INTERMEDIATE BULK CONTAINER (IBC) AND ASSOCIATED PALLET

Abstract

An intermediate bulk container system includes a molded bottle and a pallet. The molded bottle includes a bottom wall and a top wall opposite the bottom wall. A plurality of support columns extend vertically from the bottom wall and define a column thickness. A plurality of sidewalls extending vertically between the bottom wall and the top wall and horizontally between the support columns. A stiffening protrusion is defined on at least a pair of the sidewalls.

Description

BACKGROUND

An intermediate bulk container (IBC) system may facilitate the transport, storage and dispensing of bulk materials such as liquids and free-flowing powdered materials. Many IBCs are constructed with a molded bottle with a storage capacity of about 1000 liters (265 gallons) or more. The molded bottles may exhibit a generally cubic shape to permit stacking and closely packing several IBCs together, for example, on a flatbed truck. Often a pallet is provided to facilitate handling of the IBCs with a forklift, pallet jack or other heavy equipment.

To alleviate the stresses of the enclosed materials and from the weight of IBCs stacked above, some IBCs include a metallic reinforcement structure around the molded bottles. These reinforcement structures, however, add expense and may not always prevent cracking and deformation of the molded bottle. Cracking may lead to a loss of materials, which can be hazardous and further contribute to the expense. Any undue deformation of the bottles can frustrate close packing efforts and cause damage to the IBCs while handling in confined spaces. An IBC system is needed with a molded bottle that has sufficient strength to permit stacking and handling of the IBCs without compromising the internal storage volume available for bulk materials.

SUMMARY OF DISCLOSURE

Various details of the present disclosure are hereinafter summarized to provide a basic understanding. This summary is not an extensive overview of the disclosure and is neither intended to identify certain elements of the disclosure, nor to delineate the scope thereof. Rather, the primary purpose of this summary is to present some concepts of the disclosure in a simplified form prior to the more detailed description that is presented hereinafter.

The present disclosure generally relates to an IBC system having a molded bottle. The bottle includes vertical columns and sidewalls extending between the vertical columns. Stiffening protrusions may be provided on one or more of the sidewalls, such as on a right side wall and a left sidewall. Also, a gusset may be formed on a top wall of the molded bottle. The stiffening protrusions on the sidewalls may have a generally rectangular shape in vertical and horizontal directions, which distributes outwardly directed forces across the rectangular shape, and inhibits bowing or flexing of the sidewalls.

In accordance with a further aspect of the present disclosure, an intermediate bulk container system includes a molded bottle and a pallet supporting the bottom wall of the molded bottle. The molded bottle includes a top wall, a bottom wall, a plurality of sidewalls extending between the top wall and bottom walls and a plurality of support columns extending vertically from the bottom wall. Stiffening protrusions may be provided on one or more of the sidewalls, such as on a right side wall and a left sidewall. Also, a gusset may be formed on a top wall of the molded bottle.

According to an embodiment consistent with the present disclosure, a molded bottle for an intermediate bulk container system comprises a bottom wall, a top wall opposite the bottom wall, a plurality of columns extending vertically from the bottom wall, and a plurality of sidewalls extending vertically between the bottom wall and the top wall and horizontally between the plurality of columns, each of the plurality of columns extending vertically further than the plurality of sidewalls, wherein the plurality of sidewalls comprises a front sidewall, a rear sidewall opposite the front sidewall, a right sidewall extending horizontally between front sidewall and the rear sidewall, and a left sidewall opposite the right sidewall and extending horizontally between front sidewall and the rear sidewall, and wherein the left sidewall and the right sidewall each comprise a stiffening protrusion, the stiffening protrusion having an upper end and extending vertically upward from the bottom wall to the upper end, the upper end being vertically below the top wall such that the stiffening protrusion terminates before the top wall.

In another embodiment, an intermediate bulk container system comprises a molded bottle including a top wall, a bottom wall, a plurality of sidewalls extending between the top wall and bottom walls, and a plurality of support columns extending vertically from the bottom wall, wherein the plurality of sidewalls comprises a front sidewall, a rear sidewall opposite the front sidewall, a right sidewall extending horizontally between front sidewall and the rear sidewall, and a left sidewall opposite the right sidewall and extending horizontally between front sidewall and the rear sidewall, and the left sidewall and the right sidewall each comprise a stiffening protrusion, the stiffening protrusion having an upper end and extending vertically upward from the bottom wall to the upper end, the upper end being vertically below the top wall such that the stiffening protrusion terminates before the top wall; and a pallet supporting the bottom wall of the molded bottle.

Any combinations of the various embodiments and implementations disclosed herein can be used in a further embodiment, consistent with the disclosure. These and other aspects and features can be appreciated from the following description of certain embodiments presented herein in accordance with the disclosure and the accompanying drawings and claims.

BRIEF DESCRIPTION OF THE DRAWINGS

The following figures are included to illustrate certain aspects of the embodiments, and should not be viewed as exclusive embodiments. The subject matter disclosed is capable of considerable modifications, alterations, combinations, and equivalents in form and function, as will occur to those skilled in the art and having the benefit of this disclosure.

FIG. 1A is an upper perspective view, with parts separated, of an IBC system, in accordance with one or more embodiments of the present disclosure, illustrating an upper side of the IBC system.

FIG. 1B is a bottom perspective view of the IBC system of FIG. 1, illustrating an underside of the IBC system.

FIG. 2A is an upper right perspective view of the molded bottle of the IBC system of FIGS. 1A and 1B from the right side.

FIG. 2B is an upper left perspective view of the molded bottle of the IBC system of FIGS. 1A and 1B from the left side.

FIG. 2C is a cross-sectional side view of the molded bottle illustrating a vertical cross-section of the molded bottle.

FIG. 3A is a perspective view of the pallet of the IBC system of FIG. 1.

FIG. 3B is a perspective view of the pallet of the IBC system of FIG. 1 illustrating an underside of the pallet.

FIG. 4 is a perspective view of two IBC systems stacked vertically.

DETAILED DESCRIPTION

A more complete understanding of the components, processes and apparatuses disclosed herein can be obtained by reference to the accompanying drawings. These figures are merely schematic representations based on convenience and the ease of demonstrating the present disclosure and are therefore not intended to indicate relative size and dimensions of the devices or components thereof and/or to define or limit the scope of the exemplary embodiments.

