BACKGROUND
Storage containers are widely used in the shipping industry to contain, store, and transport goods. Storage containers come in various sizes and must be both capacious and durable in order to be useful. Bulk storage containers in particular are bulky and heavy. Consequently, these containers take up significant storage space even when empty. In addition, storage containers often are not well suited for storing, transporting, or discharging fluids and semi-fluid contents.
The present invention addresses these and other needs.
SUMMARY OF THE INVENTION
The invention provides, in part, improved collapsible bins for storing goods, such as solids, semi-solids, or fluids. In various embodiments, the bins have a base about the same size as a pallet to facilitate handling and storage. Bins include a plurality of sidewalls (typically four), a cover, and a base. The base includes a floor-mounted sump for discharging the contents of the bin. The bin sidewalls and cover hingably connect to the base, and the sidewalls and cover can collapse and nest inside the base to reduce the storage space consumed by empty bins.
The invention also provides, in part, storage systems that include a collapsible bin and a bag liner (e.g., a bag-in-box) that is configured to discharge bin contents through a sump mounted in the floor of the bin.
In various embodiments, the invention provides a reusable, stackable and collapsible bin for holding contents. The bin can include a base having a top and a bottom and a floor which is attached to the base. The floor can be attached to the top of the base. The bin can include a plurality of (e.g., four) sidewalls having post extensions. A plurality of (e.g., four) posts are attached to the base, and the plurality of sidewalls can be hingably attached to the plurality of posts. A bin cover can be hingably attached to at least one of the plurality of sidewalls. In addition, the floor can include a sump projecting below the floor into the base, the sump defining a cavity and forming an opening for discharging contents of the bin.
In various embodiments, the invention provides a storage system which includes a reusable, stackable and collapsible bin as well as a bag liner disposed in the collapsible bin. The bag liner can be partially or entirely disposed in the interior of the collapsible bin. The bag liner can have sidewalls which are configured to cause the bag liner to assume the shape of the interior of the bin. In addition, the bag liner can include one or more ports, such as, for example, a port mounted on the bag liner and disposed in the opening formed by the sump and/or a port mounted on a top of the bag liner.
Embodiments of the collapsible bin and/or the storage system can include one or more of the following features.
The sump in the floor can be positioned near a periphery of the floor.
The floor of the bin can slope towards the sump to facilitate discharge of bin contents.
The bottom of the base can form a pallet assembly configured to be stackable on a second collapsible bin.
The plurality of sidewalls can be attached to the plurality of posts by hinge pins.
The plurality of sidewalls can be configured to move from a substantially vertical position to a substantially horizontal, stowed position within the periphery of the base.
The plurality of sidewalls can nest within the base when in the stowed position.
The plurality of sidewalls can remain hingably attached to the plurality of posts when in the stowed position.
The collapsible bin in the stowed position can be configured to be stackable on the plurality of posts of a second collapsible bin, the second collapsible bin being in a stowed position.
The collapsible bin and the bag liner each can have four sidewalls.
The bag liner can have dimensions which are larger than the interior dimensions of the collapsible bin.
The bag liner can have a second port mounted on a top of bag liner for providing access to the interior of the bag liner.
BRIEF DESCRIPTION OF DRAWINGS
The figures are not necessarily to scale, emphasis instead generally being placed upon illustrative principles. The figures are to be considered illustrative embodiments in all respects and are not intended to limit the invention, the scope of which is defined only by the claims.
FIG. 1 is a top perspective view of a bin having a side mounted access door, in accordance with an illustrative embodiment.
FIG. 2 is a top view of the bin shown in FIG. 1.
FIG. 3 is a side view of the bin shown in FIG. 1.
FIG. 4 is a front view of the bin shown in FIG. 1.
FIG. 5 is a top perspective view of a bin with the cover open and the access door open, in accordance with an illustrative embodiment.
FIG. 6 is a top view of the bin shown in FIG. 5.
FIG. 7 is a side view of the bin shown in FIG. 5.
FIG. 8 is a perspective view of a bin base, in accordance with an illustrative embodiment.
FIG. 9 is a top view of the base shown in FIG. 8.
FIG. 10 is a side view of the base shown in FIG. 8.
FIG. 11 is a cross-section through plane A-A of the base shown in FIG. 9.
FIG. 12 is a front view of the base shown in FIG. 8.
