines 20. The strip 210 may be substantially similar to the strip 200 and may comprise a discrete, one-piece strip or band of material with any desired width W210, as shown in FIG. 3C.
The second strip 210 extends in the longitudinal direction along at least a portion of the longitudinal length L_WPof the wall panels 11-18, in which the portion is measured between inner and outer edges 210-1, 210-1′, 210-2, 210-2′ of the strip 210. In some examples, the second strip 210 may be spaced apart from the first strip 200 and may extend along a portion L_W-210of the longitudinal length L_WPof the wall panels 11-18. In some particular examples, the second strip 210 may be located at approximately a midsection of the wall panels 11-18. In other examples, the first outer edge 210-1′ of the strip 210 may extend further toward the first longitudinal edge 52 of the blank B′, as indicated by L_W-210′. In further examples, the second outer edge 210-2′ of the second strip 210 may extend further toward the second longitudinal edge 54 of the blank B′, as indicated by L_W-210″, such that the second outer edge 210-2′ of the second strip 210 overlaps the first outer edge (not labeled) of the first strip 200. In yet further examples, the second strip 210 may overlap with the first strip 200 and may also extend up to the first longitudinal edge 52 of the blank, as indicated by L_W-210′″. In some particular examples in which the second strip 210 overlaps the first strip 200, the second strip 210 may extend in the longitudinal direction along at least a portion of the longitudinal length L_BFof the bottom flaps 22, 23, 25, 26, 28-31 (not shown).
The second strip 210 helps to reinforce the bulk container 10 along the fold lines 20 between the wall panels 11-18, and a spacing between the first and second strips 200, 210 may be adjusted to help prevent shifting of the product and splitting and/or tearing of the bulk container 10 in sections that are not covered by the strips 200, 210. The greater width Wino of the strip 210 (as compared to conventional straps) may help to resist movement of the strip 210 in the longitudinal direction due to shifting of the product, particularly after a small split or tear in one of the fold lines is initiated. Although not shown, it is understood that the partially-assembled blank B′ may comprise three strips, four strips, etc. and that these strips may be spaced apart from each other and/or overlapping.
As shown in FIGS. 3C and 3D, the first strip 200 comprises an inner surface 208, an outer surface 209, and first and second ends 200A, 200B, in which a portion of the second end 200B overlaps and is adhered to a portion of the outer surface 209 near the first end 200A. In particular, the first end 200A may comprise an adhesive 204A on the outer surface 209, the second end 200B may comprise adhesive 204B on the inner surface 208, or both. The portion of overlap between the first and second ends 200A, 200B may generally correspond to the adhesive areas 204A, 204B (also referred to herein collectively with reference numeral 204). The second strip 210 similarly comprises an inner surface 218, an outer surface 219, and first and second ends 210A, 210B, in which a portion of the second end 210B overlaps and is adhered to a portion of the outer surface 219 near the first end 210A. The first end 210A may comprise an adhesive 214A on the outer surface 219, the second end 210B may comprise adhesive 214B on the inner surface 218, or both. The portion of overlap between the first and second ends 210A, 210B may generally correspond to the adhesive areas 214A, 214B (also referred to herein collectively with reference numeral 214).
The second end 200B of the first strip 200 is folded over the first end 200A in the direction of arrow 218 in FIG. 3D and secured to form a seam or joint 202, as shown in FIG. 3C. The second end 210B of the second strip 210 is similarly folded over the first end 210A in the direction of arrow 218 in FIG. 3D and secured to form a seam or joint 212, as shown in FIG. 3C. Any additional strips (not shown) may be folded and secured in a similar fashion. In some examples, the overlap between the respective first and second ends 200A, 210A and 200B, 210B may comprise four to eight inches in the lateral direction (see line L₂in FIG. 1). Although the joints 202, 212 are depicted in FIG. 3C as both being located at a similar position for convenience, e.g., over panel 15, it is understood that the strips 200, 210 may be oriented such that the joints 202, 212 are located at different lateral positions. For example, one joint, e.g., joint 202 may be located over corner panel 17, and the other joint, e.g., joint 212, may be located over corner panel 15.