Although specific terms are used in the following description for the sake of clarity, these terms are intended to refer only to the particular structure of the embodiments selected for illustration in the drawings and are not intended to define or limit the scope of the disclosure. In the drawings and the following description below, it is to be understood that like numeric designations refer to components of like function.

The singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise.

As used herein, the terms “generally” and “substantially” are intended to encompass structural or numeral modification which do not significantly affect the purpose of the element or number modified by such term.

The terms “about” and “approximately” can be used to include any numerical value that can vary without changing the basic function of that value. When used with a range, “about” and “approximately” also disclose the range defined by the absolute values of the two endpoints, e.g. “about 2 to about 4” also discloses the range “from 2 to 4.” Generally, the terms “about” and “approximately” may refer to plus or minus 10% of the indicated number.

Exemplary embodiments of the present disclosure relate to an IBC system having a molded bottle for a given volumetric capacity for bulk materials. The molded bottle of the IBC system may have various features formed on its various sidewalls to stiffen and bolster support of the molded bottle when bulk material is contained therein, so as to inhibit undesirable bowing or flexing. In embodiments, stiffening protrusions are formed on at least a pair of the sidewalls. In embodiments, a gusset is formed on a top wall of the molded bottle. A pallet of the IBC system facilitates handling of the IBC system with a forklift.

Referring now to FIGS. 1A and 1B, there is shown an exemplary embodiment of an IBC system 100 in accordance with the present disclosure. The IBC system 100 (hereinafter, the system 100) generally includes a molded bottle 102, a pallet 104, and connectors 106 for securing the molded bottle 102 to the pallet 104. Each of the molded bottle 102, the pallet 104 and the connectors 106 may be constructed of thermoplastic polymers, such as polyethylene, with plastic molding techniques including injection molding, blow molding and rotational molding. As shown, the system 100 also includes a fill cap 120, which may be selectively attached to the molded bottle 102 to facilitate filling the molded bottle 102 with bulk material, and an accessory fitting 124 that may be selectively installed or uninstalled to provide access to an interior of the molded bottle 102 as desired. In addition, the system 100 may include a discharge valve 128 that allows an operator to selectively start and stop the flow of material from the molded bottle 102, and the system 100 may further include a dust cover 129 that may be fitted over the discharge valve 128 to inhibit dirt and debris from accessing the discharge valve 128.

The molded bottle 102 may have an interior capacity of varying volume. In embodiments, the molded bottle 102 includes an interior capacity of 275 gallons or more. As shown, the molded bottle 102 includes a plurality of support columns 108a, 108b, 108c, 108d (collectively or individually, support columns 108) and a plurality of sidewalls extending between the support columns 108. Also, the molded bottle 102 includes a front sidewall 110, a rear sidewall 111, a right sidewall 112, and a left sidewall 113 extending between the support columns 108. In particular, the front sidewall 110 extends horizontally between support column 108a and support column 108b, the rear sidewall 111 extends horizontally between support column 108c and support column 108d, the right sidewall 112 extends horizontally between support column 108b and support column 108c, and the left sidewall 113 extends horizontally between support column 108a and support column 108d. Thus, support column 108a may be referred to as a front-left support column, support column 108b may be referred to as a front-right support column, support column 108c may be referred to as a rear-right support column, and support column 108d may be referred to as a rear-left support column. The front sidewall 110, the rear sidewall 111, the right sidewall 112, and the left sidewall 113 may collectively be referred to as the “sidewalls 110-113.”

The molded bottle 102 also includes a top wall 114 and a bottom wall 115 opposite the top wall 114. The top wall 114 and the bottom wall 115 extend between the sidewalls 110-113 and, together with the support columns 108, enclose an interior volume of the molded bottle 102. As described in greater detail below, the support columns 108 may have a different material thickness or a same material thickness as compared to than the sidewalls 110-113 and/or the top and bottom walls 114, 115. Thus, the sidewalls 110-113, the top and bottom walls 114-115, and the support columns 108 may all have uniform wall thickness.

The top wall 114 includes a threaded fill opening 118 to which the fill cap 120 may be attached. The fill cap 120 may be a standard 6 or 9 inch IBC fill cap as recognized in the art. An auxiliary port 122 is defined in the top wall 114, which permits, for example, accessories to be attached to the molded bottle 102, additives to be poured into the interior of the molded bottle 102, or for collecting fluid samples from the molded bottle 102. The accessory fitting 124 may be received within the auxiliary port 122 when the auxiliary port 122 is not in use. The front sidewall 110 includes a discharge port 126 through which fluids and flowable solids (e.g., grains or powders) may be drained. The discharge valve 128 may be received within the discharge port 126 to permit an operator to selectively start and stop the flow of material through the discharge port 126.

Regarding the pallet 104, the pallet 104 generally includes a front side surface 130, a rear side surface 131 opposite the front side surface 130, a right side surface 132, and a left side surface 133 opposite the right side surface 130 (collectively, the side surfaces 130-133). Also, the pallet 104 generally includes an upper surface 134 and a lower surface 135 that is opposite the upper surface 134, and the side surfaces 130-133 extend between the upper surface 134 and the lower surface 135. In embodiments, the front side surface 130 and the rear side surface may each have a length of about 40 inches, while the left side surface 133 and the right side surface 132 may each have a length of about 48 inches, such that the pallet 104 defines a standard 40 inch by 48 inch footprint of the IBC systems 100. In other embodiments, larger or smaller footprints may be defined.

The upper surface 134 of the pallet 104 includes a pair of inclined pads 138a, 138b, which each slope downward from the right and left surfaces 132, 133 respectively in the direction of arrows 140a, 140b. Also, a trough 142 is defined between the inclined pads 138a, 138b. In particular, the inclined pad 138a is a right inclined pad that slopes downward, as shown by arrow 140a, from the right side surface 132 towards the trough 142, and the inclined pad 138b is a left inclined pad that slopes downward, as shown by arrow 140b, from the left side surface 133 towards the trough 142. The trough 142 slopes downward, from the rear surface 131 towards the front surface 130, in the direction of arrow 144. As described below, with reference to FIG. 1B, the bottom wall 115 of the molded bottle 102 includes a corresponding geometry to facilitate drainage of materials from the molded bottle 102, with the bottom wall 115 of the molded bottle having a corresponding geometry that corresponds with the geometry of the inclined pads 138a, 138b and the trough 142.

