U.S. patent application number 09/798670 was filed with the patent office on 2002-09-05 for foldable storage container.
This patent application is currently assigned to Pratt Industries, Inc. Invention is credited to Holladay, John Thomas.
Application Number | 20020121542 09/798670 |
Document ID | / |
Family ID | 25173990 |
Filed Date | 2002-09-05 |
United States Patent
Application |
20020121542 |
Kind Code |
A1 |
Holladay, John Thomas |
September 5, 2002 |
FOLDABLE STORAGE CONTAINER
Abstract
A foldable container comprising a sheet of material having a
plurality of panels hingedly connected together to permit folding
thereof into a polygonal shape for storing liquid, solid or
granular material. Male and female flaps are hingedly connected to
the panels, and are foldable into an interlocked arrangement to
form the container bottom. A lid can be provided having a lid panel
and one or more lid flaps hingedly connected thereto. The lid flaps
each have a lid opening and a handle portion, and the sheet has
corresponding panel openings and handle portions. The lid flaps
have locking tabs that can be extended through the aligned lid and
panel openings to secure the lid in place.
Inventors: |
Holladay, John Thomas;
(Jackson, TN) |
Correspondence
Address: |
Jason A. Bernstein
BERNSTEIN & ASSOCIATES, P.C.
6600 Peachtree Dunwoody Road, N.E.
Embassy Row 400, Suite 495
Atlanta
GA
30328-1649
US
|
Assignee: |
Pratt Industries, Inc
|
Family ID: |
25173990 |
Appl. No.: |
09/798670 |
Filed: |
March 2, 2001 |
Current U.S.
Class: |
229/109 ;
229/125.28; 229/157 |
Current CPC
Class: |
B65D 5/10 20130101; B65D
5/701 20130101; B65D 5/14 20130101; B65D 5/4608 20130101 |
Class at
Publication: |
229/109 ;
229/125.28; 229/157 |
International
Class: |
B65D 005/10; B65D
043/02 |
Claims
Claimed is:
1. A container, comprising: a) a sheet of material having a
plurality of panels hingedly connected together and foldable into a
polygonal shape; b) said sheet having at least one male flap
hingedly connected to at least one of said panels, each said male
flap having a head portion and a neck portion disposed between said
head portion and said panel; and c) said sheet having at least one
female flap hingedly connected to at least one of said panels, each
said female flap having an end and at least one slot defined in
said end; d) such that said male flap and said female flap are
capable of being folded to form a container bottom with each said
male flap neck extending through at least one of said female flap
slots.
2. The container of claim 1, wherein said plurality of panels
comprises at least eight panels foldable into an octagonal
shape.
3. The container of claim 2, wherein said female flap has a
semi-octagonal shape.
4. The container of claim 1, wherein said at least one male flap
comprises two or more male flaps and said at least one female flap
comprises two or more female flaps.
5. The container of claim 4, wherein said male flaps and said
female flaps are alternately arranged so that one of said male
flaps is disposed between said two female flaps, and said male
flaps and said female flaps extend from alternate panels so that
when said panels are folded to form said container then said male
flaps are oppositely arranged and said female flaps are oppositely
arranged.
6. The container of claim 5, wherein said slot of said female flap
has a depth that is at least one half of a width of said neck
portion of said male flap.
7. The container of claim 5, wherein said slot of said female flap
has a depth that is no more than one half of a width of said head
portion of said male flap.
8. The container of claim 1, wherein said sheet has one or more
intermediate flaps each hingedly connected to one of said panels,
each of said intermediate flaps interposed between one of said male
flaps and one of said female flaps.
9. The container of claim 8, wherein said panels having
intermediate flaps connected thereto have a first length, said
panels having male flaps and female flaps connected thereto have a
second length, and said first length is less than said second
length by an offset amount that is substantially the same as a
thickness of said sheet, wherein said male flaps and said female
flaps can be folded over said intermediate flaps in a generally
flat arrangement.
