WO2008039507A9

WO2008039507A9 - Vertical support and single-wrap collapsible container

Info

Publication number: WO2008039507A9
Application number: PCT/US2007/020823
Authority: WO
Inventors: John H Lapoint
Original assignee: Wrangler Corp
Priority date: 2006-09-27
Filing date: 2007-09-27
Publication date: 2008-09-04
Also published as: WO2008039507A2; US20080073353A1; WO2008039507A3

Abstract

A container comprising a collapsible continuous rigid structure defining a plurality of outer surfaces and a plurality of inner surfaces that can be used for storing and/or transporting materials. A liner uniformly affixed to at least one inner surface, such that the liner defines a sealable cavity within which material can be contained. At least one stay member is affixed to at least one outer surface such that at least a portion of the at least one stay member is positioned approximate a corner formed by two adjacent outer surfaces so as to provide support to the rigid structure. A continuous or single cover is affixed to at least one outer surface and to the at least one stay member. Further, at least one inelastic member is connecting the plurality of inner and/or outer surfaces so as to provide support for the continuous rigid structure.

Description

VERTICAL SUPPORT AND SINGLE-WRAP COLLAPSIBLE CONTAINER

BACKGROUND OF THE INVENTION

1. Field of the Invention

[0001] The present invention relates to containers used for storing and/or transporting materials. In particular, the present invention involves collapsible containers that may be used to transport bulk materials including, but not limited to, hazardous materials.

2. Discussion of Background Information

[0002] Conventional bulk containers are used for receiving, storing, transporting, and discharging all types of flowable materials; both non-hazardous and hazardous. Typical bulk containers include bulk bags or rigid box structures, such as metal containers. The bag type containers tend to be lightweight and easily collapsible when they are empty and can transform into small volumes for easy storage and shipping. However, it is difficult to load and unload a bulk bag because it lacks rigidity and thus it cannot support itself in an open orientation during loading. In other words, bulk bags are generally not tough or sturdy enough to withstand the rigorous movements of mechanical devices such as forklifts, accidental drops into cargo holds, or stacking. On the other hand, the rigid box structures or metal containers have the necessary rigidity to facilitate loading, to permit stacking of loaded containers, and to allow easy handling with forklifts and other mechanical devices. However, while the storage volume of metal containers is considerable, the volume of storable material within multiple containers is diminished by the fact that the metal containers are generally cylindrical in shape. Cylinders generally cannot be stored in a space-efficient manner. In addition, metal containers are expensive to rent or purchase. As such, there is a need for containers that will store a high volume of materials while being storable in a low volume storage facility.

[0003] In order to overcome the limitations associated with flexible bags and rigid box structures or metal containers, a collapsible container assembly has been developed. John H. Lapoint III (hereafter "Lapoint") of Kennebunk, ME, the inventor of the present invention, developed the known collapsible container assembly. The Lapoint collapsible storage container is described in U.S. Pat. No. 6,520,403 issued Feb. 18, 2003, U.S. Pat. No. 6,000,604, issued Dec. 14, 1999, and in U.S. Pat. No. 5,323,922 issued Jun. 28, 1994. The contents of the above-mentioned patents are incorporated herein for reference.

[0004] The collapsible container developed by Lapoint is based upon a multi- walled box as shown in Figure 1. In this configuration, container 1 includes a base 3 and coupled walls 2, 4, 6, and 8, such that the walls are made of a rigid member. Each wall is formed as a sandwich of tough woven flexible material encasing the rigid member, e.g., a corrugated board. The two outer woven flexible materials are coupled together to retain the rigid member between them. Opposing walls, 2 and 8 each include integral flaps 9a and 9b respectively, which are made from a flexible material and preferably omit the need for the rigid member. Wall 6 includes a short flap 5 and wall 4 includes integral covering flap 11. As indicated in U.S. Patent 6,520,403, flap 11 is designed to provide a single complete covering that ensures that the material in container 1 will not escape under expected transport conditions. Liner 13 is designed to retain a volume of material (including liquid), at least as great as the volume of the cavity of the container 1 and preferably to extend beyond the upper dimensions of the wall sections 2, 4, 6 and 8. Liner 13 includes an opening 13a for receiving bulk material 15.

[0005] Walls 2, 4, 6, and 8 of container 1 are coupled together and arranged so that they can be collapsed adjacent to one another while remaining coupled together in a substantially flat configuration when nothing is retained within container 1. One advantage of the Lapoint bulk container over the metal container is that it is stored easily and occupies much less space compared to the metal containers. In addition, the Lapoint bulk containers are substantially less expensive than the conventional metal containers, since they weigh less and are able to store more material.

[0006] However, while the Lapoint bulk container described above is an improvement over conventional bulk containers, there are many ways that it may be improved. First, the Lapoint bulk container's collapsibility could be improved in such a way that it would reduce the overall folded dimensions. Secondly, the Lapoint bulk container could be improved by utilizing existing elements to form a bottom for the bulk container. Thirdly, the Lapoint bulk container could be improved by incorporating a cover that would protect the contained materials against the elements. Fourthly, the Lapoint bulk container could be improved by strengthening the region of the collapsible portions of the container with a device.