FIG. 13 is a top perspective view of a collapsed bin, in accordance with an illustrative embodiment.
FIGS. 14-16 are perspective views of a partially erected bin, in accordance with an illustrative embodiment.
FIG. 17 is a perspective view of an erected bin, in accordance with an illustrative embodiment.
FIG. 18 is a top perspective view of a bin having a cover mounted opening, in accordance with an illustrative embodiment.
FIG. 19 is a top view of the bin shown in FIG. 18.
FIG. 20 is a top perspective view of a bin with the cover open and a bag liner in the bin, in accordance with an illustrative embodiment.
FIG. 21 is a top perspective view of a bin with the cover closed and a bag liner in the bin, in accordance with an illustrative embodiment.
FIG. 22 is a bag liner port disposed in a sump opening, in accordance with an illustrative embodiment.
FIG. 23 shows an expanded bag liner, in accordance with an illustrative embodiment of the invention.
FIGS. 24A-B show an unexpanded bag liner, in accordance with an illustrative embodiment of the invention.
DETAILED DESCRIPTION
The invention provides, in part, bins for storage and transportation of goods. FIG. 1 shows a top perspective view of a bin 10 having a plurality of sidewalls 14, a base 18, and a cover 30, in accordance with an illustrative embodiment. One sidewall of bin 14 can include a movable access door 52 which permits access to the bin's interior. Bin 10 can have any number of sidewalls 14a-n and, therefore, can be any suitable shape. However, four sidewalls 14, yielding a bin with a substantially square or rectangle-shaped footprint, are preferred for ease of manufacture and use. Preferably, the bin is substantially cube- or parallelpiped-shaped. In various embodiments, bin 10 has a width “W” of about 50.5 inches (see FIG. 2), and length “L” of about 42.5 inches (FIG. 2), and a height “H” of about 42.5 inches (see FIG. 3). These dimensions are exemplary and non-limiting, and it will be appreciated that other dimensions can be used in accordance with the invention. Although bin 10 can have a base footprint approximately the same size as a pallet to facilitate handling, it will be appreciated that bin 10 can be scaled to any suitable size. Cover 30 can be a single section (e.g., flap) or it can be multiple sections (e.g., 2 or more pieces), which coordinate to close the top of bin 10. In some embodiments, cover 30 is attached to a sidewall by one or more hinges.
FIG. 2 shows a top perspective view of a bin 10 having two cover sections 30a and 30b, which cooperate to substantially close the top of the bin 10. Where multiple cover sections 30a, 30b are used, each cover section can be secured to different (e.g., a first and a second) sidewalls 14 using separate (e.g., a first and a second) hinges. FIG. 3 shows a side view of bin 10, with sidewall 14 supported by base 18.
FIG. 4 shows a front view of bin 10. As shown in FIG. 4, one or more sidewalls 14 can be releasably secured using, for example, cam lock latches or sliding bolt latches 84, which engage the adjacent sidewalls or posts. Sidewalls that are releasably secured can be opened to provide access to the bin's interior. In a preferred embodiment, each sidewall 14 is hingably attached between two posts 48 by, for example, one or more pins. In addition, one or more sidewalls 14 optionally can include an access door 52 that nests inside the sidewall. Although an access door is shown in the front sidewall in FIG. 4, any sidewall 14 can have an access door. In some embodiments, access door 52 is attached to sidewall 14 by one or more hinges 54 located at the bottom, side, or top of access door 52. Access door 52 can be secured in a closed position using one or more cam lock latches or sliding bolt latches 80 that engage the sidewall. Access door 52 can be any size. For example, in one embodiment, access door 52 is about 21 inches wide and about 16 inches high.
FIG. 5 shows a top perspective view of bin 10, with the cover and access door open, in accordance with an illustrative embodiment. Referring to FIG. 6, which shows a top view of an open bin, bin 10 can include a floor 38 and a floor mounted sump 46, which forms a sump cavity. Sump 46 drops below the floor 38 (see FIG. 7) into the pallet assembly 42 and facilitates discharging of liquid from bin 10 by, for example, gravity flow. Floor 38 can be sloped towards sump 46 to further aid in discharging liquid. For example, in one embodiment, the floor is sloped about 2.5 degrees. Sump 46 can be a single integral piece or it can be formed from several pieces that are joined by, for example, welding. In addition, sump 46 can be integral with or attached to floor 38. In some embodiments, sump 46 is positioned at the periphery of floor 38 and substantially on-center, such that the sump easily can be accessed.