10. A container, comprising: a) a sheet of material having a
plurality of panels hingedly connected together and foldable into a
polygonal shape, at least one of said panels having a panel opening
defined therein and a panel handle portion adjacent said opening;
b) a lid having a lid panel and at least one lid flap hingedly
connected thereto, wherein said lid panel is sized to be received
within said polygonal folded sheet; c) said lid flap having a first
section hingedly connected to said lid panel, said first section
having a lid opening defined therein and a lid handle portion
adjacent said opening, wherein said lid opening can be aligned with
said panel opening and said lid handle portion can be aligned with
said panel handle portion; and d) said lid flap having an end
section hingedly connected to said first section, said end section
having a main portion and at least one locking tab extending
therefrom and hingedly connected thereto, wherein said end section
can be extended through said panel opening and said lid opening
only when said locking tab is folded over said main portion.
11. The container of claim 10, wherein said at least one lid flap
comprises four lid flaps.
12. The container of claim 10, wherein said at least one lid panel
has an octagonal shape.
13. The container of claim 10, wherein said lid opening has a width
and said main portion of said lid end section has a width that is
substantially the same as or less than said width of said lid
opening.
14. The container of claim 10, wherein said lid opening has a
length and said main portion of said lid end section has a length
that is substantially the same as or less than said length of said
lid opening.
15. The container of claim 10, wherein: a) said sheet has a
thickness and said lid has a thickness; b) said panel handle
portion has a width and said lid handle portion has a width that is
substantially the same as said width of said panel handle portion;
c) said lip flap has a second section hingedly connected to said
first section, said second section having a width that is
substantially the same as said thickness of said sheet; d) said lip
flap has a third section hingedly connected to said second section,
said third section having a width that is substantially the same as
said width of said lid handle portion; and e) said lip flap has a
fourth section hingedly connected to said third section, said
fourth section having a width that is substantially the same as
said thickness of said sheet and said thickness of said lip
combined; f) such that said end section is hingedly connected to
said fourth section.
16. A container, comprising: a) a sheet of material having eight
panels hingedly connected together and foldable into an octagonal
shape, four of said panels having a panel opening defined therein
and a panel handle portion adjacent said opening, wherein said
sheet has a thickness and said panel handle portion has a width; b)
said sheet having two male flaps each hingedly connected to at
least one of said panels, each of said male flaps having a head
portion and a neck portion between said head portion and said
panel; c) said sheet having two female flaps each hingedly
connected to at least one of said panels, each of said female flaps
having a semi-octagonal shape with an end and two slots defined in
said end, each of said slots having a depth that is at least one
half of a width of said neck portion of said male flap and no more
than one half of a width of said head portion of said male flap; d)
wherein said male flaps and said female flaps are alternately
arranged so that one of said male flaps is disposed between said
two female flaps, and said male flaps and said female flaps extend
from alternate panels so that when said panels are folded into said
octagonal shape then said male flaps are oppositely arranged and
said female flaps are oppositely arranged; e) wherein said male
flaps and said female flaps are capable of being folded to form a
container bottom with each said male flap neck extending through at
least one of said female flap slots; f) said sheet having one or
more intermediate flaps each hingedly connected to one of said
panels, each of said intermediate flaps interposed between one of
said male flaps and one of said female flaps, wherein said
intermediate flaps have a first length, said panels having male
flaps and female flaps connected thereto have a second length, and
said first length is less than said second length by an offset
amount that is substantially the same as said thickness of said
sheet, wherein said male flaps and said female flaps can be folded
over said intermediate flaps in a generally flat arrangement; g) a
lid having a lid panel and four lid flaps hingedly connected
thereto, wherein said lid panel has an octagonal shape and is sized
to be received within said octagonal folded sheet, wherein said lid
has a thickness; h) each of said lid flaps having a first section
hingedly connected to said lid panel, said first section having a
lid opening defined therein and a lid handle portion adjacent said
opening, wherein said lid handle portion has a width that is
substantially the same as said width of said panel handle portion,
wherein said lid opening can be aligned with said panel opening and
said lid handle portion can be aligned with said panel handle
portion; i) each of said lid flaps having a second section hingedly
connected to said first section, said second section having a width
that is substantially the same as said thickness of said sheet; j)
each of said lid flaps having a third section hingedly connected to
said second section, said third section having a width that is
substantially the same as said width of said lid handle portion; k)
each of said lid flaps having a fourth section hingedly connected
to said third section, said fourth section having a width that is
substantially the same as said thickness of said sheet and said
thickness of said lip combined; and l) each of said lid flaps
having an end section hingedly connected to said fourth section,
said end section having a main portion and at least one locking tab
extending therefrom and hingedly connected thereto; wherein said
lid opening has a width and said main portion of said lid end
section has a width that is substantially the same as or less than
said width of said lid opening, and said lid opening has a length
and said main portion of said lid end section has a length that is
substantially the same as or less than said length of said lid
opening; wherein said end section can be extended through said
panel opening and said lid opening only when said locking tab is
folded over said main portion.
