This invention relates to the field of packaging, particularly to a container suitable to for transporting non-liquid products.
Granular or powdered materials, like cat litter, pet food and grain are typically manufactured, transported, and dispensed from a variety of containers, including paper and biaxially oriented polypropylene (BOPP) bags, boxes, bag-in-boxes (BIB), pails and buckets. For larger quantities up to 40 to 50 pounds, the containers are typically paper and BOPP bags, BIB's and pails/buckets (four to five gallons).
Paper and BOPP bags are sealed at each end by stitching through crepe tape (one to two inch paper or BOPP strips). The ends of the bags are typically v-shaped, which makes the package difficult to display or store in a vertical position. Additionally, once the package is opened, the contents often spill due to the v-shaped bottom of the bag. Since paper and BOPP bags are not self-supporting, they are usually palletized, transported, shelved and advertised in a horizontal position. The horizontal position allows visibility of only a small portion of the container from the end, reducing visibility of advertisements and product claims and requiring greater storage area (shelf space). Paper and BOPP bags that are in excess of 20 pounds and are difficult to carry and typically do not have a handle.
Another typical package for such products is pails and buckets, which are generally constructed from high density polyethylene (HDPE). Buckets and pails typically have a snap on/off lid comprised of HDPE and a handle made of either HDPE or metal. Both types of handles often have a HDPE cover or grip to provide comfort while carrying the package. Buckets and pails are often difficult to carry due to their diameter, requiring the individual to attempt to carry the container at a position away from their leg at an awkward position. Oftentimes the bucket will hit the individual's leg during transport interfering with walking. The snap on/off lids are often difficult to open and/or close to re-seal. While it is easy to access the material via the snap on/off lid, the product cannot be easily dispensed from the container due to the bulk and weight of the container. Buckets and pails can be recycled due to the fact that they are constructed from HDPE. If the container has a metal handle, it must be separated from the container and the HDPE handle cover must be removed from the handle. During recycling, the bucket/pail is rigid, does not compress and consumes excessive space during transportation and at the recycling facility. Storage and palletizing efficiency is reduced, due to the fact that empty space exists between buckets and pails. Some buckets and pails are square or rectangular shaped to reduce the empty space, but do not completely eliminate the space.
BIB's and boxes for granular and powdered material are constructed of corrugated paper. Boxes or BIB's typically have a top handle made of HDPE or two handles cut into the corrugated paper at the top of each side of the container. Boxes are sealed to prevent the material from leaking from the container, while the BIB utilizes a polyethylene bag to contain the product. Boxes and BIB's are typically sealed at the top by tape. While this type of container provide easy access to the material within, it is difficult to dispense the material from the bulky container. The boxes are also difficult to carry as described above due to the bulky nature container and the location of the handles on the package. The HDPE handle is uncomfortable while carrying the container and the side handles often tear while being carried. Boxes and BIB's are either square or rectangular shaped and eliminate wasted space during transportation. Additionally, boxes and BIB's eliminate wasted space on shelves and the front panel can be utilized for advertising and product claims. While these containers are constructed from recyclable corrugated paper, they are rigid and must be deconstructed prior to recycling. The BIB's and boxes with HDPE handles must be removed prior to recycling. The polypropylene bag in the BIB must be disposed of separately.
What is needed is a container for granular or powdered material that is ergonomic (easy to carry, provides easy access to and allows the product to be dispensed easily), economic (costs less than HDPE containers or corrugated paper), ecologic (uses less material than HDPE or corrugated paper containers, can be re-used and recycled) and efficient (no space between packages during transport, better utilization of shelf space and conformable to the product in the container).