FIG. 8 shows a perspective view of a bin base, in accordance with an illustrative embodiment. As shown in FIG. 8, base 18 can include a pallet assembly 42, floor 38, sump 46, sump cover, and a plurality of posts 48. Pallet assemblies are well known in the art and provide many advantages, including ease of transport, when incorporated into storage and shipping containers. Pallet assembly 42 can include one or more posts 58 that protect sump 46 from damage from forklifts, pallet jacks, or similar devices. In some embodiments, the pallet assembly forms a space 70 about 3.4 inches high (see FIG. 4), although it will be appreciated that other heights can be used.
Posts 48 can be attached to or integral with base 18. In some embodiments, posts 48 are substantially parallel and can be located at each corner of base 18. Posts 48 can be any suitable shape. Referring to FIG. 2, in various embodiments, posts 48 are substantially “L” shaped in cross-section, defining an inside width “IW” of about 48 inches and an inside length “IL” of about 40 inches. Post shape is important for strength and for stacking bins that are erected or collapsed.
FIG. 9 shows a top view of bin base 18, and FIG. 10 shows a side view of bin base 18. FIG. 11 shows a cross-section through plane A-A of FIG. 9. As can be seen in FIG. 11, floor 38 slopes towards sump 46 in this embodiment. FIG. 12 shows a front view of base 18.
Referring to FIG. 13, sidewalls 14 and cover 30 can collapse and nest within base 18 to reduce the amount of storage or cargo space (e.g., floor space or shelf space) occupied by empty bins. When bin 10 is in a stowed configuration, sidewalls 14 remain attached to posts 48 to prevent the stowed sidewalls from sliding off base 18. Preferably, posts 48 protrude above the topmost stowed sidewall 14 and cover 30 to allow stowed collapsible bins 10 to be stacked on top of each other. Preferably, sidewalls 14 and cover 30 fit substantially within the footprint of base 18 to reduce the space occupied by a stowed bin.
In a preferred embodiment, each sidewall 14 is hingably attached to two posts 48 by, for example, hinge pins secured to the outside edges of the sidewalls that engage corresponding mounts (e.g., holes) on the posts. As will be appreciated, hinge pins instead can be secured to the posts 48 and the corresponding mount located on the sidewalls. The hinge pins permit the sidewalls to be moved from an upright, vertical position to a flat, stowed position while remaining attached to bin base 18. In addition, the hinges are positioned such that collapsed sidewalls and attached cover pieces stack on top of one another on base 18, as shown in FIG. 13. In some embodiments, this is accomplished by setting a predetermined order in which the sidewalls are collapsed, and setting the height of each sidewall pivot point accordingly. For example, the first collapsed sidewall can have the lowest pivot point so that it lays flat on floor, the second collapsed sidewall can have a slightly higher pivot point so that the second collapsed sidewall lays flat on the first collapsed sidewall and/or cover piece, and so on.
In some embodiments, during bin assembly, a first long sidewall 14a is moved into an upright position (see FIG. 14). Then, the other long sidewall 14b is moved into an upright position (see FIG. 15). Next, a first short sidewall 14c is moved into an upright position (see FIG. 16). Finally, the other short sidewall 14d is moved into an upright position (see FIG. 17). To collapse the bin, sidewalls 14a-d are lowered in the reverse order.
FIG. 18 shows a top perspective view of a bin having a cover mounted opening, in accordance with an illustrative embodiment. Sidewalls 14 can include or incorporate post extensions 60, which engage posts 48 and provide stability to the bin. In some embodiments, the bin has two long sides and two short sides, and each of sidewalls along the long sides (i.e., the long sidewalls) incorporates two post extensions 60 that engage posts 48 when the long sidewalls are moved into an upright position. In some embodiments, the sidewalls along the short sides of the bin (i.e., the short sidewalls) releasably engage the long sidewalls or the post extensions of the long sidewalls by, for example, cam lock latches or sliding bolt latches 84. The tops of posts 48 can form or include self-centering caps or castings 62 that register in corresponding receptacles in the bottom of post extensions 60 (see FIGS. 8-12). Thus, when long sides are moved into an upright position, post extensions 60 rest on castings 62, which not only assist in aligning posts 48 with sidewall post extensions 60 during bin assembly, but also help to secure long sidewalls in an upright position. In some embodiments, the hinge pins have sufficient play or travel to allow the bottom of post extensions to clear castings 62 as the sidewalls are moved between upright and collapsed positions. In addition, the tops of post extensions 60 can form or include self-centering caps or castings 64 that engage corresponding receptacles on the bases of other bins to assist in stacking assembled bins. Base 18 also can include hinge plates 50 configured to interlock with, and therefore support, erected sidewalls.