SUMMARY OF THE PRESENT INVENTION

[0007] The present invention is directed to a container comprising a collapsible continuous rigid structure defining a plurality of outer surfaces and a plurality of inner surfaces. Further, a liner uniformly affixed to at least one inner surface of the plurality of inner surfaces, such that the liner defines a sealable cavity within which material can be contained. Further still, at least one stay member is affixed to at least one outer surface of the plurality of outer surfaces such that at least a portion of the at least one stay member is positioned approximate a corner formed by two adjacent outer surfaces so as to provide support to the rigid structure. A continuous or single cover is affixed to at least one of the plurality of outer surfaces and to the at least one stay member. Further, at least one inelastic member is connecting at least two inner surfaces of the plurality of inner surfaces and/or at least two outer surfaces of the plurality of outer surfaces so as to provide support for the continuous rigid structure.

[0008] According to an aspect of the invention,

[0009] According to an aspect of the invention,

[0010] Other exemplary embodiments and advantages of the present invention may be ascertained by reviewing the present disclosure and the accompanying drawing.

BRIEF DESCRIPTION OF THE DRAWINGS

[0011] The present invention is further described in the detailed description which follows, in reference to the noted plurality of drawings by way of non-limiting examples of exemplary embodiments of the present invention, in which like reference numerals represent similar parts throughout the several views of the drawings, and wherein:

[0012] Figure 1 is a perspective view of the collapsible container as disclosed in the PRIOR ART in U.S. Patent 6,520,403.

[0013] Figure 2 is an elevated perspective view of the collapsible container according to the present invention that includes at least one vertical support or stay member.

[0014] Figure 3 is an exploded perspective view of the collapsible container according to the present invention that includes multiple vertical supports or stay members.

[0015] Figure 4 is a partial cut-away elevated perspective view of the collapsible container according to the present invention, such that a portion of which is magnified for descriptive purposes relating to the vertical support or stay member.

[0016] Figure 5 is an elevated perspective view of a sealed collapsible container in accordance with the present invention that includes a top cover.

[0017] Figures 6, 7 and 8 are a series of partial plan views of the present invention illustrating the mechanism by which the container is collapsed. [0018] Figure 9 is an elevated perspective view of the collapsible container according to the present invention that shows multiple vertical supports or stays members and multiple support members or patches.

[0019] Figure 10 is a plan view of the collapsible container according to the present invention as shown in Figure 9 that shows multiple vertical supports or stay members and multiple support members or patches.

[0020] Figure 11 is a plan view of the collapsible container according to the present invention that shows multiple vertical supports or stay members.

[0021] Figures 12 is a plan view of the collapsible container according to the present invention that shows multiple vertical supports or stay members and multiple support members or patches in a half open position.

[0022] Figures 13 is a plan view of the collapsible container according to the present invention that shows multiple vertical supports or stay members and multiple support members or patches in an open position.

[0023] Figure 14 is an exploded perspective view of the collapsible container according to the present invention that includes multiple vertical supports or stay members.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS [0024] The particulars shown herein are by way of example and for purposes of illustrative discussion of the embodiments of the present invention only and are presented in the cause of providing what is believed to be the most useful and readily understood description of the principles and conceptual aspects of the present invention. In this regard, no attempt is made to show structural details of the present invention in more detail than is necessary for the fundamental understanding of the present invention, the description taken with the drawings making apparent to those skilled in the art how the several forms of the present invention may be embodied in practice.

[0025] Fig. 1 shows a container 1 , as mentioned above relating to U.S. Patent

6,520,403 having a base 3 and coupled walls 2, 4, 6 and 8, such that the walls are made of a rigid member. Each wall is formed of a sandwich of tough woven flexible material encasing the rigid member, e.g., a corrugated board. The two outer woven materials are coupled together to retain the rigid member there-between. A liner 13 is designed to retain a volume of material, e.g., including liquid, at least as great as the volume of the cavity of the container 1. The liner 13 further includes an opening 13a for receiving the bulk material 15. The walls 2, 4, 6 and 8 of container 1 are coupled together and arranged so that they can be collapsed adjacent to one another while remaining coupled together in a substantially flat configuration when nothing is retained within the container 1.

[0026] The container represented as prior art in Fig. 1 has the disadvantage of a collapsible container that could be structured differently so as to reduce the overall folded dimensions of the container. Further, the container could be improved by utilizing existing elements to form a bottom of the bulk container. Further still, the container could be improved by incorporating a cover that protects the contained materials against the elements.

[0027] The above-mentioned improvements over the prior art are addressed by John H. Lapoint III of Kennebunk, ME, the inventor of the present invention in U.S. Published Patent Application Number 11/054,532, (hereafter '532) filed Feb. 9, 2005 and published Aug. 10, 2006. The content of the above-mentioned U.S. Published Patent Application '532 is incorporated herein by reference.

[0028] The collapsible container represented as prior art in Fig. 1 has further disadvantages such that the approximate region of the collapsible portions of the container could be strengthen to prevent potential deforming of the container while container is being filled or even during storing of the materials in the container.

[0029] The above-mentioned improvements over the prior art are addressed by John H. Lapoint III of Kennebunk, ME, the inventor of the present invention in pending U.S. Patent Application Number 11/333,879, (hereafter '879) filed Jan. 18, 2006. The content of the above-mentioned U.S. pending Patent Application '879 is incorporated herein by reference.

[0030] The present invention shown in Fig. 2, discloses an elevated perspective view of the collapsible container 10 of the present invention having at least one vertical support or stay member rigid enough for stacking, storing and transporting a variety of materials. Unlike the metal containers, however, the container of the present invention can be collapsed from a substantially cubic volume into a substantially flat square for easy stacking and storage. The present invention thus provides numerous benefits to the user, as described more fully below with reference to the drawings.