Referring now to FIG. 1B, the bottom wall 115 of the molded bottle 102 includes a pair of inclined panels 148a, 148b which each slope downward from the right and left sidewalls 112, 113 respectively in the direction of arrows 150a, 150b. The molded bottle 102 also includes a trough 152 that is defined between the pair of inclined panels 148a, 148b. In particular, the inclined panel 148a is a right inclined panel that slopes downward, as shown by arrow 150a, from the right sidewall 112 towards the trough 152, and the inclined panel 148b is a left inclined panel that slopes downward, as shown by arrow 150b, from the left sidewall 113 towards the trough 152. In embodiments, the inclined panels 148a, 148b are generally flat. The trough 152 slopes downward from the rear sidewall 111 to the discharge port 126 in the direction of arrow 154. The inclined panels 148a, 148b and the trough 152 facilitate complete drainage of molded bottle 102 through the discharge port 126. When the molded bottle 102 is placed on the pallet 104, the inclined panels 148a, 148b are fully supported on the inclined pads 138a, 138b (FIG. 1A). By providing full support of the inclined panels 148a, 148b out to the right and left sidewalls 112, 113, a greater portion of the footprint of the IBC system 100 may be occupied by the interior volume of the molded bottle 102.

A plurality of blind holes 156 are defined in the bottom wall 115 of the molded bottle 102 and a plurality of corresponding through bores 158 extend through the pallet 104. The blind holes 156 align with the through bores 158 defined in the pallet 104 such that the connectors 106 may pass through the through bores 158 and be received in the blind holes 156. In some embodiments, the blind holes 156 and the connectors 106 may be threaded, and in some embodiments the connectors 106 may establish a friction fit with the blind holes 156 to secure the molded bottle 102 to the pallet 104. The bottom wall 115 also includes elongated indentations 160 defined therein. The elongated indentations 160 provide structural reinforcement to the inclined panels 148a, 148b of the bottom wall 115, and may be constructed as kiss-offs. A kiss-off is a bridging structure formed during rotational molding at locations where two mold surfaces come in close proximity, but do not contact one another, wherein the plastic deposited on the two mold surfaces can flow together to create the elongated indentations 160 due to the proximity of the mold surfaces.

Referring now to FIG. 2A, each of the support columns 108 includes an upper end 202a and a bottom end 202b, with the bottom end 202b being substantially coterminous with the bottom wall 115, and with the upper end 202a being located vertically above the top wall 114. As shown, a pallet stacking structure 204 is provided at the upper end 202a of each of the support columns 108. Thus, each of the support columns 108 of the molded bottle 102 extends vertically/upward from the bottom wall 115 to the pallet stacking structure 204 at the upper end 202a of each support column 108. The pallet stacking structures 204 are disposed above the top wall 114 and define the uppermost surfaces of the molded bottle 102. The pallet stacking structures 204 are arranged to securely engage the pallet 104 of the IBC system 100 to facilitate stacking IBC systems 100 on top of one another (see FIG. 4). In particular, the pallet stacking structures 204 engage corresponding features of the lower surface 135 of the pallet 104, and thereby inhibit relative sliding between the molded bottle 102 and the pallet 104 that is stacked on top of the molded bottle 102. Also, by supporting an upper IBC system 100 on the pallet stacking structures 204, the weight of the upper IBC system 100 will be transferred through the support columns 108 and the pallet 104.

The pallet stacking structures 204 each include a flat base surface 206 with inner and outer alignment plateaus 208, 210 extending therefrom on inner and outer sides of the flat base surface 206, and with a portion of the flat base surface 206 extending between and separating the inner and outer alignment plateaus 208, 210. The inner alignment plateau 208 is disposed on an inner side of the flat base surface 206 that is closer to the top wall 114, such that the inner alignment plateau 208 is closer to the top wall 114 of the molded bottle 102, and the outer alignment plateau 210 is disposed on an outer side of the flat base surface 206 that is further from the top wall 114 than the inner side of the flat base surface 206, such that the outer alignment plateau 210 is further from the top wall 114 than the inner alignment plateau 208. In embodiments, the inner and outer alignment plateaus 208, 210 extend vertically an equal distance from the flat base surface 206 such that they have a common elevation, and, in such embodiments, that the top surfaces of the inner and outer alignment plateaus 208, 210 may be parallel with each other. The alignment plateaus 208, 210 extend into similarly shaped recesses defined in lower surface 135 (FIG. 3B) of a pallet 104 when the pallet 104 is stacked thereon. As further discussed below, vertical surfaces of the alignment plateaus 208, 210 that face each other are configured to receive a portion of the pallet 104 (i.e., an anti-teeter bar 312) to inhibit relative sliding of the pallet 104 on the molded bottle 102, as the vertical surfaces of the alignment plateaus 208, 210 would engage a side of such anti-teeter bar 312 if the pallet 104 attempted to slide. A protrusion 212 of the pallet stacking structures 204 extends along an outermost sidewall 213 of the respective support column 108, with the outermost sidewall 213 of the front right support column 108b and the rear right support column 108c being oriented similar to the right sidewall 112, and with the outermost sidewall 213 of the front left support column 108a and the rear left support column 108d being oriented similar to the left sidewall 113. The protrusion 212 extends to a greater height above the flat base surface 206 than the alignment plateaus 208, 210 (i.e., the protrusion 212 extends vertically further than the common elevation of the alignment plateaus 208, 210) and may serve to guide a pallet 104 into position as it is being stacked on the pallet stacking structures 204. The protrusion 212 may also engage a corresponding feature within the pallet 104, such that the protrusion 212 operates to contact and bear weight from the pallet 104 (and anything stacked on top of the pallet 104). In addition, the protrusion 212 may help inhibit relative sliding of the pallet 104 on the molded bottle 102. For example, an inner vertical surface of the protrusion 212 may engage a corresponding surface of the pallet 104 (i.e., defined by an indentation 304 in FIGS. 3A-3B) if the pallet 104 is slid, to thereby inhibit relative sliding motion. Thus, the inner and outer alignment plateaus 208, 210, as well as the protrusions 212, may operate to inhibit relative sliding between the molded bottle 102 and the pallet 104 that is stacked on top of the molded bottle 102, and in the illustrated embodiment, these features would inhibit all horizontal sliding of the pallet 104 on the pallet 102 as any one or more of them would be engaged by the pallet 104 when the pallet 104 attempted to slide in any horizontal direction. In embodiments, upper surfaces of the outer alignment plateaus 208, 210 do not contact the lower surface 135 of the pallet 104 when the pallet 104 is stacked on the pallet stacking structures 204, such that just the flat base surface 206 bears the weight and downward force of the items stacked thereon and such that the force is transmitted to the molded bottle 102 via the flat base surface 206 and the protrusion 212, rather than via the outer alignment plateaus 208, 210 which function solely to inhibit relative sliding between the pallet 104 and the molded bottle 102. In embodiments, in addition to resisting sliding, the protrusion 212 also bears the weight and downward force, for example, in embodiments where the indentations 304 are sized so as to create such constant engagement that would permit transmission of downward force form the pallet 104 onto an upper surface of the protrusion 212.