In some examples, the strips 200, 210 may be secured only via the respective joints 202, 212 formed between the ends 200A, 200B and 210A, 210B. With reference to FIGS. 3C, 3D, and 5, to apply the strip(s) 200, 210 to the partially-assembled blank B′, the strip(s) 200, 210 is placed around the outer perimeter P_B′-1of the blank B′ and the respective ends 200A, 200B and 210A, 210B are secured such that the strip(s) 200, 210 fit snugly around the blank B′ to prevent movement of the strip 200, 210 in the longitudinal direction. The joints 202, 212 exhibit high tensile and shear strength and can withstand a large amount of force exerted in a direction indicated by arrow 220 in FIG. 3C, without detaching. For example, when the blank B′ comprising one or both strips 200, 210 is assembled into the bulk container 10 shown in FIG. 4, the product placed into the interior space 66 of the bulk container 10 presses against the wall panels 11-18 and bottom surface 46, subjecting the strips 200, 210 to a force in the direction indicated by arrow 220. The ends 200A, 200B and 210A, 210B may be easily peeled apart by grasping the second end 200B, 210B of each strip 200, 210 and pulling it upward and away from the first end 200A, 200B, as indicated by arrow 222 in FIG. 3C. The amount of force required to separate the ends 200A, 200B and 210A, 210B in the direction indicated by arrow 222 is significantly less than the amount of force required to separate the ends 200A, 200B and 210A, 210B in the direction indicated by arrow 220, which helps to keep the strips 200, 210 secured while the bulk container 10 is in use but allows a user to easily peel the ends 200A, 200B and 210A, 210B apart and remove the strips 200, 210 when needed. In some examples, the material of the strip 200, 212 may allow some flexure and stretching in the direction of arrow 220 to account for expansion and contraction of the bulk container 10.
In other examples, in addition to the joints 202, 212, one or more areas of the inner surface 208, 218 of the one or more strips 200, 210 may be adhered to the outer surface 50 of the blank B′, as shown in FIG. 3C. In some instances, with reference to the second strip 210, one or more discrete areas of the inner surface 218 of the strip 210 may be adhered via adhesive to the outer surface 50 of the blank B′, as generally indicated by adhesive areas 216. The areas 216 depicted in FIG. 3C are representative, and it is understood that any suitable area(s) of the strip 210 may be adhered to the blank B′. For example, the areas may be located primarily along the edges and/or center of the strip 210 (not shown). In other examples (not shown), the areas may comprise one or more stripes extending along a length of the strip 210 (e.g., in the direction of arrow 220) and located along the edges and/or center of the strip 210.
In further instances, with reference to the first strip 200, substantially an entirety of the inner surface 208 of the strip 200 may be adhered —via adhesive to the outer surface 50 of the blank B′, as indicated by adhesive area 206. Although not visible in FIG. 3C, the portion of the inner surface 208, 218 beneath the joints 202, 212 in one or both of the strips 200, 210 may be adhered to the outer surface 50 of the blank B′. In addition, although not shown in FIG. 3C, it is understood that the strip 200 may also be adhered to the blank B′ at one or more discrete areas and that the strip 210 may be adhered to the blank B′ along substantially an entirety of the strip 210.