A container typically made of a pliable material such as BOPP (polypropylene film that is extruded and stretched in X and Y directions) that possesses sufficient tensile strength to, for example, pass a standardized drop test with up to 50 pounds of product. The container, when filled, is substantially cuboid (or cube) in shape and has two flaps extending from upper edges of the front and rear panels. The flaps have fold lines such that, the flaps fold together and holes cut in upper regions of the flaps form handles for convenient transportation of the container and contents. Lengthwise across a top panel of the container is an elongated closure device (zipper, Velcro or Ziploc) that opens for accessing the materials stored within and closes to seal the container. The elongated closure device continues at least partially across two triangular side flaps such that, when open, the triangular side flaps serve as pouring spouts. In some embodiments, a side flap retainer is connected between the side flaps to removably hold the side flaps in place against the top of the container and to stow the flaps during filling and transportation.
In one embodiment, a container is disclosed including four connected and substantially rectangular panels including a front panel, rear panel, left panel and right panel. The container is sealed on the bottom by a substantially rectangular bottom section that has four edges. Each edge of the bottom section is connected to a respective bottom edge of a corresponding one of the four substantially rectangular panels. A first flap extends from an upper edge of the front panel and has a first fold line. The first fold line is substantially parallel to the upper edge of the front panel and divides the first flap into an upper first flap and a lower first flap. A second flap extends from an upper edge of the rear panel and has a second fold line. The second fold line is substantially parallel to the upper edge of the rear panel and divides the second flap into an upper second flap and a lower second flap. When the first flap is bent to approximately 90 degrees at the first fold line and the second flap is bent to approximately 90 degrees at the second fold line, the upper first flap abuts the upper second flap. A top section completes and seals the container. Each edge of the top section is connected to one of the upper edge of the front panel, the upper edge of the rear panel and upper edges of each of the left and right panel. The top section, the front panel, the rear panel the left and right panels and the bottom section are for containing a dry material, and when filled, substantially form a cuboid.
In another embodiment, a method of transporting a material is disclosed including inverting a container as previously described so that the bottom section is facing upwardly. The bottom section is bifurcated into a first bottom panel and a second bottom panel and the edge of the first bottom panel closest to the second bottom panel is disengaged with the edge of the second bottom panel closest to the first bottom panel. Next, the container is filled with the material then the edge of the first bottom panel closest to the second bottom panel is affixed to the edge of the second bottom panel closest to the first bottom panel, thereby sealing the container (e.g. by stitching, adhesives, heat-seal, etc.). The container is then inverted such that the first flap and the second flap are upward and picked up and carried by the first flap and the second flap.
In another embodiment, a container for holding, storing and transporting dry materials is disclosed. The container includes four connected and substantially rectangular panels: a front panel, rear panel, left panel and right panel. A substantially rectangular bottom section includes four edges, such that each edge of the bottom section is connected to a respective bottom edge of a corresponding one of the four substantially rectangular panels enclosing a bottom area of the container. A first flap extends from an upper edge of the front panel and has a first fold line. The first fold line is substantially parallel to the upper edge of the front panel and divides the first flap into an upper first flap and a lower first flap. A first handle hold is cut/formed in the upper first flap. A second flap extends from an upper edge of the rear panel and has a second fold line. The second fold line is substantially parallel to the upper edge of the rear panel and divides the second flap into an upper second flap and a lower second flap. A second handle hold is cut/formed in the upper second flap. When the first flap is bent to approximately 90 degrees at the first fold line and the second flap is also bent to approximately 90 degrees at the second fold line, the upper first flap abuts the upper second flap. The container has a top section. Each edge of the top section is connected to one of the upper edges of the front panel, the upper edge of the rear panel and upper edges of each of the left and right panel, thereby closing the container for holding a dry material such that the container substantially forms a cuboid. The top section of the container has a first and second triangular side flap and a side flap retainer. A first edge of the first triangular side flap is connected to the upper edge of the left panel and a first edge of the second triangular side flap is connected to the upper edge of the right panel. A first end of the side flap retainer is interfaced to a vertex of the first triangular side flap and a distal end of the side flap retainer is interfaced to a vertex of the second triangular side flap, thereby urging the vertex of the first triangular side flap towards the vertex of the second triangular side flap and urging the first and second triangular side flaps to lay against the top section. The side flap retainer has a fastener that disengageably connects a first length of the side flap retainer that is interfaced to the vertex of the first triangular side flap from a second length of the side flap container that is interfaced to the vertex of the second triangular side flap. Thereby, when the fastener is disengaged, the first triangular side flap and second triangular side flaps are free to bend outwardly and away from the top section. The top section also includes an elongated closure device running substantially parallel to both the upper edge of the front panel and the upper edge of the rear panel and continuing across a portion of each of the first and second triangular side flaps. The elongated closure device has a closed position in which the container is sealed and an opened position in which access to the material in the container is provided.