Referring now to FIGS. 2A and 2B, the sidewalls 110-113 may include geometry and/or features formed that stiffen and bolster support of the molded bottle 102 when bulk material is contained therein, so as to inhibit undesirable bowing or flexing of sidewalls 110-113. In the illustrated embodiment, the sidewalls 112, 113 each include a stiffening protrusion 216. The stiffening protrusions 216 each include a lower end 218a and an upper end 218b. The lower end 218a is proximate to the bottom wall 115 of the molded bottle 102 and the protrusion extends vertically upward from the bottom wall 115 towards the upper end 218b and towards the top wall 114. However, the upper end 218b of the stiffening protrusion 216 is located vertically below (lower) than the top wall 114, such that the stiffening protrusion 216 terminates before the top wall 114, thereby defining a gap 219a between the upper end 218b and the top wall 114. Thus, each of the protrusions 216 has a vertical dimension V that is less than a vertical dimension V′ existing between the top wall 214 and the bottom wall 215. Also, each of the protrusions 216 has a width dimension W that is less than a width dimension W′ of the right sidewall 112 and the left sidewall 113, where the width dimension W′ of the right sidewall 112 and the left sidewall 113 is measured between the support columns 108b, 108c bordering the right sidewall 112 and between the support columns 108a, 108d bordering the left sidewall 113, respectively. Each protrusion 216 includes a first edge 221a and a second edge 221b, and the width dimension W is measured between the first and second edges 221a-221b. Also, a gap 219b is defined on the sidewalls 112, 113, between the first and second edges 221a-221b of the protrusion 216 and the support column 108a-108d neighboring the first and second edges 221a-221b. Thus, the protrusion 216 extends horizontally to a lesser extent than which the right sidewall 112 and the left sidewall 113 extend horizontally, such that the gap 219b exists between edges 221a-221b of the protrusion 216 and the support column 108a-108d. In embodiments, the edges 221a-221b are substantially parallel, such that the protrusion is substantially rectangular in shape. In embodiments, the protrusion has a chamfered or sloped portion 223 proximate the lower end 218a, such that the protrusion 216 slopes inward/downward towards the bottom wall 115 and towards an interior cavity of the molded bottle 102. In the illustrated embodiment, the chamfered or sloped portion 223 is slightly curved such that it is bowed outward towards the bottom wall 115, as indicated via line 225. Also in the illustrated embodiment, the edges 221a-221b of the protrusion 216 meet the upper end 218b at curved edges 227. Stated differently, the edges 221a,22b meet or transition into the upper end 218b at the curved edges 227.

In embodiments, the protrusions 216 are provided on the front sidewall 110 and/or on the rear sidewall 111. However, in the illustrated embodiment, the protrusions 216 are not provided on sidewalls 110-111. Rather, in the illustrated embodiment, the front sidewall 110 includes a front curved portion 227 and the rear sidewall 111 includes a rear curved portion 229 (FIG. 2A). The rear curved portion 229 extends vertically, from the bottom wall 115 to the top wall 114, and includes a chamfered upper end 231a proximate the top wall 114 and a chamfered lower end 231b proximate the bottom wall 115, with the chamfered upper end 231a defining a surface that slopes inward and upward towards the upper wall 114 and the chamfered lower end 231b defining a surface that slopes inward and downwards towards the bottom wall 115. The front curved portion 227 extends vertically towards the top wall 114, and includes a chamfered upper end 233a proximate the top wall 114. The front curved portion 227 also includes a curved lower end 233b that conforms with the curvature of a recess 235 formed in the front wall 110 for providing clearance for the discharge port 126 and the discharge valve 128 provided thereon. However, in the illustrated embodiment, the front curved portion 227 does not fully extend to the bottom wall 115, such that a gap 237 is defined between the curved lower end 233b and the bottom wall 115. In other embodiments, however, the curved lower end 233b may extend down to the bottom wall 115, for example, edges 239a-239b of the front curved portion 227 between which the curved lower end 233b extends may extend vertically downward to border the bottom wall 115.

In the illustrated embodiment, the front curved portion 227 and the rear curved portion 229 are curved in the horizontal direction as designated by the curved arrows “H”. In the illustrated embodiment, the front curved portion 227 and the rear curved portion 229 have equal curvature; however, in other embodiments, the front curved portion 227 and the rear curved portion 229 have unequal curvature. In the illustrated embodiment, the curvature of the front curved portion 227 and the rear curved portion 229 is substantially constant between the top wall 114 and the bottom wall 115, but in other embodiments, the curvature of either or both will vary vertically at different vertical elevations.