In examples in which the strips 200, 210 are adhered to the outer surface 50 of the blank B′, the adhesive areas 206, 216 help to prevent the strips 200, 210 from moving in the longitudinal direction along the wall panels 11-18 of the blank B′ and the assembled bulk container 10 (see FIG. 4). As described in detail with respect to the joints 202, 212, the areas in which the strips 200, 210 are adhered to the blank B′ exhibit high tensile and shear strength and resist detachment of the strips 200, 210 from the blank B′ when subjected to forces in the direction indicated by arrow 220 in FIG. 3C. However, the strips 200, 210 may be easily peeled away from the outer surface 50 of the blank B′ (or the outer surface 68 of the bulk container 10; see FIG. 4) by grasping and pulling the second end 200B, 210B of each strip 200, 210 upward and away from the first end 200A, 200B (i.e., in the direction indicated by arrow 222) and pulling the strips 200, 210 away from the outer surface 50, 68 of the blank B′ or bulk container 10 around the remainder of the outer perimeter P_B′-1, P_10-1(see FIG. 5).
The adhesive may comprise a heat set or heat seal adhesive, such as an acrylic emulsion heat seal adhesive or EVA type heat seal film adhesive. Forming the joints 202, 212 and/or adhering one or more areas 206, 216 of the strip(s) 200, 210 to the outer surface 50 of the blank B′ via a heat seal adhesive requires application of heat sufficient to at least partially melt the heat seal adhesive. In some examples, an entirety of the inner and/or outer surface 208, 209, 218, 219 of each strip 200, 210 may be coated with heat seal adhesive, and heat may be selectively applied to one or more areas of the strips 200, 210. For example, heat may be applied only at the overlapping areas 204, 214 to form the joints 202, 212 that secure the ends 200A, 200B, 210A, 210B of the strips 200, 210. Heat may optionally also be applied to the areas 206 and/or 216 to adhere the strips 200, 210 to the outer surface 50 of the blank B′. In some cases, the strips 200, 210 may be pre-coated by a manufacturer of the material comprising the strips 200, 210. In other examples, the heat seal adhesive may be applied to one or more discrete areas (e.g., 204/214 and/or 206) of the strips 200, 210, and heat may be applied to adhere the strips 200, 210 to the outer surface 50 of the blank B′ at these areas.
The adhesive may also comprise a cold set or cold seal adhesive, such as adhesives comprising one or more epoxy resins, cyanoacrylate adhesives, and PVA-based synthetic adhesives. Forming the joints 202, 212 and/or adhering one or more areas 206, 216 of the strips 200, 210 to the outer surface 50 of the blank B′ may comprise, for example, applying a liquid cold seal adhesive to the desired areas of the strips 200, 210 (and/or to the outer surface 50 of the blank B′) and allowing the cold seal adhesive to dry. Alternatively, one or more areas of the inner and/or outer surface 208, 209, 218, 219 of each strip 200, 210 may be pre-coated with cold seal adhesive and covered with a protective paper backing. One or more sections of the paper backing may be peeled off and pressure may be applied so that the strips 200, 210 adhere to themselves at the joints 202, 212 and/or to the outer surface 50 of the blank B′.
With reference to FIGS. 5 and 7, the bulk container 10 may comprise one or more strips of material 230 that extend around an inner perimeter P_10-2of the bulk container 10 in a direction that is substantially perpendicular to the fold lines 20 connecting the wall panels 11-18. The strip 230 may be used in place of, or in addition to, the one or more strips 200, 210 on the outer surface 68 of the bulk container 10. The strip 230 may be substantially similar to the strips 200, 210 and may comprise a discrete, one-piece strip or band of material. The strip 230 is depicted in FIG. 7 as being located at approximately a midsection of the bulk container 10, but it is understood that the strip 230 may be placed at any suitable location along the height H_Bof the bulk container 10 and may also extend onto an interior bottom surface 48 of the bulk container 10 (not shown). With reference to FIGS. 4 and 7, the wall panels 11-18 define the height H_Bof the bulk container 10, and the strip 230 extends vertically along at least a portion of the height H_Bof the bulk container 10. As described herein with respect to the strips 200, 210, the strip 230 may comprise any desired width, and in some instances, the width may be between about 12 inches and about 40 inches. In some examples (not shown), the bulk container 10 may comprise two or more strips of material extending around the inner perimeter P_10-2, in which the two or more strips may be spaced apart or overlapping as described herein.