The invention can be best understood by those having ordinary skill in the art by reference to the following detailed description when considered in conjunction with the accompanying drawings in which:
Reference will now be made in detail to the presently preferred embodiments of the invention, examples of which are illustrated in the accompanying drawings. Throughout the following detailed description, the same reference numerals refer to the same elements in all figures.
Although the container disclosed is ideal for advertising, transporting, storing and dispensing pet products such as litter (e.g. granular clay) or animal food, the container is not limited to any particular use or contained material. It is anticipated that the disclosed container be used to contain any loose, solid, powdered or granular material, including, but not limited to: cement, pebbles, stones, sand, mulch, softener salt, pool chemicals, laundry detergent, cereal, grain, seed, fertilizer, etc. The disclosed container is also useful for use with many other forms of dry material such as rags, clothing, nails, scrap, etc.
Referring to
It is anticipated that the sides be made of a cloth-like, flexible material that, in some embodiments, has sufficient tensile strength to survive a drop test with up to 50 pounds of material, as will be described providing what is known as soft sides (as opposed to rigid side as would be found with corrugated cardboard box containers, pails or buckets.
Throughout the description and in the figures, the container 10 is shown in a filled configuration or shown as if it were full of a material such as animal litter (e.g. granular clay), water softener salt (pellets or granular), sand, concrete, dry animal feed, seed, fertilizer, etc. As shown in
In
Referring to
In
Additionally, when the fastening mechanism 30/32/34 is open (or at least partially open), the side flaps 20 that are open function as a pour spouts.
The body of the container 10 is preferably made from a polypropylene material. For example, the container is made from polypropylene film that is extruded and stretched in X and Y directions, called Biaxially Oriented Polypropylene (BOPP). This material has increased strength and has been widely used as a package material (e.g. for fresh produce). Biaxially Oriented Polypropylene (BOPP) is easy to coat, print, and laminate. Polypropylene recycles well and, after the contents of the container 10 are depleted, the container 10 collapses, requiring a low amount of space during transportation to incinerators/recycling centers. Furthermore, after depletion of the contents of the container 10, the container 10 is useful for many home/business uses such as trash, leaf collection, etc. Since the container 10 is not destroyed or damages during typical use, the container 10 is refillable and/or fully recyclable and refillable.
It is anticipated that the container 10 be produced in any dimension. In some embodiments, the container 10 is produced in standard width and depth sizes with different height sizes depending upon the volume and weight of the contents 40. By standardizing on a particular width and depth, the same pallet size and storage shelf size works for several different volume/weight containers 10. For example, in a sample embodiment, a container 10 for containing 40 pounds of clay litter measures 11 inches wide, 8 inches deep and 14 inches high. By making 60 pound containers 10 with the same width (11 inches), same depth (8 inches), but different height, 21 inches, the same floor space dimensions, shelf dimensions, and/or pallet dimensions holds the same number of containers 10 in one layer, enabling transitions from one capacity container 10 to another capacity container 10 without changing storage/transportation arrangements. Since the containers 10 stack well, the horizontal space is then used to store/transport more or less containers 10. For example, two layers of 60 pound containers 10 or three layers of 40 pound containers 10.
The fastening mechanism 30/32/34 is any edge coupling fastening mechanism such as the zipper 30/32/34 as shown. Other fastening mechanisms 30/32/34 are envisioned, including, but not limited to, plastic snap seals, plastic slider zippers, hook and loop material, etc. In some embodiments, the fastening mechanism 30/32/34 is a destructive mechanism such that, after opening, there are no resealing capabilities. Examples of such are perforated tear lines, pull strings that break the top surface, etc.
