CROSS-REFERENCE TO RELATED APPLICATION

[0001] This application is based on and claims priority to U.S. Provisional Patent Application No. 61/644,247 filed on May 8, 2012, which is incorporated herein by reference in its entirety for all purposes.

FIELD OF THE INVENTION

[0002] The present invention relates generally to the field of bulk bins. More particularly, the present invention relates to a bulk bin that can accommodate removable feet and collapsible sidewalls.

BACKGROUND

[0003] A bulk bin, also known as a bulk box, skid box, tote box, or gaylord, is a pallet-sized box used to store and ship bulk quantities of material. Bulk bins are often made of corrugated fiberboard, molded plastic, sheet metal, or metal wire. Many bulk bins have covers. Bulk bins are preferably at least semi-reusable, with molded plastic and metal wire being the most durable. Corrugated fiberboard bins may be used only a handful of times, but molded plastic, sheet metal, and metal wire bulk bins may be used hundreds of times before needing to be replaced.

[0004] Bulk bins are widely used in the food industry, where they are used to transport bulk meat or produce. In food applications, it is necessary to be able to thoroughly and completely clean the bulk bins between uses. The equipment and manpower necessary to clean the bulk bins cause many food producers to use services that provide a steady supply of clean bulk bins to the producer, and accept used bulk bins in return, which are then washed and reused. It is thus advantageous for the service providers to use a bulk bin that may be collapsed thereby reducing the space requirements of the bulk bin during transport.

[0005] Existing bulk bins present a number of limitations that reduce the efficiency and cost-effectiveness of returnable container services. Typical collapsible bulk bins connect each side wall to a bottom surface via a hinge or plurality of hinges. When not in use, the side walls may be folded down onto the bottom surface.

[0006] Depending on the overall size of the bulk bin, it is common for two side walls to have a height greater than half the width of the bottom surface so that only one of the side walls will lie flat on the bottom surface, while the opposing side wall will overlap and lie on top thereof. This causes the overlying side wall to be in a final nonparallel folded position relative to the bottom surface, i.e., at an angle of incidence greater than zero. Thus, the overall height of the folded bulk bin is significantly increased by the angled, overlapping side wall when in the folded position.

[0007] Existing bulk bins utilize a wide variety of folding hinges and

configurations to minimize the profile of the collapsed bulk bin. Existing designs suffer from the use of metal hinge pins that present nooks and spaces for bacteria to grow and that make cleaning particularly difficult. Additionally, existing collapsible bulk bins often require that the walls be collapsed in a specific order to achieve the smallest overall height of the collapsed bulk bin.

[0008] Bulk bins are typically moved around a production facility or warehouse by forklifts or pallet jacks. The rough nature of such movement causes the bottom of the bulk bin, specifically the legs or sidewalls that raise the bulk bin base from the floor, to be particularly susceptible to damage. Damage to the legs or sidewalls of the bulk bin is a common failure point, and often causes otherwise usable bulk bins to need replacement.

[0009] As such, there is a need for a bulk bin that may be easily collapsed, does not use metal hinges, and has feet that may be removed and replaced to extend the usable life of the bulk bin.

SUMMARY

[0010] One version of the present invention is a collapsible bulk bin that includes a base having a plurality of horizontal retention tabs and vertical retention tabs arranged to form hinge channels. A plurality of first side walls having at least one hinge pin body and at least one wall retention tab are rotatably attached to the base by inserting the at least one hinge pin body into the hinge channels, thereby allowing the first side walls to rotate between a vertical and collapsed position. Adjacent to the plurality of first side walls, a plurality of second side walls having at least one hinge pin body and at least one resilient latch are rotatably attached to the base by inserting the at least one hinge pin body into the hinge channels allowing the second side walls to rotate between a vertical and collapsed position. The first and second side walls are removably attached to each other when in the vertical position by engaging the at least one resilient latch with the at least one wall retention tab. The first and second side walls lay parallel to each other and to the base when in the collapsed position.