A portion of a second end 230B of the strip 230 overlaps and is adhered to a portion of a first end 230A of the strip 230, as described with respect to strips 200, 210. In addition, the strip 230 is adhered in one or more areas to an inner surface 70 of the bulk container 10. In some instances, one or more discrete areas (not shown) of the strip 230 may be adhered via adhesive to the inner surface 70 of the bulk container 10, and in other instances, substantially an entirety of the strip 230 may be adhered via adhesive to the inner surface 70 of the bulk container 10, as described in detail with respect to the strips 200, 210. The adhesive may comprise a heat or cold seal adhesive.
The strip 230 may be applied to the flat blank B, as shown in FIG. 1, or to the partially-assembled blank B′, as shown in FIG. 2. For example, with reference to FIGS. 1 and 7, the strip 230 may be adhered to one or more portions of the inner surface (not shown) of the flat blank B during manufacture such that the first and second ends of the strip 230 extend up to the outer edges of the respective corner panels 18A, 18B. When the wall panels 18A, 18B are joined to form the partially-assembled blank B′ shown in FIG. 2 (e.g., a portion of an outer surface of wall panel 18B is adhered to a portion of an inner surface of wall panel 18A), one end of the strip 230 may be adhered to the wall panel 18A such that the end is sandwiched between and adhered to the wall panels 18A, 18B. The other end of the strip 230 is adhered to the wall panel 18B to form a band that is adhered to the inner surface (not separately labeled) of the partially-assembled blank B′ and extends around an inner perimeter P_B′-2of the partially-assembled blank B′ (see FIG. 5).
Similar to the strips 200, 210, the strip 230 helps to prevent splitting and/or tearing along the fold lines 20 and loss of product containment. In addition, adhering the strip 230 to the inner surface 70 of the bulk container 10 helps to prevent the strip 230 from moving in the longitudinal direction along the wall panels 11-18. Also similar to the strips 200, 210, the strip 230 exhibits high tensile and shear strength and resists detachment when subjected to forces in the direction indicated by arrow 220 in FIG. 3C but may still be easily peeled away from the inner surface 70 of the bulk container 10.
The strips 200, 210, 230 may be applied to the flat blank B or the partially-assembled blank B′ using automated machinery for forming and folding blanks. The strips 200, 210, 230 may be easily peeled away and separated from the bulk container 10 or blank B/B′, as described herein, such that the bulk container 10 or blank B/B′ may be recycled with other cardboard and paperboard products and the strips 200, 210, 230 may be separately recycled in an appropriate manner.
FIGS. 8 and 9 are flowcharts of exemplary methods of forming a bulk container from a flat blank, in accordance with the present disclosure. The blank may comprise a blank B, as shown in FIG. 1, which comprises a plurality of wall panels 11-18 foldably connected along first fold lines 20 and a plurality of bottom flaps 22, 23, 25, 26, 28-31 connected to one end of the plurality of wall panels 11-18 along second fold lines 24, 27, 32.
With reference to FIG. 8, the method 800 begins at Step 802 with providing a partially-assembled blank in which lateral ends of the flat blank are joined. The partially-assembled blank may comprise blank B′, as shown in FIG. 2, in which lateral edges 56, 58 of the blank B from FIG. 1 are folded toward each other and joined to form the partially-assembled blank B′. The method continues with providing a strip of material comprising a first end and a second end at Step 804. The strip of material may comprise, for example, strip 200 as shown in FIGS. 3A-3D, which comprises a first end 200A and a second end 200B. Although only strip 200 is referenced with respect to FIG. 8, it is understood that the strip of material could also comprise strip 210 as described herein.