17. The container of claim 16, wherein said sheet is made of a
corrugated paper board.
18. The container of claim 16, wherein said panels each have a
generally rectangular shape.
19. The container of claim 16, wherein said male flap heads are
disposed generally within said container and said male flap necks
are disposed generally outside said container when said flaps are
folded to form said container bottom.
20. The container of claim 16, wherein said sheet is foldable into
a generally flat arrangement.
21. A container, comprising: a) a sheet of material having a
plurality of panels hingedly connected together and foldable into a
polygonal shape; b) said sheet having at least one male flap
hingedly connected to at least one of said panels, each said male
flap having a head portion and a neck portion disposed between said
head portion and said panel; c) said sheet having at least one
female flap hingedly connected to at least one of said panels, each
said female flap having an end and at least one slot defined in
said end, such that said male flap and said female flap are capable
of being folded to form a container bottom with each said male flap
neck extending through at least one of said female flap slots; and
d) at least one port defined in said material comprising at least
one flap having a hinged side and a cut portion to permit flexing
of the material at the hinged side.
22. The container of claim 21, wherein said at least one port is
defined in said lid.
23. The container of claim 21, wherein said at least one port is
defined in said panel.
24. The container of claim 21, further comprising a frangible
portion defined in at least one flap.
Description
FIELD OF THE INVENTION
[0001] The present invention relates generally to storage and
shipping containers and, more particularly, to a foldable container
formed from one or more foldable panels with foldable flaps.
BRIEF DESCRIPTION OF THE PRIOR ART
[0002] Dry materials such as powdered, granulated, or pelletized
chemicals are commonly used in many industrial and commercial
applications. Such materials are typically shipped to a location
for use and stored on-site until needed. The materials are commonly
stored and shipped in generally rigid containers made of metal.
Metal containers are generally strong and durable to prevent
leakage of the materials, but are generally heavy and thus
difficult to handle and more costly to ship.
[0003] There are known in the art a number of generally
lightweight, foldable containers for general use. U.S. Pat. No.
2,771,851 to Rabby discloses a two-piece container for carrying
heavy loads. The container is hexagonal and has a bottom formed by
flaps that extend downward from the container sides and are
foldable across the open bottom of the container. The container
sides have register slots at lower portions thereof through which
extensions of the bottom flaps can pass. The extensions can be
folded to form saddles to retain the extensions in place.
[0004] U.S. Pat. No. 2,736,485 to Rabby discloses a box with a
readily attachable end closure. A hexagonal container has sides
forming open lower and upper ends with vertical slots in the sides
near the lower and upper ends. A bottom end closure wall and a top
end closure wall each have flaps connected thereto, each flap
having a height sufficient to fold around one of the container ends
and along the outside of the container sides to the slots. Securing
tabs extend from the flaps, and locking tabs extend from the
securing tabs, with the locking tabs and securing tabs sized to
pass through the vertical slots, and the locking tabs lock the flap
in place.
[0005] U.S. Pat. No. 518,898 to Schmidt discloses a tubular paper
box. The box has two opposing hexagonal flaps extending from and
foldable over each box end. Four tetragonal flaps extend from and
can be folded over each end, with two of the tetragonal flaps
positioned on either side of each hexagonal flap.
[0006] U.S. Pat. No. 4,736,885 to Negus, Sr. discloses a polygonal
bulk container having a polygonal bottom panel that is folded over
the open bottom of the container. The polygonal bottom panel is
glued to a reinforcing square tab and a web construction having
tabs and extensions.
[0007] U.S. Pat. No. 1,585,505 to McIndoe discloses a carton
comprising a body part with a foldable top end flap extending from
an upper portion thereof and a foldable bottom end flap extending
from a lower portion thereof. A plurality of projection flaps
extend from the body part and the ends such that they can be folded
over the ends for reinforcement of the carton.