[0011] In one embodiment, the collapsible bulk bin includes removable support feet inserted into the base. The support feet include threaded portions that engage corresponding threads included in the base. Instead of feet, the bin could use standard openings to accommodate the forks of a moving device. Permanently attached feet could also be used.

[0012] It will be understood by those skilled in the art that one or more aspects of this invention can meet certain objectives, while one or more other aspects can lead to certain other objectives. Other objects, features, benefits and advantages of the present invention will be apparent in this summary and descriptions of the disclosed embodiment, and will be readily apparent to those skilled in the art. Such objects, features, benefits and advantages will be apparent from the above as taken in conjunction with the accompanying figures and all reasonable inferences to be drawn therefrom.

BRIEF DESCRIPTION OF THE DRAWINGS

[0013] FIG. 1 is a perspective view of a reusable bulk bin in accordance with the invention;

[0014] FIG 2 is an exploded perspective view of the reusable bulk bin of FIG. 1;

[0015] FIG. 3 is a perspective view of the bulk bin of FIG. 1 with the side walls in a folded configuration;

[0016] FIG. 4 is another perspective view of the bulk bin of FIG. 1 showing only two of the side walls attached;

[0017] FIG. 5 is a detail view of the bulk bin of FIG. 1 taken generally along the line 5-5 in FIG. 4 showing one embodiment of a floating hinge in accordance with the invention;

[0018] FIG. 6 is a detail view of the floating hinge of FIG. 5 showing how the hinge is assembled; [0019] FIG. 7 is a detail view of the bulk bin of FIG. 1 taken generally along the line 7-7 in FIG. 4 showing another embodiment of a floating hinge in accordance with the invention;

[0020] FIG. 8 is a detail view of the floating hinge of FIG. 7 showing how the hinge is assembled;

[0021] FIG. 9 is a detail view of the bulk bin of FIG. 1 taken generally along the line 9-9 in FIG. 4 showing two side walls removably attached to each other;

[0022] FIG. 10 is another detail view of the two side walls of FIG. 9 showing how the walls are removably attached to each other;

[0023] FIG. 11 is a section view of the bulk bin of FIG. 1 taken generally along the line 11-11 in FIG. 3 showing how the side walls fold on top of each other;

[0024] FIG. 12 is a section view of the bulk bin of FIG. 1 taken generally along the line 12-12 in FIG. 3 showing how the side walls fold on top of each other;

[0025] FIG. 13A is a section view of the floating hinge of FIG. 5 showing the side wall removed from the base;

[0026] FIG. 13B is another section view of the floating hinge of FIG. 5 showing the side wall being inserted onto the base;

[0027] FIG. 13C is another section view of the floating hinge of FIG. 5 showing the side wall removably attached to the base;

[0028] FIG. 14A is a section view of the bulk bin of FIG. 1 taken generally along the line 14A-14A in FIG. 9 showing two side walls removably attached to each other;

[0029] FIG. 14B is another section view of the two side walls of FIG. 14A showing the side walls disconnected from each other; [0030] FIG. 15A is a section view of the bulk bin of FIG. 1 taken generally along the line 15A-15A in FIG. 9 showing two side walls removably attached to each other;

[0031] FIG. 15B is another section view of the two side walls of FIG. 15A showing the side walls disconnected from each other;

[0032] FIG. 16 is a perspective view of another embodiment of a reusable bulk bin base in accordance with the invention;

[0033] FIG. 17 is a perspective view of a removable support foot in accordance with the invention shown attached to the reusable bulk bin base of FIG. 16;

[0034] FIG. 18 is a perspective view of the removable support foot of FIG. 17;

[0035] FIG. 19 is an exploded perspective view of the removable support foot and corresponding threaded section of the reusable bulk bin base of FIG. 17;

[0036] FIG 20 is a cross-sectional view of the removable support foot and corresponding threaded section of the reusable bulk bin base of FIG. 17;

[0037] FIG. 21 A is a partial cross-sectional view of another embodiment of a removable support foot and corresponding threaded section of a reusable bulk bin base in accordance with the invention;

[0038] FIG. 21B is a partial cross-sectional view of another embodiment of a removable support foot and corresponding threaded section of a reusable bulk bin base in accordance with the invention;

[0039] FIG. 21C is a partial cross-sectional view of another embodiment of a removable support foot and corresponding threaded section of a reusable bulk bin base in accordance with the invention; [0040] FIG. 22 is a detail view of the removable support foot and corresponding threaded section of a reusable bulk bin base of FIG. 21C;

[0041] FIG. 23 is a perspective view of another embodiment of a reusable bulk bin base in accordance with the invention; and

[0042] FIG. 24 is a perspective view of another embodiment of a reusable bulk bin base in accordance with the invention.