At Step 806, the strip is applied to an outer surface of the partially-assembled blank in a direction substantially perpendicular to the first fold lines, in which the strip extends around an outer perimeter of the partially-assembled blank and in which the second end of the strip overlaps a portion of the first end of the strip. As described herein, the strip 200 is applied to the outer surface 50 of the partially-assembled blank B′ in a direction that is substantially perpendicular to the fold lines 20 connecting the wall panels 11-18, as shown in FIGS. 3A-3D. The strip 200 extends around the outer perimeter P_B′-1of the partially-assembled blank B′, as shown in FIGS. 3A, 3B, and 5. As seen in FIGS. 3C and 3D, the second end 200B of the strip 200 overlaps a portion, e.g., 204, of the first end 200A of the strip 200.
The method continues with adhering the second end of the strip to the portion of the first end of the strip with an adhesive at Step 810, after which the method may terminate. As described herein, one or both of the first or second end 200A, 200B of the strip 200 may comprise adhesive 204A, 204B (pre-coated or separately applied). Adhering the second end 200B of the strip 200 to the first end 200A of the strip 200 may comprise forming the joint 202 by, for example, applying heat, e.g., when the adhesive is a heat seal adhesive. When the adhesive is a cold seal adhesive, adhering the first and second ends 200A, 200B of the strip 200 may comprise forming the joint 202 by applying liquid cold seal adhesive and allowing it to dry or removing a protective paper backing and applying pressure.
The method 800 may optionally comprise the further Step 812 of adhering one or more areas of the strip to an outer surface of the bulk container with the adhesive. As described herein, one or more areas 206, 216 of the strips 200, 210 may be adhered to the outer surface 50 of the blank B′, as shown in FIG. 3C. In some instances, the strip 200 may be adhered to the outer surface 50 of the blank B′ via adhesive at one or discrete areas (see 216 in strip 210), and in other instances, the strip 200 may be adhered to the outer surface 50 of the blank B′ along substantially an entirety 206 of the strip 200.
Following application of a strip of material to the blank, at least one additional strip of material may be applied, as indicated by Steps 914-918 in the method 900 depicted in FIG. 9. At least one additional strip of material is provided at Step 914, in which the at least one additional strip comprises a first end and a second end. The at least one additional strip of material may comprise, for example, strip 210 as shown in FIGS. 3B-3D, which comprises a first end 210A and a second end 210B. Although only strip 210 is referenced with respect to FIG. 9, it is understood that the at least one additional strip of material could also comprise strip 200 as described herein.
At Step 916, the at least one additional strip is applied to the outer surface of the partially-assembled blank in the direction substantially perpendicular to the first fold lines, in which the at least one additional strip extends around the outer perimeter of the partially-assembled blank and in which the second end of the at least one additional strip overlaps a portion of the first end of the at least one additional strip. As described herein, the strip 210 is applied to the outer surface 50 of the partially-assembled blank B′ in a direction that is substantially perpendicular to the fold lines 20 connecting the wall panels 11-18, as shown in FIGS. 3B-3D. The strip 210 extends around the outer perimeter P_B′-1of the partially-assembled blank B′, as shown in FIGS. 3B and 5. As seen in FIGS. 3C and 3D, the second end 210B of the strip 210 overlaps a portion, e.g., 214, of the first end 210A of the strip 210.
At Step 918, the second end of the at least one additional strip is adhered, with an adhesive, to the portion of the first end of the at least one additional strip, after which the method may terminate. As described herein, one or both of the first or second end 210A, 210B of the strip 210 may comprise adhesive 214A, 214B (pre-coated or separately applied). Adhering the second end 210B of the strip 210 to the first end 210A of the strip 210 may comprise forming the joint 212 by, for example, applying heat, e.g., when the adhesive is a heat seal adhesive. When the adhesive is a cold seal adhesive, adhering the first and second ends 210A, 210B of the strip 210 may comprise forming the joint 212 by applying liquid cold seal adhesive and allowing it to dry or removing a protective paper backing and applying pressure.
While particular embodiments of the present invention have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this invention.