The top wall 114 includes a concavity 228 surrounding the threaded fill opening 118. The concavity 228 provides clearance for the fill cap 120 when an IBC system 100 is stacked on the molded bottle 102 (see FIG. 4). Also, a gusset 230 is formed on the top wall 114 for providing structural support and rigidity to the molded bottle 102. The concavity 228 is formed in the central part of the gusset 230, about the threaded opening 118, and interconnects the support columns 108 with the top wall 114. As shown in FIG. 2C, an upper surface 232 of the gusset 230 is raised vertically, relative to an upper surface 234 of the concavity 228. A plurality of drain troughs 236 (FIG. 5A) are formed in the top wall 114 and in the gusset 230, each of which extends between the concavity 228 and one of the sidewalls 110-113. As shown, the drain troughs 230 extend downward through the gusset 230 to effectively divide the gusset 230 into four corner components 230a-230d, each of which is associated with a respective one of the support columns 108a-108d. A surface 238 of the drain troughs 236 is offset vertically below the upper surface 234 of the concavity 228 (i.e., the surfaces 238 are oriented at a vertical elevation that is below the surface 234) and the surface 238 of the drain troughs 236 are sloped downward towards the sidewall 110-113 with which they are associated, such that the drain troughs 230 drain liquids and thereby prevent liquids from being captured within the concavity 228 when an IBC system 100 is stacked on the molded bottle 102, as they provide a path to drain the liquids spilled within the concavity 228 away from the concavity 228 and the fill opening 118, and down and over the sidewalls 110-113. As shown in FIG. 2C, the surface 238 of the drain trough 236 extending towards the front wall 110 slopes, from the concavity 228, downward towards the bottom wall 115 and towards the front sidewall 110, to thereby permit fluid to drain away from the concavity 228 through the drain trough 236 and down the front sidewall 110; whereas, the surface 238 of the drain trough 236 extending towards the rear wall 111 slopes, from the concavity 228, downward towards the bottom wall 115 and towards the rear sidewall 111, to thereby permit fluid to drain away from the concavity 228 through the drain trough 236 and down the rear sidewall 111.

Thus, generally surrounding the concavity 228 are the four corner components 230a-230d of the gusset 230, with the first corner component 230a formed on the top wall 114 and extending from the first corner support column 108a towards the concavity 228, the second corner component 230b formed on the top wall 114 and extending from the second corner support column 108b towards the concavity 228, the third corner component 230c formed on the top wall 114 and extending from the third corner support column 108c towards the concavity 228, and the fourth corner component 230d formed on the top wall 114 and extending from the fourth corner support column 108d towards the concavity 228. The four corner components 230a-230d of the gusset 230 help maintain rigidity of the molded bottle 102, for example, when the pallet 104 of the IBC system 100 is stacked on the molded bottle 102 and/or when the pressure of internal materials (liquids) within the molded bottle 102 exerts an outwardly directed force on the sidewalls 110-113. In the illustrated embodiment, gusset 230 does not contact the pallet 104 when stacked on the molded bottle 102, due to the relative vertical elevation of the surface 238; however, in other embodiments, the surface 238 of the gusset 230 is further elevated, vertically, such that it may contact the pallet 104 and thereby provide a bearing surface for the pallet when stacked on the molded bottle 102.

FIG. 2C is a side cross-section of the molded bottle 102 and depicts an interior cavity 250 of the molded bottle 102. As shown, an interior of the bottom wall 115 includes protrusions 240, 242, which correspond to the blind holes 156 and indentations 160 (FIG. 1B) described above

The support columns 108a, 108b, 108c, 108d of the molded bottle 102 may be constructed to define a column thickness that is greater than or equal to a sidewall thickness of sidewalls 110-113. For example, the material forming the support columns 108a, 108b, 108c, 108d may have the column thickness T0 while the material forming the sidewalls 110, 111, 112, 113 may have the sidewall thickness T1, and T0 may be greater than or equal to T1. In some embodiments, the column thickness T0 may be at least or about 15 percent greater than the sidewall thickness T1. In other embodiments, the column thickness T0 may be between about 10 and about 15 percent or between about 15 and about 40 percent greater than the sidewall thickness T1. Rotational molding processes may be defined to permit a greater amount of material to be deposited on mold surfaces forming the support columns 108a, 108b, 108c, 108d than on mold surfaces forming the sidewalls 110, 111, 112, 113. Also, the top and bottom walls 114, 115 of the molded bottle 102 may be constructed with a wall thickness that is the same as the same sidewall thickness T1 or left sidewalls 110-113 and/or the wall thickness TO of the support columns 108a-108d.

Referring to FIGS. 3A and 3B, the pallet 104 may be constructed as a one-piece molded component. The through bores 158 extend through the top surface 134 of the pallet 104 to permit passage of the connectors 106 (FIG. 1B). The through bores 158 are elongated to accommodate any deformations or misalignments that may otherwise frustrate the connection of connectors 106 to molded bottle 102. A stabilizing lug 302 protrudes upward at a periphery of the top surface 134 at the rear surface 131 and abuts the chamfered lower end 231b of the rear curved portion 229 (FIG. 2A) to thereby help secure the molded bottle 102 on the pallet 102. A pair of indentations 304 are defined in the right and left surfaces 132, 133, and are shaped to receive and interlock with the protrusions 212 (FIG. 2A) of the molded bottle 102 therein.

Spaced apart elongated slots 306 extend between the right and left surfaces 132, 133 of the pallet 104 and define entry slots for a forklift or other equipment for handling the IBC systems 100. Similarly, spaced apart elongated slots 308 extend between the front and rear surfaces 130, 131. Vertical openings 310 extend from the top surface 134 to the lower surface 135 and intersect the elongated slots 308. The vertical openings 310 may facilitate molding of anti-teeter bars 312 (FIG. 3B) extending across the elongated slots 308. For example, a first or upper mold portion/piece (i.e., a first mold half) for the pallet 104 may extend into the vertical openings to create a top surface of the anti-teeter bars 312 as well as the top surface 134 of the pallet 104. A second or lower mold portion/piece (i.e., a second mold half) may form the lower surface 135 (FIG. 3B) of the pallet 104 including lower surfaces of the anti-teeter bars 312. In this manner, the pallet 104 may be constructed using only two molds portions/pieces (i.e., a pair of mold halves), which can simplify demolding processes for constructing a pallet with anti-teeter bars 312 formed therein. Thus, the vertical openings 310 provide a means of passing through the pallet 104 to form/mold the anti-teeter bars 312 therein without having to use additional tooling, for example, that may need to access the part from the sides in order to create the anti-teeter bars. Rotational molding techniques may facilitate construction of the pallet 104 with the vertical openings 310 defined therein.