[0008] U.S. Pat. No. 1,497,671 to Crowell discloses a fiber
corrugated board barrel formed from a single piece of corrugated
board folded at creases in the board into a hexagonal or octagonal
shape. The bottom has edge flanges and connector strips for
securing to the barrel.
[0009] U.S. Pat. No. 3,204,849 to Vinney discloses a hexagonal,
corrugated shipping container comprising six panels folded into a
hexagonal shape. Top and bottom closure members have tabs for
securing to the panels.
[0010] Foldable containers provide the advantage of being
lightweight and generally easier and more efficient to handle and
ship, as well as requiring less storage space when in the folded
configuration. None of these foldable containers, however, have
proven entirely suitable for storing and shipping materials such as
powdered chemicals.
[0011] Accordingly, what is needed but not found in the prior art
is a container that is strong and durable to prevent leakage of the
materials, yet lightweight for ease and efficiency in handling and
shipping, and foldable for requiring less storage space when in the
folded configuration.
SUMMARY OF THE INVENTION
[0012] Generally described, the present invention provides a
container having a foldable sheet of material and a lid. The sheet
has a plurality of panels that are hingedly connected together to
permit folding thereof into a polygonal shape. In a preferred
embodiment, eight regular panels and an overlap panel can be
provided that are foldable into an octagonal shape.
[0013] The sheet has at least one and preferably two male flaps
each hingedly connected to at least one of the panels. The male
flaps have a head portion and a neck portion. The sheet also has at
least one and preferably two female flaps each hingedly connected
to at least one of the panels. The female flaps have ends with at
least one and preferably two slots in each of the ends. The sheet
may further have at least one and preferably four intermediate
flaps each hingedly connected to one of the panels interposed
between one of the male flaps and one of the female flaps.
[0014] To form the container, the sheet is folded into the
polygonal shape, with the panels thereby forming the sides of the
container. The intermediate flaps are folded over the open bottom
end of the container, then the female flaps are folded over the
intermediate flaps. The male flaps are then folded over female
flaps and extended through the female flap slots, with the male
flaps head portions interlocked with the slots.
[0015] Turning now to the top of the container, at least one and
preferably four of the panels have a panel opening, with the
portion of the panels between the panel opening and the panel ends
forming a panel handle portion. The lid has a lid panel and at
least one and preferably four lid flaps hingedly connected
thereto.
[0016] Each of the lid flaps has a first section hingedly connected
to the lid panel, with each first section having a lid opening
defined therein and a lid handle portion adjacent the opening.
Second, third, and fourth sections can be provided and hingedly
connected together. Each of the lid flaps has an end section
hingedly connected to the fourth section. Each end section has a
main portion and at least one locking tab hingedly connected
thereto. The end section can be extended through the aligned panel
and lid openings only when the locking tab is folded over the main
portion.
[0017] To assemble the lid onto the folded sheet to form the
container, the lid flaps and the locking tabs are folded up and the
lid panel is inserted into the folded sheet so that the panel and
lid openings are aligned. The second and third sections are then
folded over and down the folded sheet, the end section is inserted
through the aligned openings, and the locking tabs are unfolded.
The lid is now securely attached to the folded sheet to form the
container. The container can be picked up and otherwise handled by
using the aligned handle portions and the aligned openings as
handles.
[0018] These and other objects, features, and advantages of the
present invention are discussed or apparent in the following
detailed description of the invention, in conjunction with the
accompanying drawings and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] The various features and advantages of the invention will be
apparent from the attached drawings, in which like reference
characters designate the same or similar parts throughout the
figures, and in which:
[0020] FIG. 1 is a perspective view of the present container
invention;
[0021] FIG. 2 is a plan view of a sheet of the container in an
unfolded configuration;
[0022] FIGS. 3-6 are bottom plan views showing the folding assembly
of the bottom flaps of the container;
[0023] FIG. 7 is a plan view of a bottom panel of the
container;
[0024] FIG. 8 is a detail perspective view of an opening in a panel
of the sheet of the container;
[0025] FIG. 9 is a top plan view of the lid of the container;
[0026] FIG. 10 is a detail side view of the lid being assembled on
the container;
[0027] FIG. 11 is a cross-section view taken at line A-A of FIG.
10;
[0028] FIG. 12 is a detail side view of the lid fully assembled on
the container; and
[0029] FIG. 13 is a cross-section view taken at line A-A of FIG.