Referring again to FIG. 18, a cover 30 includes two sections 30a and 30b which close the top of bin 10. One or more cover sections can include an opening 104 to permit access to the bin's interior. The opening can be concealed by a lockable access door to deter tampering with bin contents. In some embodiments, opening 104 is covered by sliding retainer 110. In addition, sliding retainer 110 can secure a bin liner or bin liner port to the bin cover. The structural components of the cover can be recessed in cover 30 for better collapsibility when the bin is in a stowed configuration.
In some embodiments, a first cover section 30a can be larger than a second section 30b. In addition, a first cover section 30a can overlap a second cover section 30b, thereby securing the second cover section in the closed position. First 30a and second 30b cover sections are configured to interlock with each other and/or one or more sidewalls to add rigidity and strength to the bin. Either or both cover sections can be secured to bin sidewalls 14 by, for example, spring loaded bolt latches 118, 120. In some embodiments, cover 30 includes at its periphery one or more studs that protrude from the interior facing surface of the cover and engage a sidewall 14 when cover 30 is in the closed position, thereby adding structural rigidity. In addition, the periphery of cover 30 can include an extrusion or an attached member that interlocks with a sidewall to add further rigidity to the closed bin.
In various embodiments, the base (including posts, floor, sump, and pallet assembly), sidewall, and cover of bin 10 are made of aluminum. However, as will be appreciated, any suitable metal or other materials can be used to manufacture the bin components.
In various embodiments, sidewalls 14, cover 30, and floor 38 are composed of a plurality of elongate extruded members for enhanced rigidity. However, sheet material also can be used for all or a portion of the sidewalls, cover, or floor. As noted above, one or more sidewalls 14 can incorporate a vertical post extension 60. The elongate members and post extensions can be secured together by any suitable means, such as, for example, by welding. The extruded members making up the floor can have a trapezoidal longitudinal cross-section (e.g., a first end of the members have a thicker cross section than a second end of the members) to facilitate manufacturing and installing a sloped floor. To add further strength, the extruded members can be joined together by tongue and groove connectors.
In various embodiments, storage systems are provided. These storage systems can include a collapsible bin which has a bag or liner inside the bin (e.g., a bag-in-box). The liner not only can contain the bin's contents (e.g., liquid or other products), but can protect the bin from its contents and also can protect the contents from contamination and from the ambient environment (e.g., moisture). Referring to FIG. 23, in a preferred embodiment, the liner is a plastic gusseted bag 200 having a top 212, a bottom 216, and two gusseted sides 220, which cause the bag to assume a substantially cube or parallelpiped shape when filled. Bag liners can be constructed of multiple (e.g., 2, 3, 4, 5, or more) plastic sheets, which are superimposed in a bonded or non-bonded state for added strength. The bag liner can have or form one or more attachments points, such as a hole or grommet in a fin of the bag liner, by which the bag liner can be secured to and/or suspended in a bin. In some embodiments, the bag liner is sealed, but includes one or more resealable ports that allow access to the interior of the bag liner. For example, the bag liner can have an upper resealable port 204 mounted on or near the top of the bag liner that allows the bag liner to be filled after it is installed in the bin. In addition, the bag liner can have a lower resealable port 208 at or near the bottom of the bag liner for discharging the contents of the bin.
FIGS. 24A-B show an unexpanded bag liner, in accordance with an illustrative embodiment of the invention. In this embodiment, the bag liner has a length 230 of about 90⅛ inches from seam to seam, and a width 234 of about 53 inches from seam to seam. A one inch wide fin 236 can extend around the outside edge of all seams, increasing the overall length 238 to about 92⅛ inches, and the overall width 242 to about 55 inches. These dimensions and the dimensions shown in FIG. 24B are exemplary and non-limiting, and it will be appreciated that other dimensions can be used in accordance with the invention.