[0031] Figure 2 is an elevated perspective view of the collapsible container 10 of the present invention. The container 10 preferably includes four sides 12, 14, 16, 18 that are arranged in a symmetrical fashion so as to form part of a cubic structure defining a cavity 31 within which materials may be contained. The four sides 12, 14, 16, 18 are preferably integral portions of a continuous rigid structure. That is, the four sides 12, 14, 16, 18 are not structurally independent, and therefore provide a greater degree of rigidity and structural integrity than the current state of the art containers. The four sides 12, 14, 16, 18 preferably form a rigid structure composed of corrugated board, e.g., fiber board or similar materials that may be readily manufactured while providing light weight, rigidity and ease of storage.

[0032] Still referring to Fig. 2, the container 10 of the present invention is substantially more rigid than existing containers due to at least one vertical support or stay member 60 affixed to at least one outer surface of the continuous rigid structure 40 (not shown) such that at least a portion of the at least one vertical support or stay member 60 is positioned approximate a corner 61 formed by two adjacent outer surfaces of the continuous rigid structure 40 so as to provide structural support. In a preferred embodiment vertical supports or stay members 60 are positioned approximate all four corners 61 of the container 10. The vertical supports or stay members 60 can extend the entire length of the continuous rigid structure 40, but may be shorter. Further, the continuous or single cover 20 is affixed to at least one of the plurality of outer surfaces of the continuous rigid structure 40 (not shown) and to the at least one vertical support or stay member 60. It is also possible for lifting handles 70 (not shown) to be attached to the continuous or single cover 20 along with being attached to the vertical support or stay member 60 (See Fig. 14). The aspects of the vertical support or stay member 60 will be further discussed in a moment see the discussion of Fig. 4.

[0033] Although the container 10 of the present invention in Fig. 2 is substantially more rigid than existing containers, it is also readily collapsible and storable by a user. Two of the four sides 12, 14, 16, 18 include scoring lines 42 (depicted in phantom) that permit the four sides 12, 14, 16, 18 to be collapsed into a substantially planar structure as further described herein. The scoring lines 42 allow a user to collapse and store the present invention in the minimum amount of space while maintaining the structural rigidity of the container 10.

[0034] Fig. 2 further discloses cover 20 as a substantially cubic form disposed over the four sides 12, 14, 16, 18. The cover 20 defines a bottom (not shown), as well as optional flaps 22, 24 that, in use, cooperate to enclose the contents of the container 10. The cover 20 also includes a plurality of tabs 21 that may be fixed to the interior of the four sides or inner surfaces 12b, 14b, 16b, 18b (not shown) for securing the cover 20 to the four sides 12, 14, 16, 18. The plurality of tabs 21 may be affixed thereto by glue, epoxy, resin or any other adhesive that is known in the art. [0035] Optionally, the present invention in Fig. 2 shows flaps 22, 24 having at least one end portion 26 for selectively engaging the cover 20 of the container 10, thereby securing its contents. Any conventional and secure fastening means may be used to secure an end portion 26 of a flap 22, 24 to a corresponding portion of the cover 20. For example, the end portions 26 may include a plurality of eyelets 28 which are adapted for receiving a plurality of ties 34, 36, 38 disposed on the exterior of the cover 20. The user may encapsulate the container 10 by folding flaps 22, 24 down over the cavity of the container 10 and affixing the end portions 26 to the plurality of ties 34, 36, 38 through the eyelets 28. As the cover 20 is preferably composed of a water resistant or waterproof material, the user can substantially insulate the container 10 against all kinds of moisture and corrosive elements by closing the flaps 22, 24 in the manner described above.

[0036] Alternatively, the cover 20 could exclude flaps 22, 24 such that a detachable top (not shown) can be placed over the top portion of the container and fasten to the eyelet-tie mechanism. It should be understood that the eyelet-tie mechanism is only one means by which the container 10 may be closed, and other similar mechanisms for selectively affixing two objects are equivalent to those described herein.

[0037] Still referring to Fig. 2, the four sides 12, 14, 16, 18 are sandwiched between the cover 20 and a liner 30 is affixed to the four sides 12, 14, 16, 18 on the interior portion of the container 10. The liner 30 preferably includes a fifth surface (not shown) that forms the bottom portion of the container 10. The liner 30 is preferably form-fitted to the four sides 12, 14, 16, 18 and uniformly affixed thereto by glue, epoxy, resin or any other adhesive that is known in the art. The liner 30 is affixed to the four sides 12, 14, 16, 18 in such a manner so as to render it coplanar with each of the four sides 12, 14, 16, 18. That is, the liner 30 is affixed to substantially all of the interior surfaces of the respective four sides 12, 14, 16, 18. As the liner 30 also includes the bottom portion, the liner 30 and four sides 12, 14, 16, 18 substantially form five sides of a substantially symmetric cubic structure. The liner 30 is preferably composed of a water resistant or water proof synthetic material that is also resistive to degradation by temperature and corrosive compounds.