12.
[0030] FIG. 14 is a top plan view of the lid of an alternative
embodiment of the present invention.
[0031] FIG. 15 is a top plan view of the lid of another alternative
embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0032] Referring now to FIG. 1, there is illustrated a first
preferred embodiment of the present invention, referred to
generally as the container 10. The container 10 comprises a
foldable sheet 12 of material and a lid 14. The sheet 12 can be
folded into a polygonal shape or into a generally flat arrangement.
The sheet 12 and lid 14 are preferably made of a corrugated
paperboard, plastic, metal with hinges or portions that can flex,
plastic corrugated, paper, or other generally rigid material known
in the art, preferably light in weight and having sufficient
strength to contain the intended weight of contents. This material
choice may change depending on the nature of the contents. By way
of illustration, but not limitation, the material may be coated,
waterproofed impregnated (e.g., with wax), reinforced, laminated,
or treated to have desired properties. Such properties may include,
but are not limited to, corrosive resistant, flame, heat, moisture
and/or acid/alkaline resistant, cut or puncture resistant, high
burst strength, or the like.
[0033] Referring now to FIG. 2, the sheet 12 has a plurality of
panels that are hingedly connected together to permit folding
thereof. For example, eight regular panels 18, 20, 22, 24, 26, 28,
30, and 32 (referred to hereinafter as the "panels 18-32") and an
overlap panel 16 can be provided that are foldable into an
octagonal shape. It will be understood that other numbers of panels
can be provided for forming different shaped containers as may be
desired in a given application. The sheet panels 18-32 preferably
have a generally rectangular shape, although other regular or
irregular shapes may be used.
[0034] The sheet 12 has at least one and preferably two male flaps
34 and 40 each hingedly connected to at least one of the panels
18-32. The male flaps 34 and 40 have a head portion 36 and 42 and a
neck portion 38 and 44 between the head portion 36 and 42 and the
corresponding panel 18-32. The head portions 36 and 42 have a width
37 and 43, and the neck portions 38 and 44 have a width 35 and
45.
[0035] The sheet 12 also has at least one and preferably two female
flaps 46 and 52 each hingedly connected to at least one of the
panels 18-32. The female flaps 46 and 52 have ends 48 and 54 with
at least one and preferably two slots 50 and 56 defined in each of
the ends 48 and 54. Each of the slots 50 and 56 has a depth that is
at least one half of the width 35 and 45 of the male flap neck
portions 38 and 44 and no more than one half of a width 37 and 43
of the male flap head portions 36 and 42. It will be understood
that the multiple the female flap slots 50 and 56 can all have the
same or different widths, the multiple male flap head portions 36
and 42 can all have the same or different widths, and the multiple
male flap neck portions 38 and 44 can all have the same or
different widths. The female flaps 46 and 52 preferably have a
semi-octagonal shape, that is, about one-half of an octagon,
although other regular or irregular shapes may be provided.
[0036] The male flaps 34 and 40 and the female flaps 46 and 52 are
preferably alternately arranged so that one of the male flaps 34
and 40 is disposed between the two female flaps 46 and 52.
Additionally, the male flaps 34 and 40 and the female flaps 46 and
52 are preferably connected to alternate panels 18-32, so that when
the panels 18-32 are folded into the octagonal shape then the male
flaps 34 and 40 are oppositely arranged from each other and the
female flaps 46 and 52 are oppositely arranged from each other.
[0037] The sheet 12 may further have at least one and preferably
four intermediate flaps 58, 60, 62, and 64 (referred to hereinafter
as the "intermediate flaps 58-64") each hingedly connected to one
of the panels 18-32. Each of the intermediate flaps 58-60 is
preferably interposed between one of the male flaps 34 and 40 and
one of the female flaps 46 and 52. Preferably, the panels 20, 24,
28 and 30 having intermediate flaps 58-64 connected thereto have a
first length 66, the panels 18, 22, 26, and 30 having male flaps 34
and 40 and female flaps 46 and 52 connected thereto have a second
length 67, and the first length 66 is less than the second length
67 by an offset amount 68 that is substantially the same as a
thickness 77 of the sheet 12 (see FIG. 8). Thus, the intermediate
flaps 58-64 can be folded over to provide additional strength for
the container 10, and the male flaps 34 and 40 and the female flaps
46 and 52 can be folded over the intermediate flaps 58-64 in a
generally flat arrangement. It will be understood, however, that
the container 10 can be suitably provided without the intermediate
flaps 58-64.