Claims

1. A reinforced bulk container comprising:

a plurality of wall panels defining a height of the reinforced bulk container;

a bottom surface; and

a plurality of strips of material extending around an outer perimeter of the reinforced bulk container, wherein each strip of material comprises a first end and a second end, a portion of the second end overlapping and being adhered to a portion of the first end with an adhesive, the plurality of strip of material comprising:

a first strip adjacent to the bottom surface and extending vertically along a first portion of the height of the reinforced bulk container; and

a second strip extending vertically along a second portion of the height of the reinforced bulk container, the second strip being spaced apart from the first strip.

2. (canceled)

3. The reinforced bulk container of claim 1, wherein the first strip extends vertically along about 25% of the height of the reinforced bulk container.

4. The reinforced bulk container of claim 1, wherein an outer edge of the second strip extends vertically to upper edges of the plurality of wall panels.

5. The reinforced bulk container of claim 1, wherein the first strip extends across at least a portion of the bottom surface.

6. The reinforced bulk container of claim 5, wherein the first strip extends across about 25% to about 90% of a surface area of the bottom surface.

7. The reinforced bulk container of claim 1, wherein one or more areas of at least one of the first strip or the second strip are adhered to an outer surface of the reinforced bulk container with an adhesive.

8. (canceled)

9. The reinforced bulk container of claim 1, further comprising at least one strip of material extending around an inner perimeter of the reinforced bulk container and being adhered in one or more areas to an inner surface of the reinforced bulk container with an adhesive.

10. The reinforced bulk container of claim 1, wherein at least one of the first strip or the second strip is between 12 inches and 40 inches wide.

11. A method of forming a reinforced bulk container from a flat blank comprising a plurality of wall panels foldably connected along first fold lines and a plurality of bottom flaps connected to one end of the plurality of wall panels along second fold lines, the method comprising:

providing a partially-assembled blank in which lateral ends of the flat blank are joined;

providing a plurality of strips of material each comprising a first end and a second end;

applying a first strip to an outer surface of the partially-assembled blank in a direction substantially perpendicular to the first fold lines, wherein the first strip extends around an outer perimeter of the partially-assembled blank adjacent to the bottom flaps and wherein the second end of the first strip overlaps a portion of the first end of the first strip, the first strip extending in a longitudinal direction along a first portion of a longitudinal length of the plurality of wall panels;

adhering the second end of the first strip to the portion of the first end of the first strip with an adhesives;

applying a second strip to the outer surface of the partially-assembled blank in the direction substantially perpendicular to the first fold lines, wherein the second strip extends around the outer perimeter of the partially-assembled blank and wherein the second end of the second strip overlaps a portion of the first end of the second strip, the second strip extending in the longitudinal direction along a second portion of the longitudinal length of the plurality of wall panels and being spaced apart from the first strip; and

adhering, with the adhesive, the second end of the second strip to the portion of the first end of the second strip.

12. (canceled)

13. The method of claim 11, wherein the first strip extends in the longitudinal direction along about 25% of the longitudinal length of the plurality of wall panels.

14. The method of claim 11, wherein an outer edge of the second strip extends in the longitudinal direction to upper edges of the plurality of wall panels.

15. The method of claim 11, wherein the first strip extends in the longitudinal direction along at least a portion of a longitudinal length of the plurality of bottom flaps.

16. The method of claim 15, wherein the first strip extends across at least 25% of the longitudinal length of the plurality of bottom flaps.

17. The method of claim 11, further comprising:

adhering one or more areas of at least one of the first strip or the second strip to the outer surface of the partially-assembled blank with an adhesive.

18. The method of claim 11, wherein at least one of the first strip or the second strip is between 12 inches and 40 inches wide.

19. (canceled)

20. The method of claim 11, wherein the partially-assembled blank further comprises at least one additional strip of material extending around an inner perimeter of the partially-assembled blank in the direction substantially perpendicular to the first fold lines, wherein one or more areas of the at least one additional strip are adhered to an inner surface of the partially-assembled blank with an adhesive.