DETAILED DESCRIPTION

[0043] FIGS. 1-15 show one embodiment of a collapsible bulk bin 100 in accordance with the present invention. Collapsible bulk bin 100 includes a base 102 removably attached to each of two first side walls 104 and two second side walls 105 via a plurality of floating hinges. The side walls 104, 105 form an enclosure with the base 102 when the side walls are in a vertical position. FIG. 2 shows the side walls 104, 105 removed from the base 102. In the embodiment shown, the side walls 104, 105 may be removed from the base 102 without tools, which improves the ease with which the side walls may be cleaned and/or replaced.

[0044] FIG. 3 shows the side walls 104, 105 in a collapsed or folded position. The side walls 104, 105 may be folded down inwardly across the base 102 to a position parallel with the bottom of the base. Folding the side walls 104, 105 onto the base 102 causes the collapsible bulk bin 100 to occupy less space, which is advantageous when storing or shipping empty bins.

[0045] FIG. 4 shows the collapsible bulk bin 100 with one first side wall 104 and one second side wall 105 attached to the base 102 so that the interior of the bin is viewable. [0046] FIGS. 5-6 are detail views of a first floating hinge 200 for the first side wall 104 in accordance with the invention. The first floating hinge 200 includes a horizontal retention tab 202 and a vertical retention tab 204. The horizontal retention tab 202 is offset from the base 102 a distance slightly larger than the diameter of a hinge pin body 206 to allow the hinge pin body to freely rotate and be displaced vertically along the horizontal retention tab 202. In the embodiment shown, a plurality of hinge pin bodies 206 are integrally formed into the first side wall 104. The hinge pin bodies 206 engage the floating hinge 200 along vertical bearing surface 208 and are retained within the hinge by vertical retention tab 204. Additionally, the vertical retention tab 204 prevents inadvertent removal of the first side wall 104. In the embodiment shown, each first side wall 104 is removably attached to the base 102 by two first floating hinges 200, but more or less floating hinges may be used without departing from the invention.

[0047] The first floating hinge 200 allows the first side walls 104 to be collapsed in either order, yet still lay flat on top of the base 102. FIGS 13A-C show how the first side wall 104 is inserted or removed from the base 102. The hinge pin body 206 is inserted below the vertical retention tab 204 and over the horizontal retention tab 202. The first side wall can then be lowered onto the floating hinge 200. During normal operation, the first side wall 104 is not removed from the base 102, but it may be removed for cleaning or replaced if needed.

[0048] Turning now to FIGS. 7-8, detail views of a second floating hinge 300 for the second side walls 105 in accordance with the invention are shown. Each second floating hinge 300 includes a horizontal retention body 302 and a vertical retention body 304. The horizontal retention bodies 302 are offset from the base 102 a distance slightly larger than the diameter of hinge pin bodies 306 to allow the hinge pin bodies 306 to freely rotate and be displaced vertically along the vertical retention body 304. As shown, the hinge pin bodies 306 are integrally formed with the second side walls 105. The hinge pin bodies 306 engage the floating hinge 300 along horizontal retention body 302 and are retained within the hinge by vertical retention tab 304.

[0049] In addition to the hinge pins 306, the second side walls 105 also include locking tabs 308 that engage the vertical retention body 304 when the second side walls are in the vertical position. The locking tabs 308 prevent the second side walls 105 from displacing vertically when the second side walls are in the vertical position. When the second side walls 105 are folded, the locking tabs 308 disengage from the vertical retention body 304, which allows the hinge pin bodies 306 to float vertically in the second floating hinge 300, which allows the second side walls to lay fiat on top of each other when folded.