FIG. 20 shows a top perspective view of a bin 10 with the cover 30a, 30b open and a bag liner 200 in the bin, in accordance with an illustrative embodiment. The bag liner can be secured to the sidewalls, posts extensions, or cover. In the embodiment shown in FIG. 20, the bag liner includes a resealable port, such as a screw top port. As shown in FIG. 21, the bag liner is configured such that when cover 30a, 30b of bin 10 is closed, a resealable port 204 on the top of bag 200 is disposed through opening 104 in cover section 30a. Opening 104 can be configured to engage and secure resealable port 204 to cover section 30a. In some embodiments, a sliding retainer 110 (see FIG. 19) can be included to further secure resealable port 204 to cover piece 30a.
In some embodiments, the bag liner is configured to discharge the contents of the bag liner (e.g., liquid) through the opening formed by the sump. Referring to FIG. 22, the bag liner is configured such that a lower resealable port 208 is disposed through sump opening 88. In some embodiments, this is accomplished by using a slightly oversized bag liner, i.e., a bag liner that, when filled, has a dimension (e.g., length, width, and/or volume) slightly larger than a dimension of a bin. When an oversized bag liner is filled, there is sufficient slack in the bag material to permit lower resealable port 208 to drop into sump 46. In some embodiments, sump opening 88 is configured to engage and secure resealable port 208. In addition, a cover 92 can be used to protect the lower resealable port 208 and to deter tampering with bin or bag contents. In various embodiments, to minimize the risk of bag liner rupture, the bag liner is configured such that, when contents (e.g., liquid) are placed inside the bag liner, there is no significant gap or airspace between the outside edge of the bag liner and the inside edges and corners of the bin or sump. In other words, the bag liner is fully supported by the bin, thereby reducing the likelihood of bag liner rupture.
The collapsible bins and bin storage systems described herein are capable of meeting applicable intermediate bulk container (IBC) certification standards for storing and transporting liquids. For example, applicable U.S. Department of Transportation and U.N. certifications require containers to pass various tests, which can include drop testing, vibration testing, stack testing, and internal pressure testing.
The use of headings and sections in the application is not meant to limit the invention; each section can apply to any aspect, embodiment, or feature of the invention.
Throughout the application, where compositions are described as having, including, or comprising specific components, or where processes are described as having, including or comprising specific process steps, it is contemplated that compositions of the present teachings also consist essentially of, or consist of, the recited components, and that the processes of the present teachings also consist essentially of, or consist of, the recited process steps.
In the application, where an element or component is said to be included in and/or selected from a list of recited elements or components, it should be understood that the element or component can be any one of the recited elements or components and can be selected from a group consisting of two or more of the recited elements or components. Further, it should be understood that elements and/or features of a composition, an apparatus, or a method described herein can be combined in a variety of ways without departing from the spirit and scope of the present teachings, whether explicit or implicit herein.
The use of the terms “include,” “includes,” “including,” “have,” “has,” or “having” should be generally understood as open-ended and non-limiting unless specifically stated otherwise.
The use of the singular herein includes the plural (and vice versa) unless specifically stated otherwise. Moreover, the singular forms “a,” “an,” and “the” include plural forms unless the context clearly dictates otherwise. In addition, where the use of the term “about” is before a quantitative value, the present teachings also include the specific quantitative value itself, unless specifically stated otherwise.
It should be understood that the order of steps or order for performing certain actions is immaterial so long as the present teachings remain operable. Moreover, two or more steps or actions may be conducted simultaneously.
Where a range or list of values is provided, each intervening value between the upper and lower limits of that range or list of values is individually contemplated and is encompassed within the invention as if each value were specifically enumerated herein. In addition, smaller ranges between and including the upper and lower limits of a given range are contemplated and encompassed within the invention. The listing of exemplary values or ranges is not a disclaimer of other values or ranges between and including the upper and lower limits of a given range.
The aspects, embodiments, features, and drawings of the invention are to be considered illustrative in all respects and are not intended to limit the invention, the scope of which is defined only by the claims. Other embodiments, modifications, and usages will be apparent to those skilled in the art without departing from the spirit and scope of the claimed invention.
Patent Application
20120012492