[0038] Referring now to FIGS. 3-6, there are illustrated the steps
for folding the sheet 12 to form the container 10. As shown in FIG.
3, the sheet 12 is folded so that the overlap panel 16 overlaps
with the end panel 32, the panels 18-32 thereby forming the sides
of the container 10. The overlap flap 16 can be secured to the end
panel 32 by glue or another adherent, staples, or other fasteners
known in the art. It will be understood that the sheet 12 can be
provided without the overlap panel 16 and the end panels can be
fastened together directly, if so desired.
[0039] As shown in FIG. 4, the intermediate flaps 58-64 are folded
over the open bottom end of the container 10. As shown in FIG. 5,
the female flaps 46 and 52 are then folded over the intermediate
flaps 58-64. As shown in FIG. 6, the male flaps 34 and 40 are then
folded over female flaps 46 and 52 and extended through the female
flap slots 50 and 56, with the male flaps head portions interlocked
with the slots. The male flap heads 36 and 42 are thus disposed
generally within the container 10 and the male flap necks 38 and 44
are disposed generally outside the container 10. The intermediate
flaps 58-64, male flaps 34 and 40, and female flaps 46 and 52 are
thus foldable and interlockable to form a container bottom 57 (see
FIG. 1). Referring to FIG. 7, a bottom panel insert 69 may be
inserted into the container 10 and disposed above the folded
intermediate flaps 58-64, male flaps 34 and 40, and female flaps 46
and 52 for providing added strength.
[0040] Turning now to the top of the container 10, and referring
now to FIG. 8, at least one and preferably four of the panels 18-32
have a panel opening 70 defined therein. The portion of the panels
18-32 between the panel opening 70 and the panel ends 74 forms a
panel handle portion 73 having a width 72. The panel openings 70
may be provided with foldable panel opening flaps 76, as may be
desired.
[0041] Referring now to FIG. 9, the lid 14 has a lid panel 75 and
at least one lid flap 78 hingedly connected thereto. The number of
lid flaps 78 may correspond to the number of panel openings 70, so,
for example, four lid flaps 78 may be provided. The lid 14 has a
thickness 79 (see FIG. 10), and the lid panel 75 is sized and
shaped to be received within the folded sheet 12. Thus, the lid
panel 75 may have a shape corresponding to the shape of the folded
sheet 12, so, for example, the lid panel 75 may have an octagonal
shape.
[0042] Each of the lid flaps 78 has a first section 80 hingedly
connected to the lid panel 75. Each first section 80 has a lid
opening 82 defined therein and a lid handle portion 87 adjacent the
opening 82. Each lid opening 82 has a length 84 and a width 85.
Each lid handle portion 87 has a width 86 that is substantially the
same as the width 72 of the panel handle portion 87, wherein the
lid opening 70 can be aligned with the panel opening 82 and the lid
handle portion 87 can be aligned with the panel handle portion
87.
[0043] Each of the lid flaps 78 has a second section 88 hingedly
connected to the first section 80, with the second section 88
having a width 90 that is preferably substantially the same as the
sheet thickness 77. Each of the lid flaps 78 has a third section 92
hingedly connected to the second section 88, with the third section
92 having a width 94 that is preferably substantially the same as
the width 79 of the lid handle portion 87. Each of the lid flaps 78
has a fourth section 96 hingedly connected to the third section 92,
with the fourth section 96 having a width 98 that is preferably
substantially the same as the sheet thickness 77 and the lid
thickness 79 combined.
[0044] Each of the lid flaps 78 has an end section 100 hingedly
connected to the fourth section 96. Each end section 100 has a main
portion 102 and at least one locking tab 104 hingedly connected
thereto. Each main portion 102 of the lid end section 100 has a
length 106 that is substantially the same as or less than the
length 84 of the lid opening 82, and a width 108 that is
substantially the same as or less than the width 85 of the lid
opening 82, so that the end section 100 can be extended through the
panel opening 70 and the lid opening 82 only when the locking tab
104 is folded over the main portion 102.