[0038] Figure 3 is an exploded perspective view of the container 10 of the present invention. As shown, the continuous rigid structure 40 is shown having scoring lines 42 disposed thereon. As previously noted, the continuous rigid structure 40 is preferably comprised of corrugated board, although other equivalent structures that provide the necessary rigidity, weight, and ease of use may also be used. The liner 30 is substantially similar in size and shape to the continuous rigid structure 40, except for its fifth side (not shown) that forms the bottom of the container 10. The liner 30 optionally includes a folding portion 32 (shown in cross- hatch) that is folded over the top of the continuous rigid structure 40 and vertical support or stay member 60, then affixed to the exterior thereof by glue, epoxy, resin or any other suitable adhesive material or method. In one embodiment of the container 10, the liner 30 may be gathered and sealed by any conventional means for containing the contents of the container 10. In a preferred embodiment, the liner 30 is uniformly affixed to the interior of the continuous rigid structure 40 so as to integrate the surfaces of the liner 30 with the inner surfaces of the continuous rigid structure 40. The resultant structure is referred to as an integrated rigid structure 50. Incorporated with the integrated rigid structure is the vertical support or stay member 60 that is affixed to the outer surface of the continuous rigid structure 40 and then covered by cover 20.

[0039] Still referring to Fig. 3, the vertical support or stay member 60 is affixed to the outer surface of the continuous rigid structure 40 by methods known in the art such as by bonding, gluing and stapling. Cover 20 can then be laminated over the vertical support or stay member 60 along with the continuous rigid structure so as to form an even more structurally support container.

[0040] Fig. 3 shows the continuous rigid structure 40 with the vertical support

60 and liner 30, formed into the integrated rigid structure 50. For example, the liner 30 can be bonded, laminated and/or glued to the inner surfaces of the continuous rigid structure 40, and then the vertical support 60 can be affixed approximate the corners 61 of the continuous rigid structure 40. Finally, the cover 20 may be laminated, bonded and/or glued to both the vertical support 60 and the continuous rigid structure 40 to formulate the integrated rigid structure 50. The plurality of flaps 21 can then be folded over the integrated rigid structure 50 and affixed to the interior thereof. That is, the flaps 21 are affixed to the liner 30, which has been previously affixed to the continuous rigid structure 40, so as to prevent any exposure of the continuous rigid structure 40 to the elements or the materials stored in the container 10.

[0041] The interplay between the cover 20, liner 30 and continuous rigid structure 40 with the vertical support or stay member 60 can be seen in Figure 4, which is a partial cut-away elevated perspective view of the collapsible container of the present invention, a portion of which is magnified for descriptive purposes. The magnified portion M depicts the top edge of the container 10 where the continuous rigid structure 40 with the vertical support or stay member 60 forms the core of a series of overlapping materials. As shown, the liner 30 is disposed on one side of the continuous rigid structure 40, and the cover 20 is disposed on its opposite side. The foldable portion 32 is folded over the continuous rigid structure 40 and vertical support or stay member 60, then disposed underneath the cover 20. While the tab 21 is folded over the continuous rigid structure 40, vertical support or stay member 60 and the foldable portion 32 and affixed to the interior of the liner 30. As shown therefore, both the tab 21 and the foldable portion 32 protect the top of the continuous rigid structure 40 and vertical support or stay member 60 from any elemental interference. Also shown in Figure 4 is the bottom portion of the liner 30 that comprised the bottom portion of the container 10. Further, It is also possible for lifting handles 70 (not shown) to be attached to the continuous or single cover 20 along with being attached to the vertical support or stay member 60 (See Fig. 14).

[0042] Figure 5 is an elevated perspective view of a sealed collapsible container 10 in accordance with the present invention. As shown, a top cover 32 is positioned on top of the container 10 and aligned with the plurality of ties 34, 36, 38. The plurality of ties 34, 36, 38 may be looped through the eyelets 35 on the end portions of top cover 32 in order to secure the top cover 32 and seal the container 10. It should be noted that either arrangement, using flaps 22, 24 or top cover 32, the container 10 is sealable against the elements, and in particular, the contained materials are shielded from moisture and debris. Further, It is also possible for lifting handles 70 to be attached to the continuous or single cover 20 along with being attached to the vertical support or stay member 60 (not shown). The lifting handles 70 may be attached by means of sewing, gluing and stapling. Fig. 5 shows the scoring lines 42 which allow a user to collapse and store the present invention in the minimum amount of space while maintaining the structural rigidity of the container 10.

[0043] Figures 6, 7 and 8 are a series of partial plan views of the present invention illustrating the mechanism by which the container is collapsed. Unlike existing semi-rigid containers, the container of the present invention 10 is collapsible into a small area for easy storage and transport.

[0044] Figure 6 is a partial plan view of the container 10 of the present invention omitting the cover 20 and vertical support or stay member 60. As shown, the surface of the bottom of the container 10 is the liner 30. Scoring lines 42 are shown disposed on opposing sides of the continuous rigid structure 40. It should be noted that the scoring lines 42 are symmetrically placed about the continuous rigid structure 40 such that the container 10 is collapsible into a small space, through the introduction of an accordion-fold, without stretching the liner 30 and cover 20 (not shown) which comprise the bottom of the container 10. The scoring lines 42 are disposed on the continuous rigid structure 40 such that it is readily collapsible as described. However, the scoring lines 42 are not sufficiently deep so as to damage or diminish the structural integrity of the present invention. [0045] Figure 7 is a partial plan view of the container 10 of the present invention shown at a midpoint during its collapse including the vertical supports or stay members 60. Figure 8 a partial plan view of the container 10 of the present invention in its collapsed state wherein it forms a substantially planar object that is substantially square and easily stored and transported.

