Bulk bin with integrated shock absorber

The present application claims the benefit of Provisional Application No. 61/904,836 filed Nov. 15, 2013, the contents of which are incorporated herein by reference.

N/A

The present invention is generally directed toward bulk bin containers with shock absorbing elements that distribute forces from an impact to a stack of such containers; and more particularly, to bulk bin containers with bottom structures that include integrated shock absorbers to more evenly distribute horizontal forces impacting two or more stacked bins.

Plastic bulk bin containers typically consist of a base and four hingeably connected sidewalls. The sidewalls are in an approximately horizontal position when the bulk container is in a collapsed state, and in a vertical position when the container is erected to receive shipping goods. The sidewalls have features along each side that interlock with adjacent sidewalls when containers are erected. Most bulk bin containers are designed to stack on each other in the erected state, with and without the use of top caps.

To align containers in a stack and prevent them from sliding off each other when no top cap is used, the bottom section of a container base is typically recessed to fit in-between the sidewalls of an erected container. This recess is typically between ½″ and 1″ deep.

One weakness of this prior design becomes apparent when a stack of containers is subjected to impacts as typically occur in use. For example: a stack of loaded containers is moved via fork lift, and the stack is moved into an obstacle, such as a guide rail; stacks of loaded containers are moved by rail and encounter horizontal impacts as they occur in switching situations; and during stacking of loaded containers, the upper container is slightly angled and moved into position above the lower container until the recess on the bottom of the upper container hits the inside top edge of a sidewall in the lower container.

In all these instances, one of the sidewalls of the lower container is subjected to high horizontal forces at the top edge of the sidewall that try to push the wall outward, generated by movement of the upper container. These forces result in high stresses in the upper sections of the two adjacent corners of the sidewall of the lower container, which quite often result in breakage as shown in FIG. 3 .

The present invention provides structure to distribute forces resulting from impacts to stacked bulk bins and reduces or prevents the amount of damage caused by such impacts. The present invention is described below and shown in the Figures.

The present invention is directed to a bulk bin container with collapsible sidewalls having integrated shock absorbing elements. The shock absorbing elements absorb impacts to a stack of containers to prevent or limit damage to the containers.

In accordance with a first embodiment, a collapsible bulk bin container with one or more shock absorbing elements is provided. The container includes a base having a rectangular bottom portion including a first side, a second side, a third side and a fourth side, a first base corner, a second base corner, a third base corner and a fourth base corner. A first sidewall extends upward from the first side of the base, a second sidewall extends upward from the second side of the base, a third sidewall extends upward from the third side of the base, and a fourth sidewall extends upward from the fourth side of the base. The first, second, third and fourth sidewalls form a rectangular opening at a top end of the container. A first sidewall corner is formed between the first sidewall and the second sidewall, a second sidewall corner is formed between the second sidewall and the third sidewall, a third sidewall corner is formed between the second sidewall and the third sidewall and a fourth sidewall corner is formed between the fourth sidewall and the first sidewall. A first shock absorbing element is positioned at the first base corner for contacting an interior side of the first sidewall corner of another like container when stacked on the like container.

As used herein, a “like” container is another container that includes at least features that allow it to stack with the claimed container. The “like” container does not have to be identical to the present container. However, an identical container would also be considered a “like” container.

The bulk bin container further comprises a second shock absorbing element positioned at the second base corner, a third shock absorbing element positioned at the third base corner, and a fourth shock absorbing element positioned at the fourth base corner. Each of the second, third and fourth shock absorbing elements contact interior portions of the second, third and fourth sidewall corners respectively of the like container. The shock absorbing elements can be formed from an elastomeric material, or other suitable material(s).

The shock absorbing elements can be L-shaped and can include a rounded outer corner portion. The shock absorbing element can be a continuous piece, or can be formed by a plurality of segments with or without a gap between adjacent segments.

Additionally, the shock absorbing elements can include a plurality of holes or other structures to facilitate the absorption of energy during an impact. Moreover, the holes in the main material forming the element can be filled with another type of material.

The base can include a plurality of feet extending downward from a bottom portion of the base. Additionally, the base can include a plurality of stringers connected to the feet. The stringers can form the first base corner, the second base corner, the third base corner and the fourth base corner. The shock absorbing elements can be positioned proximate an outer portion of the corners formed by the stringers.

The base corner portion formed by the stringers can include an inset portion. The inset is used to accommodate wider shock absorbing elements.