Accordingly, embodiments of the present disclosure also pertain to methods of manufacturing the pallet 104, wherein the method includes molding the top surface 134 of the pallet 104 via a first/upper mold portion/piece and molding the lower surface 135 of the pallet 104 via a second/lower mold portion/piece. In this method, the first/upper mold portion/piece includes protrusions with upper features that form the vertical openings 310 and top surface of the anti-teeter bars 312 (respectively), such that molding the top surface 134 further includes molding the vertical openings 310 (via the protrusion) and (at least) the top surface of the anti-teeter bars 312 (via the upper features). Also in this method, the second/lower mold portion/piece includes lower features that form the lower surface of the anti-teeter bars 312, such that molding the lower surface 135 further includes molding (at least) the lower surface of the anti-teeter bars 312 (via the lower features).

As illustrated in FIG. 3B, the anti-teeter bars 312 extend across the elongated slots 308. The anti-teeter bars 312 are sized and shaped to engage the flat base surface 206 and interlock with (and between) the inner and outer alignment plateaus 208, 210 of the pallet stacking structures 204 (FIG. 2A) to thereby inhibit relative sliding of the pallet 104 on the molded bottle 102. The elongated slots 306, 308 surround a central foundation 314, which may be spaced above the upper surface 232 of the gusset 230 (FIGS. 2B, 2C) of the molded bottle 102 when the pallet 104 is stacked on top of the molded bottle 102. The central foundation 314 includes a generally circular clearance 316 therein to receive the fill opening 118 of the molded bottle 102 and the fill cap 120 when the bottle 102 is stacked below the pallet 104.

Ground supports 320 extend along the right and left surfaces 132, 133. The ground supports 320 may share a common elevation with the anti-teeter bars 312 and the central foundation 314. Ground supports 320 may also share elevation with other portions of the lower surface 135 of the pallet 104, such as central ground supports 321 proximate to the front and rear surfaces 130, 131 of the pallet, as well as corner ground supports 323 at the four corners of the pallet proximate to the anti-teeter bars 312. Each of the corner ground supports 323 is connected to one of the anti-teeter bars 312 and provides a surface that bears against the pallet stacking structures 204 and the flat base surface 206 thereof when the pallet 104 is stacked on top of the molded bottle 102. Together with the anti-teeter bars 312 and the central foundation 314, the ground supports 320, the central ground supports 321, and the corner ground supports 323 may support the pallet 104 when resting on a flat ground surface. However, the ground supports 320 and the central ground supports 321 do not necessarily engage the top wall 114 of a molded bottle 104 when the pallet 104 is stacked upon the molded bottle 102.

Referring now to FIG. 4, a stack 400 of two IBC systems 100 is illustrated. A stack 400 of two IBC systems 100 may readily be loaded for transport, for example within a semi-trailer. In other embodiments (not shown), the IBC systems 100 may be stacked vertically in stacks of three or more IBC systems 100 for storage or other applications.

The pallet 104 of an upper IBC system 100 engages the pallet engaging structures 204 of a molded bottle 102 of a lower IBC system 100. The anti-teeter bars 312 (FIG. 3B) and the corner ground supports 323 bears on the flat base surface 206 of the pallet stacking structures 204 of the support columns 108 when the pallet 104 is stacked on top of the molded bottle 102 of the lower foundation.

Embodiments disclosed herein include:

A. A molded bottle for an intermediate bulk container system, the molded bottle comprising: a bottom wall; a top wall opposite the bottom wall; a plurality of columns extending vertically from the bottom wall; and a plurality of sidewalls extending vertically between the bottom wall and the top wall and horizontally between the plurality of columns, each of the plurality of columns extending vertically further than the plurality of sidewalls, wherein the plurality of sidewalls comprises a front sidewall, a rear sidewall opposite the front sidewall, a right sidewall extending horizontally between front sidewall and the rear sidewall, and a left sidewall opposite the right sidewall and extending horizontally between front sidewall and the rear sidewall, and wherein the left sidewall and the right sidewall each comprise a stiffening protrusion, the stiffening protrusion having an upper end and extending vertically upward from the bottom wall to the upper end, the upper end being vertically below the top wall such that the stiffening protrusion terminates before the top wall.

B. An intermediate bulk container system, comprising: a molded bottle including a top wall, a bottom wall, a plurality of sidewalls extending between the top wall and bottom walls, and a plurality of support columns extending vertically from the bottom wall, wherein the plurality of sidewalls comprises a front sidewall, a rear sidewall opposite the front sidewall, a right sidewall extending horizontally between front sidewall and the rear sidewall, and a left sidewall opposite the right sidewall and extending horizontally between front sidewall and the rear sidewall, and the left sidewall and the right sidewall each comprise a stiffening protrusion, the stiffening protrusion having an upper end and extending vertically upward from the bottom wall to the upper end, the upper end being vertically below the top wall such that the stiffening protrusion terminates before the top wall; and a pallet supporting the bottom wall of the molded bottle.