[0046] According to another embodiment of the present invention, Fig. 9 discloses an elevated perspective view of the collapsible container 10 of the invention. The container 10 preferably includes a first side 12, a second side 14, a third side 16 and a fourth side 18, all of which cooperate to define a substantially cubic volume therein. The plurality of sides 12, 14, 16, 18 preferably delineate a continuous rigid structure 40 that is formed from a semi-rigid material such as plastic, fiberboard or cardboard. In a preferred embodiment, the continuous rigid structure 40 is formed of cardboard such that it can be easily and economically produced while providing a substantial amount of rigidity as a containment device.

[0047] Still referring to Fig. 9, the continuous rigid structure 40 includes a pair of scoring lines 42 that are preferably disposed on opposing sides. For example, the scoring lines 42 may be disposed on the first side 12 and third side 16, or alternatively on the second side 14 and the fourth side 18. The scoring lines 42 are preferably disposed along the center of the respective sides thereby ensuring uniform and symmetrical folding attributes as described more fully below. That is, a scoring line disposed on the first side 12 will be disposed equidistant between the junction of the first side 12 and the second side 14 and the junction between the first side 12 and the fourth side 18, as illustrated in Figure 9. [0048] Fig. 9 shows the container 10 substantially more rigid than existing containers due to at least one vertical support or stay member 60 affixed to at least one outer surface of the continuous rigid structure 40, such that at least a portion of the at least one vertical support or stay member 60 is positioned approximate a corner 61 formed by two adjacent outer surfaces of the continuous rigid structure 40 so as to provide structural support. In a preferred embodiment vertical supports or stay members 60 are positioned approximate all four corners 61 of the container 10. The vertical supports or stay members 60 can extend the entire length of the continuous rigid structure 40, or alternatively may be shorter then the entire length of the continuous rigid structure 40. Further, the continuous or single cover 20 (not shown) can be affixed to at least one of the plurality of outer surfaces of the continuous rigid structure 40 and to the at least one vertical support or stay member 60. Further still, the vertical support or stay member 60 can be affixed to the outer surface of the continuous rigid structure 40 by methods known in the art such as by bonding, gluing and stapling. Cover 20 (not shown) can be laminated over the vertical support or stay member 60 along with the continuous rigid structure 40 so as to form an even more structurally support container.

[0049] Still referring to Fig. 9, the continuous rigid structure 40 comprises a semi-rigid material as noted above, the collapsible container 10 of the present invention includes at least one inelastic member 48 that interconnects each respective side of the continuous rigid structure 40. As shown in Figure 9, there are two inelastic members 48 that are interwoven between the four sides of the continuous rigid structure 40 in a symmetrical fashion so as to define a network of internal trusses between each of the four sides 12, 14, 16 and 18. In a preferred embodiment, each of the inelastic members 48 shown is formed from a single element that can be connected to itself at an overlap 49. The inelastic members 48 are shown anchored to each of the four sides 12, 14, 16 and 18 of the continuous rigid structure 40 by passing through a series of passages 44 that connect an inner surface of each of the four sides to an opposing outer surface. In such a manner, the internal truss system defined by the inelastic members 48 is integrated into the continuous rigid structure 40 thus forming the collapsible container 10. Further, the preferred embodiment includes support members or patches 51 that are substantially fixed in and around the surrounding surface area of the passages 44 on the continuous rigid structure 40. One of the benefits gaining in having the support members or patches 51 fixed to the surrounding surface area of the passages 44 is an added structural support to the container 10. Some other advantages of adding the internal truss system with a support-backing patch to the outer continuous fiberboard, is that the truss restricts the scored sidewalls from protruding over the edge of a pallet, squares up the container onto the pallet, resulting in superior stacking capability. A second critical function the truss system can provide is during the transportation of materials within the container. The handling and vibration during transport can disfigure the container if the truss system is not installed in the container, such that the container would most likely not be safe to stack. Further, the truss system can restrict bulge and maintains a square-like shape to the container during all phases of handling the container. Further still, the interaction between the scored sidewalls and the truss system promotes and enhances the discharging process during the emptying phase of the container. The force and shear velocity due under gravity from the force of movement from the material can be enough force to cause the scored sidewalls to project outwards, if the truss system were not present. Thus, resulting in an incomplete discharge of the material from the container. In most cases, this could cause potential problems for the customer. Further, the truss forces from the two scored sides can travel towards each other in an inwardly fashion creating a cone like funnel shape bottom providing the slope and angel necessary for complete discharge. The patch supports can be made from fabric or any rigid substrate, which can help prevent the straps from possibly cutting the board as well as keep the sidewalls in tack until the container is completely emptied. The inclusion of corner vertical wood or composite stays in each corner bonded by glue or staples can achieve a current unit stacking strength from about 7900 lbs to over 15,000 lbs. By permanently affixing the stays to the outside of the fiberboard or rigid substrate on two scored sides can not only enhance the ability of stacking. Further, when the container is collapsed, the score sides can have enough clearance to accommodate any added depth to the sidewall due to the patch and/or stays. Further still, it is possible the support members or patches 51 can be selected from at least one material or a combination of materials from a group consisting of polypropylene, polyester, nylon, polypropylene blend, thermoplastic polymer, polyethylene, woven polypropylene, high density polyethylene, low density polyethylene.