[0050] In the embodiment shown, the floating hinges 200, 300 do not include any moving parts, which combined with the ability to move the hinge pin bodies 206, 306 in the vertical as well as rotational directions allows easy cleaning and sterilization of the floating hinges. Of course, alternative floating hinge designs may be used without departing from the invention.

[0051] Turning now to FIGS. 9-10, in the embodiment shown, the first side walls 104 are removably attached to the second side walls 105 by resilient latches 106 that are integrally formed in the second side walls and engage corresponding wall retention tabs 108 integrally formed in the adjoining first side walls. FIGS. 14A-B show how the resilient latch 106 displaces as the second side wall 105 is rotated into the vertical position adjacent to the first side wall. The resilient latch 106 then snaps into engagement with the wall retention tab 108 to removably attach the adjacent side walls 104, 105 to each other. Like the floating hinges 200, 300, the resilient latch 106 does not include any moving parts, which allows easy cleaning and sterilization of the resilient latch. Adjacent side walls 104, 105 may be removably attached to each other in the vertical position using any suitable latch or fastening mechanism. Of course, other latch or attachment configurations may be used without departing from the invention.

[0052] The base 102 also includes a plurality of securing tabs 110 (see FIG. 7) that engage the base of the side walls 104, 105 to further prevent rotation when the side walls are in the vertical position. To provide additional structure and support to the collapsible bulk bin 100, the embodiment shown also includes interlocking features on the first and second side walls 104, 105. As shown, a plurality of vertical side cavities 112 run along both sides of the second side walls 105. Corresponding vertical side tabs 114 (see FIGS. 15A-B) run along both sides of the first side walls 104. As shown in FIGS. 15A-B, when the side walls 104, 105 are rotated into the vertical position, the vertical side tabs 114 engage the vertical side cavities 112.

[0053] At least one side support tab 113 extends from the vertical side cavities 112. The side support tab 113 includes a notch 115 that interlocks a rib 116 (see FIG. 1) on the side wall 104, 105 when the side walls are in the folded configuration. The support tab 113 prevents the second side walls 105 from excessive movement when the collapsible bulk bin 100 is in the folded configuration. Of course, any other suitable means for providing additional structure and support to the collapsible bulk bin 100, whether in the vertical or folded configurations, may be used without departing from the invention.

[0054] FIGS. 11-12 are section views of the collapsible bulk bin 100 with the side walls 104, 105 in the folded configuration. As is shown, the hinge pin bodies 206, 306 float as needed within the floating hinges 200, 300 to allow the side walls 104, 105 to lay flat on top of the base 102 and each other. To fold a side wall 104, 105, an operator depresses the resilient latch 106, releasing it from the wall retention tab 108 and rotates the side wall so that it lays flat on top of the base 102. The floating hinges 200, 300 allow the side walls 104, 105 to be folded in any order, yet lay parallel to the base 102 when folded. The first side walls 104 are folded first, with the second side walls 105 folded on top of the first side walls. The floating configuration of the floating hinges 200, 300 allow the first side walls 104 to be folded in any order, with the second side walls 105 folded in any order on top thereof.

[0055] In the alternative embodiment shown in FIG. 16, a plurality of support feet 450 are removably attached to a base 400 and protrude a sufficient distance from the base to allow forks from forklifts and pallet jacks to pass under the base. The inclusion of removable support feet 450 may prolong the usable life of the base 400 because the area below the base where the forks of a forklift or pallet jack are inserted is the hardest wearing part of the collapsible bulk bin. Often perfectly usable bins must be replaced because of damage suffered to the support below the base. Using removable feet enables quick, cost-effective replacement of broken parts without having to discard the entire bin. Of course, standard walls with openings to accept the forks of a moving device could also be used. [0056] Turning now to FIGS. 17-20, a support foot 450 in accordance with the present invention is shown. The support foot 450 includes a bottom 452, a cylindrical portion 454, a threaded section 456, an o-ring 458, and a wear-indicator 460. As shown, the support foot 450 is hollow to save weight and to ensure that the support foot is weaker than the base 400 so that the inexpensive support foot fails before the base and without damaging the base. Additionally, the interior void 462 of the support foot may be shaped, e.g., into a hexagonal shape, to facilitate removal of the support foot 450 in the event that a portion of the support foot breaks. The interior void 462 may be hollow or filled with any suitable material such as polyurethane foam. The support feet 450 are constructed of any suitable material to provide necessary support and wear

characteristics.