Each of embodiments A and B may have one or more of the following additional elements in any combination: Element 1: wherein each of the plurality of sidewalls includes a sidewall width dimension measured between a pair of the plurality of columns bordering the sidewall, wherein the stiffening protrusion comprises a first edge and a second edge opposite the first edge, the first and second edges extending vertically between the bottom wall and the upper end the stiffening protrusion, the stiffening protrusion defining a stiffening protrusion width dimension measured between the first edge and the second edge, wherein the stiffening protrusion width dimension is less than the sidewall width dimension. Element 2: wherein a gap on the sidewall is defined between the first edge of the stiffening protrusion and a first neighboring one of the plurality of columns and the gap is also defined on the sidewall between the second edge of the stiffening protrusion and a second neighboring one of the plurality of columns. Element 3: further comprising a gusset extending upward from the top wall. Element 4: wherein each respective column of the plurality of support columns includes a pallet stacking structure defined at an upper end thereof. Element 5: wherein the pallet stacking structure comprises a flat base surface, an inner alignment plateau, and an outer alignment plateau, the inner alignment plateau and the outer alignment plateau being disposed on the flat base surface and extending vertically upward therefrom, the outer alignment plateau being further from the top wall than the inner alignment plateau, wherein the inner alignment plateau and the outer alignment plateau extend an equal distance from the flat base surface such that they have a common elevation. Element 6: wherein the pallet stacking structure further comprises a protrusion extending vertically upward from the flat base surface, wherein the protrusion extends vertically further than the common elevation of the inner alignment plateau and the outer alignment plateau. Element 7: wherein the pallet stacking structure comprises a flat base surface and a protrusion extending vertically upward therefrom. Element 8: wherein the pallet stacking structure further comprises an inner alignment plateau and an outer alignment plateau, the inner alignment plateau and the outer alignment plateau being disposed on the flat base surface and extending vertically upward therefrom, the outer alignment plateau being further from the top wall than the inner alignment plateau, wherein the inner alignment plateau and the outer alignment plateau extend an equal distance from the flat base surface such that they have a common elevation, and wherein the protrusion extends vertically further than the common elevation of the inner alignment plateau and the outer alignment plateau. Element 9: wherein the bottom wall includes a central trough sloping downward to a discharge port defined in a front sidewall of the plurality of sidewalls, and a pair of generally flat inclined panels, a first of the generally flat inclined panels sloping downward from the right sidewall of the plurality of sidewalls to the central trough and a second of the generally flat inclined panels sloping downward from the left sidewall of the plurality of sidewalls to the central trough. Element 10: wherein the plurality of columns, and the plurality of sidewalls are of uniform wall thickness.

Element 11: wherein the molded bottle and the pallet are each constructed of a molded thermoplastic material. Element 12: wherein each respective column of the plurality of support columns includes a pallet stacking structure defined at an upper end thereof, the pallet stacking structure interlocking with a corresponding geometry defined on a bottom surface of the pallet. Element 13: wherein the pallet stacking structure comprises a flat base surface, an inner alignment plateau, and an outer alignment plateau, the inner alignment plateau and the outer alignment plateau being disposed on the flat base surface and extending vertically upward therefrom, the outer alignment plateau being further from the top wall than the inner alignment plateau, wherein the inner alignment plateau and the outer alignment plateau extend an equal distance from the flat base surface such that they have a common elevation, and wherein the bottom surface of the pallet comprises anti-teeter bar engageable by the inner alignment plateau and the outer alignment plateau. Element 14: wherein the pallet stacking structure further comprises a protrusion extending vertically upward from the flat base surface, wherein the protrusion extends vertically further than the common elevation of the inner alignment plateau and the outer alignment plateau, and wherein the bottom surface of the pallet comprises and indentation engageable with the protrusion. Element 15: wherein the pallet stacking structure comprises a flat base surface and a protrusion extending vertically upward therefrom, and wherein the bottom surface of the pallet comprises and indentation engageable with the protrusion. Element 16: wherein the pallet stacking structure further comprises an inner alignment plateau and an outer alignment plateau, the inner alignment plateau and the outer alignment plateau being disposed on the flat base surface and extending vertically upward therefrom, the outer alignment plateau being further from the top wall than the inner alignment plateau, wherein the inner alignment plateau and the outer alignment plateau extend an equal distance from the flat base surface such that they have a common elevation, and wherein the protrusion extends vertically further than the common elevation of the inner alignment plateau and the outer alignment plateau, and wherein the bottom surface of the pallet comprises anti-teeter bar engageable by the inner alignment plateau and the outer alignment plateau. Element 17: wherein the molded bottle further comprises a gusset extending upward from the top wall. Element 18: wherein an upper surface of the gusset is oriented below a bottom surface of the pallet when the pallet is provided on an upper end of the molded bottle, with a space being defined between the upper surface of the gusset and the bottom surface of the pallet.

To aid the Patent Office and any readers of this application and any resulting patent in interpreting the claims appended hereto, applicants do not intend any of the appended claims or claim elements to invoke 35 U.S.C. 112(f) unless the words “means for” or “step for” are explicitly used in the particular claim.

The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, for example, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “contains”, “containing”, “includes”, “including,” “comprises”, and/or “comprising,” and variations thereof, when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.

Terms of orientation used herein are merely for purposes of convention and referencing and are not to be construed as limiting. However, it is recognized these terms could be used with reference to an operator or user. Accordingly, no limitations are implied or to be inferred. In addition, the use of ordinal numbers (e.g., first, second, third, etc.) is for distinction and not counting. For example, the use of “third” does not imply there must be a corresponding “first” or “second.” Also, if used herein, the terms “coupled” or “coupled to” or “connected” or “connected to” or “attached” or “attached to” may indicate establishing either a direct or indirect connection, and is not limited to either unless expressly referenced as such.

While the disclosure has described several exemplary embodiments, it will be understood by those skilled in the art that various changes can be made, and equivalents can be substituted for elements thereof, without departing from the spirit and scope of the invention. In addition, many modifications will be appreciated by those skilled in the art to adapt a particular instrument, situation, or material to embodiments of the disclosure without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiments disclosed, or to the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims. Moreover, reference in the appended claims to an apparatus or system or a component of an apparatus or system being adapted to, arranged to, capable of, configured to, enabled to, operable to, or operative to perform a particular function encompasses that apparatus, system, or component, whether or not it or that particular function is activated, turned on, or unlocked, as long as that apparatus, system, or component is so adapted, arranged, capable, configured, enabled, operable, or operative.

Claims

1. A molded bottle for an intermediate bulk container system, the molded bottle comprising: a bottom wall;a top wall opposite the bottom wall;a plurality of columns extending vertically from the bottom wall; anda plurality of sidewalls extending vertically between the bottom wall and the top wall and horizontally between the plurality of columns, each of the plurality of columns extending vertically further than the plurality of sidewalls,wherein the plurality of sidewalls comprises a front sidewall, a rear sidewall opposite the front sidewall, a right sidewall extending horizontally between front sidewall and the rear sidewall, and a left sidewall opposite the right sidewall and extending horizontally between front sidewall and the rear sidewall, andwherein the left sidewall and the right sidewall each comprise a stiffening protrusion, the stiffening protrusion having an upper end and extending vertically upward from the bottom wall to the upper end, the upper end being vertically below the top wall such that the stiffening protrusion terminates before the top wall.