[0050] Figure 10 is a plan view of the collapsible container of the present invention as shown in Figure 9. The inelastic member 48 forms a substantially octagonal profile by alternating periods on the inside of the continuous rigid structure 40 with periods on the outer surfaces of the respective sides. The inelastic member 48 is shown disposed on the outer surface of the fourth side 18. Following the arrows in Figure 10, the inelastic member 48 is then pressed through a pair of passages 44 on the fourth side 18, through which the inelastic member 48 is shown angling towards both the first side 12 and the third side 16. At the first side 12 and the third side 16, the inelastic member 48 is pressed through a pair of passages 44, from which it angles towards the second side 14. Through another pair of passages 44 on the second side 14, the inelastic member 30 meets and is fastened to itself at the overlap 49.

[0051] In a preferred embodiment, the inelastic member 48 is of a length suitable for providing a tension between the four sides of the continuous rigid structure 40 such that the continuous rigid structure 40 maintains a substantially square shaped profile as shown in Figure 10. Of particular concern is that the scoring lines 42 disposed on opposing sides of the continuous rigid structure 40 must be able to withstand a substantial load as the collapsible container 10 of the present invention is filled. As such, the inelastic member 48 is preferably composed of a material that is light, inelastic and easy to deform into the necessary profile for creating the internal truss system for the collapsible container 10. In preferred embodiments, the inelastic member 48 is polypropylene or polyester, although any other suitable synthetic, organic or inorganic polymer that can maintain its inelasticity under a load is suitable for use in the present invention. As discussed above, the support members or patches 51 are substantially fixed to the surrounding surface area of the passages 44 of the continuous rigid structure 40. Further, one of the benefits gained in having the support members or patches 51 fixed to the surrounding surface area of the passages 44 is an added structural support to the container 10. Further still, as noted above, vertical supports or stay members 60 are positioned approximate all four corners 61 of the container 10.

[0052] Figure 11 is a plan view of the collapsible container 10 of the present invention in an early step in a method of making the same. As shown, the collapsible container 10 is in a collapsed state in which it forms a substantially planar cross-section. By folding in along the scoring lines 42, a user can compress the continuous rigid structure 40 in an accordion-like manner for easy storage and transport when not in use. Note, Fig. 11 shows the support members or patches 51 substantially fixed to the surrounding surface area of the passages 44 of the continuous rigid structure 40. Further, as noted above, vertical supports or stay members 60 are positioned approximate all four corners 61 of the container 10.

[0053] In order to form the internal truss system described above (see Fig.

11 ), the planar continuous rigid structure 40 is perforated to form the plurality of passages 44, which pass continuously and symmetrically through each of the four sides of the continuous rigid structure 40. In a preferred embodiment, the plurality of passages 44 are formed by a pressing machine adapted to thread the inelastic member 40 through the passages 44 as it creates them. Alternatively, the process of forming the plurality of passages 44 and the placement of the inelastic member 48 therein may be performed manually. As discussed further below, it is also conceived that the continuous rigid structure 40 of the present invention can be lined on its interior surfaces, in which case it is desirable to fit the liner into the continuous rigid structure 40 prior to threading the inelastic members 48 through the plurality of passages. Note, the support members or patches 51 substantially fixed to the surrounding surface area of the passages 44 of the continuous rigid structure 40.

[0054] Figures 12 is a plan view of the collapsible container according to the present invention that shows multiple vertical supports or stay members and multiple support members or patches in a half open position. The inelastic member 48 is shown fastened to itself at the overlap 49. The means for fastening the inelastic member 48 to itself may include mechanical devices, adhesives and other bonding techniques. For example, the inelastic member 48 may be fasted to itself using staples, epoxies or resins. Preferably, however, the means for fastening will be an automated process such as sonic welding, which is particularly well suited to bonding materials composed of synthetic polymers such as polypropylene and polyester. As shown in Figure 12, the overlap 49 of the inelastic member 48 is located near the outer surface of the second side 14. While it is understood that the overlap 49 can be located at any point along the continuum of the inelastic member 48, it is preferred that it be located near the outer surface of a side of the continuous rigid structure 40 that does not have a scoring line 42.

[0055] Figures 13 is a plan view of the collapsible container according to the present invention that shows multiple vertical supports or stay members and multiple support members or patches in an open position. As noted before, the inelastic member 48 is preferably of a single length of material that, when stretched to its limit, will maintain the substantially square profile of the continuous rigid structure 40. In particular, when a load is placed upon the inner surfaces of the continuous rigid structure 40, the sides of the continuous rigid structure 40 that have the scoring lines 42 therein will not bow or deform in an outward direction. However, as previously noted, the inelastic member 48 will permit the inward folding of the continuous rigid structure along the scoring lines 42, thus allowing a user to collapse the continuous rigid structure 40 into a substantially planar form as shown in Figure 11. Further, Fig. 13 shows the support members or patches 51 substantially fixed to the surrounding surface area of the passages 44 of the continuous rigid structure 40. Further still, the vertical supports or stay members 60 are positioned approximate all four corners 61 of the container 10.