[0057] The threaded section 456 removably attaches each support foot 450 to a corresponding receiving threaded section 402 in the base 102. The threaded section 456 preferably transfers any side load generated if the support foot 450 is impacted by the forks of a fork lift or pallet jack into vertical ribs 404 integrated into the base rather than into the floor of the base, which could buckle or crack. The threaded section 456 further allows an operator to relatively easily replace a support foot 450 in the event it becomes damaged or worn out.

[0058] At the base of the threaded section 456 is an o-ring 458 that seals the threaded section from the outside environment. Additionally, an anti-microbial sealant may be used to further enhance the seal and prevent contamination of the interior void 462 of the support foot. Of course, other seal designs may be used in place of the o-ring 158 without departing from the invention. [0059] A wear-indicator 460 may be integrated into the support foot 450. As shown, the wear-indicator 460 is a chamfer formed between the bottom 452 and the cylindrical portion 454 of the support foot. As the bottom 452 wears, which may occur for a variety of reasons, material is scraped off of the bottom 452 and the support leg 450 is shortened. A visual inspection for the presence of the wear-indicator 460 lets an operator know when the support foot 450 is worn to a point where a pallet jack or forklift may be unable to fit underneath the base 400. Rather than a chamfer, other profiles may be used for the wear indicator without departing from the invention.

[0060] FIGS. 21A-C, and FIG. 22 reflect alternative foot designs that could be used. FIG. 21 A shows a removable support foot 500 that includes a threaded stud 502 that engages a threaded insert 504 in the bottom of a bin 506. Like the previous embodiment, an o-ring 508 is included between the removable support foot 500 and the bin 506 to seal the interior of the removable support foot 500 from the outside environment.

[0061] FIG. 2 IB shows a removable support foot 550 that includes a threaded stud 552 that engages a threaded insert 554 in the bottom of a bin 556. The treaded stud 552 further includes a bearing surface 558 that engages a corresponding bearing cavity 560 in the bin 556. Between the bearing surface and the bearing cavity is a gasket 562 to seal the interior of the removable support foot 550 from the outside environment. The bearing surface 558 engagement with the bearing cavity 560 provides increased resistance to breaking of the threaded stud 552 in the event of an impact to the removable support foot 550. [0062] FIG. 21C shows a removable support foot 600 that is press-fit into a base 602. The removable support foot 600 uses friction to retain the support foot in a receiving hollow 604 in the bottom of the base 602. Like the previously discussed designs, o-rings 606 are included between the base 602 and the removable support foot 600 to seal the interior of the support foot from the outside environment. Around the opening of the receiving hollow 604 a plurality of support ribs 608 provide increased rigidity to the connection between the base 602 and the removable support foot 600 (see FIG. 22). Of course, other removable or permanent leg designs could be developed without departing from the invention.

[0063] FIG. 23 shows another embodiment of a base 700 in accordance with the invention. The base 700 includes a plurality of support feet 702 that are integrally formed into the base and are not removable. Similarly, FIG. 24 shows yet another embodiment of a base 800 in accordance with the invention. The base 800 includes a plurality of support feet 802 that are welded or adhered to the base and are not removable. Of course, any suitable support means may be used to raise the base 700, 800 from the ground without departing from the invention.

[0064] Although the invention has been herein described in what is perceived to be the most practical and preferred embodiments, it is to be understood that the invention is not intended to be limited to the specific embodiments set forth above. Rather, it is recognized that modifications may be made by one of skill in the art of the invention without departing from the spirit or intent of the invention and, therefore, the invention is to be taken as including all reasonable equivalents to the subject matter of the appended claims and the description of the invention herein.