In accordance with another embodiment of the present invention, a stackable bulk bin container having at least one shock absorbing element is provided. The container has a rectangular base having a first side, a second side, a third side and a fourth side. A first foot extends downward from a first corner of the base, a second foot extends downward from a second corner of the base, a third foot extends downward from a third corner of the base, and a fourth foot extends downward from a fourth corner of the base. A first sidewall extends upward from the first side of the base, a second sidewall extends upward from the second side of the base, a third sidewall extends upward from the third side of the base, and a fourth sidewall extends upward from the fourth side of the base. The first, second, third and fourth sidewalls form a rectangular opening at a top end of the container. A first shock absorbing element is connected to the first foot and is configured to contact an interior portion of another like container when stacked on the like container.

The container can further comprise a second shock absorbing element connected to the second foot, a third shock absorbing element connected to the third foot and a fourth shock absorbing element connected to the fourth foot. Each of the second, third and fourth shock absorbing elements are configured to contact an interior corner portion of the like container.

The sidewalls of the container can be collapsible. Additionally, a plurality of stringers can connect the first foot, second foot, third foot and fourth foot.

Further aspects of the invention are disclosed below and shown in the Figures.

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

FIG. 1 is a perspective view of a bottom of a bulk bin container in accordance with the present invention;

FIG. 2 is a partial, enlarged perspective view of a corner of the bulk bin container of FIG. 1 ; and

FIG. 3 is a partial perspective view of a prior container with damage to the corner area.

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

FIGS. 1 and 2 show a bulk bin container 10 with a shock absorbing element 12 in accordance with the present invention. The bulk bin container 10 (shown upside down in both Figures) includes a rectangular base 14 having a first side, a second side, a third side and a fourth side and a plurality of feet 16 extending from the base along a periphery thereof. In the embodiment shown, the container 10 includes eight feet. More or fewer feet can be utilized depending on the size of the bulk bin at issue. A plurality of stringers 18 form a rectangular shape having four corners 19 , and connect the feet 16 .

The container 10 includes a first sidewall 20 , a second sidewall 22 , a third sidewall and a fourth sidewall extending from the first, second, third and fourth sides of the base 14 , respectively. The sidewalls can be hingedly connected to the base 14 and can move from a collapsed position to an erected-set-up position. The sidewalls form a rectangular opening at the top of the container (when turned base side down).

The stringers 18 are shown inset from an outer periphery of the base, and are positioned to fit within the opening formed by the sidewalls of the bulk bin container 10 .

As illustrated in FIGS. 1 and 2 , each corner formed by the stringers 18 includes a shock absorbing element 12 . The shock absorbing element 12 is generally L-shaped and includes a rounded outer corner portion 24 .

The shock absorbing element 12 extends outward from the corner 19 of the stringers 18 to contact the corner of the opening formed by the sidewalls when the container 10 is set up. As shown in FIG. 2 , the shock absorbing element 12 has a thickness that allows it to fit between the stringers 18 and the opening of the container 10 . If additional thickness is required or wanted, the stringers can be provided with an inset in the corner portion 19 to allow for a thicker shock absorbing element 12 while still maintaining the outer dimensions of the outer surface of the shock absorbing element 12 .

During use the shock absorbing element will absorb some of the kinetic energy that is transferred on impact from the upper container to the lower container (of two stacked containers). This reduces the amount of energy that can cause damage to the lower bin. The shock absorbing element also more evenly distributes the forces that occur during impact onto the corners of the lower container.

An example of damage caused by impacts to a stack of containers is shown in FIG. 3 . The corner portion of the container is broken from an impact.

The shock absorbing element 12 can be formed from an elastomeric material or other suitable material for absorbing forces. Additionally, the shock absorbing element can be formed from more than one material, and can include additional structures to enhance the absorption of energy from impacts or other movement of the containers.

As shown in FIG. 2 , the shock absorbing element 12 can include a plurality of openings 26 that will give the shock absorbing element 12 a spring-like quality. The openings 26 can be cylindrical and hollow (as shown) or can be filled with a material—such as one with a different elastic quality than the rest of the element. Moreover, the openings can be shapes other than cylindrical.

While the shock absorbing element 12 is shown as a single continuous corner piece, it can be formed from two or more pieces or segments. Additionally, shock absorbing element 12 can have a continuous outer surface 28 , or can include one or more gaps or indentations.

In one alternative embodiment, shock absorbing elements can be placed along the upper portion of the sidewalls, positioned to contact the corners 19 formed by the stringers 18 (or other corner structure for containers not having stringers). In another alternative embodiment, both the corner portion of the stringers and the upper portions of the sidewalls can include shock absorbing elements. Additionally, shock absorbing elements can be positioned along the stringers and/or the upper portions of the sidewalls at other positions (than just the corners).

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