[0056] According to another embodiment of the present invention, Fig. 14 shows an exploded perspective view of the container 10. As shown, the continuous rigid structure 40 is shown having scoring lines 42 disposed thereon. As previously noted, the continuous rigid structure 40 is preferably comprised of corrugated board, although other equivalent structures that provide the necessary rigidity, weight, and ease of use may also be used. The liner 30 is substantially similar in size and shape to the continuous rigid structure 40, except for its fifth side (not shown) that forms the bottom of the container 10. The liner 30 optionally includes a funnel section 63 having a detachable threaded spin cover 61 with opening 62, which is then affixed to the folding portion 32. In one embodiment of the container 10, the liner 30 may be gathered and sealed by any conventional means for containing the contents of the container 10. In a preferred embodiment, the liner 30 is uniformly affixed to the interior of the continuous rigid structure 40 so as to integrate the surfaces of the liner 30 with the inner surfaces of the continuous rigid structure 40. Further, a second liner 30a is substantially similar in size and shape to the continuous rigid structure 40, except for its fifth side (not shown) that forms the bottom of the container 10. The second liner 30a optionally includes a second funnel section 63a with second opening 62a, which is then affixed to the second folding portion 32a. In one embodiment of the container 10, the second liner 30 may be gathered and sealed by any conventional means for containing the contents of the container 10. In a preferred embodiment, the second liner 30a is uniformly affixed to the exterior of the continuous rigid structure 40 so as to integrate the surfaces of the second liner 30a with the exterior surfaces of the continuous rigid structure 40. An advantage incorporating the second liner 30a is to hermetically seal the material within the container 10. Then, a second continuous rigid structure 40a is shown having scoring lines 42a disposed thereon. The second continuous rigid structure 40a is preferably comprised of corrugated board, although other equivalent structures that provide the necessary rigidity, weight, and ease of use may also be used. The second liner 30a is substantially similar in size and shape to the continuous rigid structure 40a, except for its fifth side (not shown) that forms the bottom of the container 10. Finally, a continuous or single cover 200 is affixed to at least one of the plurality of outer surfaces of the second continuous rigid structure 40a and to the at least one vertical support or stay member 60a. It is also possible that lifting handles 70 can be attached to the continuous or single cover 200 along with being attached to the vertical support or stay member 60a. The continuous or single cover 200 can be selected from a foil material, a foil-like material or a pyroforic material or any combination thereof. Further, it is possible the foil material may be laminated to the polypropylene so as to provide some temperature and ultra-violet protection.

[0057] Still referring to Fig. 14, the vertical support or stay member 60a can be affixed to the outer surface of the continuous rigid structure 40a by methods known in the art such as by bonding, gluing and stapling. Cover 200 can then be laminated over the vertical support or stay member 60a along with the second continuous rigid structure 40a so as to form an even more structurally support container.

[0058] The container 10 of the present invention as described herein provides a number of tangible benefits over the existing rigid and semi-rigid containers known in the art. The container of the present invention is rigid enough for stacking, storing and transporting a variety of materials that other semi-rigid containers cannot handle. Moreover, unlike the rigid metal containers, the container of the present invention can be collapsed from a substantially cubic volume into a substantially flat square for easy stacking and storage.

[0059] It is noted that the foregoing examples have been provided merely for the purpose of explanation and are in no way to be construed as limiting of the present invention. While the present invention has been described with reference to an exemplary embodiment, it is understood that the words which have been used herein are words of description and illustration, rather than words of limitation. Changes may be made, within the purview of the appended claims, as presently stated and as amended, without departing from the scope and spirit of the present invention in its aspects. Although the present invention has been described herein with reference to particular means, materials and embodiments, the present invention is not intended to be limited to the particulars disclosed herein; rather, the present invention extends to all functionally equivalent structures, methods and uses, such as are within the scope of the appended claims.

Claims

What is claimed:

1. A container comprising: a collapsible continuous rigid structure defining a plurality of outer surfaces and a plurality of inner surfaces; a liner uniformly affixed to at least one of the plurality of inner surfaces, wherein the liner defines a sealable cavity within which material can be contained; at least one stay member affixed to at least one outer surface of the plurality of outer surfaces such that at least a portion of the at least one stay member is positioned approximate a corner formed by two adjacent outer surfaces so as to provide support to the rigid structure; a continuous or single cover affixed to at least one of the plurality of outer surfaces and to the at least one stay member.

2. The container of claim 1 , wherein at least one inelastic member connects at least two inner surfaces of the plurality of inner surfaces and at least two outer surfaces of the plurality of outer surfaces so as to provide support for the continuous rigid structure.

3. The container of claim 1 , wherein the at least one stay member is affixed to each of the plurality of outer surfaces such that each stay member is substantially positioned along each corner formed by two adjacent outer surfaces.

4. The container of claim 1 , wherein the at least one stay member is affixed to the at least one outer surface of the plurality of outer surfaces by one of bonding, laminating, glue and stapling.

5. The container of claim 1 , wherein, the at least one stay member is laminated in a composite material prior to being affixed to the at least one outer surface of the plurality of outer surfaces.

6. The container of claim 1 , wherein the at least one stay member is made of at least one material or a combination of materials from a group consisting of wood and composite.

7. The container of claim 1 , wherein the at least one stay member is one of a unitary element and more than one element.

8. The container of claim 1 , further comprising at least one inelastic member connecting at least two inner surfaces of the plurality of inner surfaces and at least two outer surfaces of the plurality of outer surfaces so as to provide support for the continuous rigid structure.

9. The container of claim 1 , wherein the continuous rigid structure includes a first scoring line and a second scoring line rendering the continuous rigid structure collapsible.

10. The container of claim 8, wherein the first scoring line and the second scoring line are on opposing surfaces of the continuous rigid structure.