Although it is preferred that the container 10 is made from a polypropylene material, any suitable material is anticipated including, but not limited to, low density polyethylene, canvas, paper, etc. It is anticipated, but not required, that a container 10 made of Polypropylene resin requires less raw material during manufacture that an equivalent volume pail/bucket/jug, resulting in lower cost and less resource usage.
The side flap retainer 22/24/26/28 shown has two resilient cords 22/26, one resilient cord 22 attached to the slider 30 and the other resilient cord 26 attached to an opposing side flap 20. Alternately, it is anticipated that the first resilient cord 22 is attached to the first side flap 20. Ends of the resilient cords 22/26 are preferably equipped with latching mechanism 24/28. Any latching mechanism 24/28 is anticipated, including, but not limited to, snap locks 24/28 (as shown), hooks, a hook and a loop, etc. It is also anticipated that the cords 22 and 26 are less resilient or not resilient (e.g. cotton cord like a shoe string) with or without a latching mechanism 24/28. In examples where there is no latching mechanism 24/28, it is anticipated that the ends of the cords 22/26 be tied together (e.g. slip knot or bowtie).
Referring to
Referring to
Equivalent elements can be substituted for the ones set forth above such that they perform in substantially the same manner in substantially the same way for achieving substantially the same result.
It is believed that the system and method as described and many of its attendant advantages will be understood by the foregoing description. It is also believed that it will be apparent that various changes may be made in the form, construction and arrangement of the components thereof without departing from the scope and spirit of the invention or without sacrificing all of its material advantages. The form herein before described being merely exemplary and explanatory embodiment thereof. It is the intention of the following claims to encompass and include such changes.
This application is a continuation of U.S. patent application Ser. No. 13/546,374, filed Jul. 11, 2012, the disclosure of which is hereby incorporated by reference.
Number | Name | Date | Kind |
---|---|---|---|
2177919 | Vogt | Oct 1939 | A |
2288105 | Plotkin | Jun 1942 | A |
2328798 | Gardner | Sep 1943 | A |
2352503 | Walton | Jun 1944 | A |
2364012 | Walton et al. | Nov 1944 | A |
2514867 | Howard et al. | Jul 1950 | A |
3249286 | Palmer | May 1966 | A |
3255950 | Marcouly et al. | Jun 1966 | A |
3314210 | Jarund | Apr 1967 | A |
4082216 | Clarke | Apr 1978 | A |
4905898 | Wade | Mar 1990 | A |
5228616 | Kjelgaard | Jul 1993 | A |
D451794 | Ichikawa | Dec 2001 | S |
6374579 | Muller | Apr 2002 | B1 |
6676011 | Luu et al. | Jan 2004 | B2 |
7380703 | Ogden | Jun 2008 | B2 |
7389909 | Crosland et al. | Jun 2008 | B2 |
7887473 | Nagata et al. | Feb 2011 | B2 |
D634646 | Belko et al. | Mar 2011 | S |
D643716 | Kozarsky et al. | Aug 2011 | S |
7992739 | Garcia | Aug 2011 | B2 |
D712735 | McCracken et al. | Sep 2014 | S |
20050051573 | Crosland et al. | Mar 2005 | A1 |
20060193541 | Norcom | Aug 2006 | A1 |
20080230406 | Cuomo | Sep 2008 | A1 |
20110017812 | Belko et al. | Jan 2011 | A1 |
20110017814 | Belko et al. | Jan 2011 | A1 |
20110297680 | Howell et al. | Dec 2011 | A1 |
20110301006 | Howell et al. | Dec 2011 | A1 |
20120060449 | Howell et al. | Mar 2012 | A1 |
20120187182 | Howell et al. | Jul 2012 | A1 |
Number | Date | Country | |
---|---|---|---|
20140013716 A1 | Jan 2014 | US |
Number | Date | Country | |
---|---|---|---|
Parent | 13546374 | Jul 2012 | US |
Child | 13614234 | US |