[0045] Referring now to FIGS. 10-12, there are illustrated the
steps for folding and assembling the lid 14 onto the folded sheet
12 to form the container 10. As shown in FIGS. 10 and 11, the lid
flaps 78 and the locking tabs 104 are folded up and the lid panel
75 is inserted into the folded sheet 12 so that the panel openings
70 and the lid openings 82 are aligned. As shown in FIGS. 12 and
13, the second section 88 and the third section 92 are then folded
over and down the folded sheet 12, the end section is inserted
through the aligned openings 70 and 82, and the locking tabs 104
are unfolded.
[0046] The lid 14 is now securely attached to the folded sheet 12
to form the container 10. The container 10 can be picked up and
otherwise handled by using the aligned handle portions 73 and 87
and the aligned openings 70 and 82 as handles. The container 10 is
thereby strong and durable to prevent leakage of the materials, yet
lightweight for ease and efficiency in handling and shipping, and
foldable for requiring less storage space when in the folded
configuration.
[0047] It will be understood that the container 10 can be provided
with the bottom 57 described herein and another lid, with the lid
14 described herein and another bottom, or with both the lid 14 and
the bottom 57. It will be further understood that the lid 14
arrangement can be used as a bottom, and the bottom arrangement can
be used as a lid.
[0048] In an alternative embodiment, shown in FIG. 14, there is an
access port 200 in the lid 14 for providing access to the contents
without having to remove the lid 14. The access port 200 comprises
a first flap 202 and a second flap 204. Sides 206 and 208 are not
cut all the way through to provide a hinge to each flap. The
remaining sides are cut. The center line 210 is cut and nicked to
provide a frangible line that can be broken when access is desired.
Alternatively, the sides 206 and 208 can be scored to create more
flexible hinges. Variations on this access port 200 are
contemplated as being within the scope of the present invention;
for example, the shape of the port 200 can be square, hexagonal,
octagonal or other shape. There can also be more than one port 200
on the lid 14 or the port(s) can be cut in the bottom panel 69. The
port 200 can alternatively comprise a single flap with one side
being hinged and the remaining sides being cut and/or nicked.
Optionally, a notch 210 can be cut and/or nicked in at least one
flap to facilitate the user opening the flap 200 with one's fingers
or an implement. The user can punch out the notch 210 and lift the
flap(s).
[0049] Alternatively, at least one port 200 can be created in one
or more of the panels 18 et seq. For example, a port 200 can be
created in a panel 18 at the bottom so that access to fluids within
the container can be obtained. Any number of ports 200 can be
created depending on the needs of the user of the container of the
present invention.
[0050] Also, a port 300, as shown in FIG. 15, can comprise more
than two flaps, for example, but not by way of limitation, there
can be three or more flaps 302, defined in the lid 14 (or one or
more panels 18 et seq.) with appropriate hinged sides 304 and cut
(and/or nicked) portions 306.
[0051] The present invention presents several distinct advantages
over the prior art. One advantage of the present invention is the
lower weight of the container (compared to conventional drums)
while maintaining desirable strength properties. The low tare
weight translates into lower shipping costs. Fiber drums must be
shipped set up. Approximately 320 standard fiber drums can be
shipped in a typical truck. Since the container of the present
invention can be broken down and stored flat, it takes up far less
space than conventional drum containers and therefore permits more
units (in the range of about 4,500) to be stored or shipped in a
given volume. This translates into far greater transporting
efficiency and shipping cost reduction. The container of the
present invention is recyclable. Currently available drums are
typically of fiber or metal construction, which are hard to dispose
of. The shape of the container of the present invention (octagonal
in a preferred embodiment) allows a handler to roll it on the floor
(typically where the user tips the container at an angle and uses
the handles for manipulating it), similar to a fiber drum. The
container of the present invention has a geometric axial cross
section with sides preferably angled at more than 90.degree.,
bulging is reduced when the container is filled.
[0052] While the invention has been described in connection with
certain preferred embodiments, it is not intended to limit the
scope of the invention to the particular forms set forth, but, on
the contrary, it is intended to cover such alternatives,
modifications, and equivalents as may be included within the true
spirit and scope of the invention as defined by the appended
claims. The terms "a," "an," and "one" as used herein are not
intended to mean only "one," but may also mean a number greater
than "one." Any patents, applications or publications referred to
herein are hereby incorporated by reference in their entirety.
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