11. The container of claim 1 , wherein the liner is uniformly affixed to each of the plurality of inner surfaces.

12. The container of claim 1 , wherein the liner is an impervious liner adapted to withstand temperatures of material in excess of 300° F.

13. The container of claim 11 , wherein the impervious liner comprises of at least one material or a combination of materials selected from a group consisting of polypropylene, nylon, polypropylene blend, thermoplastic polymer, polyethylene, woven polypropylene, high density polyethylene, low density polyethylene.

14. The container of claim 1 , wherein the liner is waterproof and/or ultraviolet protected.

15. The container of claim 1 , wherein the continuous or single cover is affixed to all the plurality of outer surfaces.

16. The container of claim 1 , wherein the continuous or single cover is affixed to at least one of the plurality of outer surfaces and at least a portion of at least one of the plurality of inner surfaces.

17. The container of claim 1 , wherein the continuous or single cover is affixed to each of the plurality of outer surfaces and at least a portion of each of the plurality of inner surfaces.

18. The container of claim 10, wherein the continuous or single cover is laminated to one of each of the plurality of outer surfaces and at least one of the plurality of outer surfaces.

19. The container of claim 1 , wherein the continuous rigid structure is a unitary device adapted for being alternately collapsed for storage and erected to a self- supporting configuration for receipt and containment of the material.

20. The container of claim 1 , wherein the material is one of non-hazardous and hazardous material.

21. The container of claim 20, wherein the material comprises a catalytic material.

22. The container of claim 1 , wherein the collapsible continuous rigid structure is selected from at least one material or a combination of materials from a group consisting of corrugated board, fiber board and composite material.

23. A container comprising: a collapsible continuous rigid structure defining a plurality of outer surfaces and a plurality of inner surfaces; a liner uniformly affixed to at least one inner surface of the plurality of inner surfaces, wherein the liner defines a sealable cavity within which material can be contained; a continuous or single cover affixed to at least one of the plurality of outer surfaces; at least one inelastic member connecting at least two inner surfaces of the plurality of inner surfaces and/or at least two outer surfaces of the plurality of outer surfaces so as to provide support for the continuous rigid structure; wherein the at least one inelastic member is in contact with at least one supporting material affixed to a portion of the at least two inner surfaces and/or the at least two outer surfaces.

24. The container of claim 22, wherein the at least one inelastic member connects the at least two inner surfaces and the at least two outer surfaces through at least one first pair of passages positioned within each inner surface of the plurality of inner surfaces and/or each outer surface of the plurality of outer surfaces, thus providing support for the continuous rigid structure.

25. The container of claim 22, wherein the at least one inelastic member connects the plurality of inner surfaces and the plurality outer surfaces through at least one first pair of passages positioned within each inner surface of the plurality of inner surfaces and/or each outer surface of the plurality of outer surfaces, thus providing support for the continuous rigid structure.

26. The container of claim 22, wherein each of the inner surfaces of the plurality of inner surfaces and/or each of the outer surfaces of the plurality of outer surfaces further define at least one second pair of passages.

27. The container of claim 25, further comprising a second inelastic member connecting the plurality of inner surfaces and the plurality of outer surfaces, such that the second inelastic member passes through each of the second pair of passages within each of the inner surfaces and/or the outer surfaces.

28. The container of claim 22, wherein the at least one inelastic member and/or the at least one supporting material is selected from at least one material or a combination of materials from a group consisting of polypropylene, polyester, nylon, polypropylene blend, thermoplastic polymer, polyethylene, woven polypropylene, high density polyethylene, low density polyethylene.

29. The container of claim 22, wherein the at least one inelastic member is comprised of a single length of material that is fastened to itself to form a continuous member.

30. The container of claim 22, wherein at least one stay member is affixed to at least one outer surface of the plurality of outer surfaces such that at least a portion of the at least one stay member is positioned approximate a corner formed by two adjacent outer surfaces so as to provide support to the rigid structure.

31. The container of claim 30, wherein the at least one stay member is affixed to each of the plurality of outer surfaces such that each stay member is substantially positioned along each corner formed by two adjacent outer surfaces.

32. The container of claim 30, wherein the at least one stay member is laminated in a composite material prior to being affixed to the at least one outer surface of the plurality of outer surfaces.

33. A container comprising: a first collapsible continuous rigid structure defining a plurality of first outer surfaces and a plurality of first inner surfaces; a first liner uniformly affixed to at least one first inner surface of the plurality of first inner surfaces, wherein the first liner defines a sealable cavity within which material can be contained; at least one inelastic member connecting at least two first inner surfaces of the plurality of first inner surfaces and/or at least two first outer surfaces of the plurality of first outer surfaces so as to provide support for the first continuous rigid structure; a second liner uniformly affixed to at least one first outer surface of the plurality of first outer surfaces, wherein the second liner sealable encloses the first liner; a second collapsible continuous rigid structure defining a plurality of second outer surfaces and a plurality of second inner surfaces; a second continuous or second single cover affixed to at least one second outer surface of the plurality of second outer surfaces.

34. The container of claim 33, wherein the at least one inelastic member is in contact with at least one supporting material affixed to a portion of the at least two inner surfaces and/or the at least two outer surfaces.

35. The container of claim 33, wherein the first and second continuous rigid structure includes a first scoring line and a second scoring line rendering the first and the second continuous rigid structure collapsible.