2. The molded bottle according to claim 1, wherein each of the plurality of sidewalls includes a sidewall width dimension measured between a pair of the plurality of columns bordering the sidewall, wherein the stiffening protrusion comprises a first edge and a second edge opposite the first edge, the first and second edges extending vertically between the bottom wall and the upper end the stiffening protrusion, the stiffening protrusion defining a stiffening protrusion width dimension measured between the first edge and the second edge, wherein the stiffening protrusion width dimension is less than the sidewall width dimension.

3. The molded bottle according to claim 2, wherein a gap on the sidewall is defined between the first edge of the stiffening protrusion and a first neighboring one of the plurality of columns and the gap is also defined on the sidewall between the second edge of the stiffening protrusion and a second neighboring one of the plurality of columns.

4. The molded bottle of claim 1, further comprising a gusset extending upward from the top wall.

5. The molded bottle according to claim 1, wherein each respective column of the plurality of support columns includes a pallet stacking structure defined at an upper end thereof.

6. The molded bottle according to claim 5, wherein the pallet stacking structure comprises a flat base surface, an inner alignment plateau, and an outer alignment plateau, the inner alignment plateau and the outer alignment plateau being disposed on the flat base surface and extending vertically upward therefrom, the outer alignment plateau being further from the top wall than the inner alignment plateau, wherein the inner alignment plateau and the outer alignment plateau extend an equal distance from the flat base surface such that they have a common elevation.

7. The molded bottle according to claim 6, wherein the pallet stacking structure further comprises a protrusion extending vertically upward from the flat base surface, wherein the protrusion extends vertically further than the common elevation of the inner alignment plateau and the outer alignment plateau.

8. The molded bottle according to claim 5, wherein the pallet stacking structure comprises a flat base surface and a protrusion extending vertically upward therefrom.

9. The molded bottle according to claim 8, wherein the pallet stacking structure further comprises an inner alignment plateau and an outer alignment plateau, the inner alignment plateau and the outer alignment plateau being disposed on the flat base surface and extending vertically upward therefrom, the outer alignment plateau being further from the top wall than the inner alignment plateau, wherein the inner alignment plateau and the outer alignment plateau extend an equal distance from the flat base surface such that they have a common elevation, and wherein the protrusion extends vertically further than the common elevation of the inner alignment plateau and the outer alignment plateau.

10. The molded bottle according to claim 1, wherein the bottom wall includes a central trough sloping downward to a discharge port defined in a front sidewall of the plurality of sidewalls, and a pair of generally flat inclined panels, a first of the generally flat inclined panels sloping downward from the right sidewall of the plurality of sidewalls to the central trough and a second of the generally flat inclined panels sloping downward from the left sidewall of the plurality of sidewalls to the central trough.

11. The molded bottle according to claim 1, wherein the plurality of columns, and the plurality of sidewalls are of uniform wall thickness.

12. An intermediate bulk container system, comprising: a molded bottle including a top wall, a bottom wall, a plurality of sidewalls extending between the top wall and bottom walls, and a plurality of support columns extending vertically from the bottom wall, wherein the plurality of sidewalls comprises a front sidewall, a rear sidewall opposite the front sidewall, a right sidewall extending horizontally between front sidewall and the rear sidewall, and a left sidewall opposite the right sidewall and extending horizontally between front sidewall and the rear sidewall, andthe left sidewall and the right sidewall each comprise a stiffening protrusion, the stiffening protrusion having an upper end and extending vertically upward from the bottom wall to the upper end, the upper end being vertically below the top wall such that the stiffening protrusion terminates before the top wall; anda pallet supporting the bottom wall of the molded bottle.

13. The system according to claim 12, wherein the molded bottle and the pallet are each constructed of a molded thermoplastic material.

14. The system according to claim 12, wherein each respective column of the plurality of support columns includes a pallet stacking structure defined at an upper end thereof, the pallet stacking structure interlocking with a corresponding geometry defined on a bottom surface of the pallet.

15. The system according to claim 14, wherein the pallet stacking structure comprises a flat base surface, an inner alignment plateau, and an outer alignment plateau, the inner alignment plateau and the outer alignment plateau being disposed on the flat base surface and extending vertically upward therefrom, the outer alignment plateau being further from the top wall than the inner alignment plateau, wherein the inner alignment plateau and the outer alignment plateau extend an equal distance from the flat base surface such that they have a common elevation, and wherein the bottom surface of the pallet comprises anti-teeter bar engageable by the inner alignment plateau and the outer alignment plateau.

16. The system according to claim 15, wherein the pallet stacking structure further comprises a protrusion extending vertically upward from the flat base surface, wherein the protrusion extends vertically further than the common elevation of the inner alignment plateau and the outer alignment plateau, and wherein the bottom surface of the pallet comprises and indentation engageable with the protrusion.

17. The system according to claim 14, wherein the pallet stacking structure comprises a flat base surface and a protrusion extending vertically upward therefrom, and wherein the bottom surface of the pallet comprises and indentation engageable with the protrusion.

18. The system according to claim 17, wherein the pallet stacking structure further comprises an inner alignment plateau and an outer alignment plateau, the inner alignment plateau and the outer alignment plateau being disposed on the flat base surface and extending vertically upward therefrom, the outer alignment plateau being further from the top wall than the inner alignment plateau, wherein the inner alignment plateau and the outer alignment plateau extend an equal distance from the flat base surface such that they have a common elevation, and wherein the protrusion extends vertically further than the common elevation of the inner alignment plateau and the outer alignment plateau, and wherein the bottom surface of the pallet comprises anti-teeter bar engageable by the inner alignment plateau and the outer alignment plateau.

19. The system of claim 12, wherein the molded bottle further comprises a gusset extending upward from the top wall.

20. The system of claim 19, wherein an upper surface of the gusset is oriented below a bottom surface of the pallet when the pallet is provided on an upper end of the molded bottle, with a space being defined between the upper surface of the gusset and the bottom surface of the pallet.