Receptacles – End wall structure – Support structure
Reexamination Certificate
1999-01-13
2001-06-12
Moy, Joseph M. (Department: 3727)
Receptacles
End wall structure
Support structure
C220S636000, C220S611000
Reexamination Certificate
active
06244459
ABSTRACT:
FIELD OF THE INVENTION
This invention relates to a bulk packaging container and, more particularly, to a bulk packaging container constructed of all polymeric materials.
BACKGROUND OF THE INVENTION
Bulk packaging containers have found widespread use for storage and shipment of bulk goods, including hazardous materials. The bulk packaging containers assume many different forms. Among these forms are intermediate bulk containers (IBCs) and portable tanks. Requirements for these types of containers are outlined in various D.O.T. and F.D.A regulations and are particularly defined in 47 CFR Section 171.8.
Among IBCs, there include numerous types of designs. These include metal IBCs, which are constructed of metal, rigid plastic IBCs which are constructed of all plastic material, and composite IBCs which include a rigid outer packaging enclosing a plastic inner receptacle. The outer packaging may consist of, for example, a wire cage or the like. Rigid plastic IBCs are often more corrosion resistant to certain chemicals because of the lack of metal in their construction.
As with any product, cost is an important constraint. In the shipping industry, size and weight requirements are also important, as they impact on shipping costs. Rigid plastic IBCs or portable tanks may often produce the most advantageous combination among cost, size and weight.
Presently, there are available IBCs and portable tanks made of all polymeric materials. These articles include a pallet-like base and bottle mounted to the base. Both the bottle and the base are made by rotational molding. Due to necessities relating to rotational molding, the base tends to be substantially larger than desired. The larger size results in increases in costs, weight and size. Also, the use of rotational molding limits the type of resins that can be used in forming the base.
With previous designs of rigid plastic IBCs and portable tank bottles, the locations and sizes of molded openings or non-openings were limited specifically to those built into the rotational molding tool. Costly and time-consuming alterations were needed to the mold to change these combinations of molded-in openings. This limited the number of combinations of openings that could be offered to customers for reasonable cost, and in a short lead time.
IBCs and portable tanks are typically designed to be stacked during shipment and/or during storage. The rigid plastic designs often include stacking guides which helps to center the upper container over the lower container in a stack, and to help prevent the upper container from sliding off the lower container. The stacking guides are often molded integrally into the shape of the top of the bottle. In previous designs, the dimensions of the stacking guides have been several times greater than the wall thickness of the bottle. This creates a cavity on the interior upper surface of the bottle which is difficult to clean through the openings in the bottle. Given the constraints of cost and regulatory testing requirements, it is not feasible to provide openings so large that a worker could physically enter the bottle for cleaning.
Finally, in designing a bottle it is necessary to provide appropriate support to withstand horizontal forces of hoop stresses due to internal head pressure and also to withstand vertical downward forces of stacking loads without buckling. Any design must keep in mind the desire to utilize less plastic resin while producing an appropriate structural strength.
The present invention is directed to solving one or more of the problems discussed above in a novel and simple manner.
SUMMARY OF THE INVENTION
In accordance with the invention, there is provided a bulk packaging container constructed of all polymeric materials. The container is in the form of a rigid plastic intermediate bulk container or portable tank. The container comprises a base of an injection molded polymeric material having a bottom adapted to be supported from beneath and an opposite top surface to define a height of approximately six inches and including plural entry slots for forklift or pallet jack entry. A bottle of a rotationally molded polymeric material has an outer wall defining an interior storage space. The outer wall comprises a bottom wall received on the base top and a top wall including means for supporting a base of another bulk packaging container. The bottle is adapted to support weight of the other bulk packaging container. Means are provided for securing the bottle to the base.
In accordance with another aspect of the invention, a rotational mold used for forming the bottle is provided with three identical opening attachment devices which accommodate an insert to mold even the largest type of opening anticipated. All of the inserts to mold all of the types and sizes of anticipated openings are made to attach to any of these identical opening attachment devices. This allows all types and sizes of opening inserts to be quickly and inexpensively mixed and matched.
In accordance with another aspect of the invention, stacking guides integrally molded in a top wall of the bottle are uniquely designed to be filled almost completely with plastic during the rotational molding process. This is achieved through a combination of the location of the stacking guides at the comer of the bottle where there is a greater tendency for resin to collect, and the shape which is round and conical to evenly and effectively collect resin within to fill the stacking guide.
In accordance with a further aspect of the invention, the bottle is adapted to include deep ribs in the sides of the bottle running part way up the sides from the bottom and part way down the sides from the top coupled with a horizontal band which has no vertical ribs in-between. The horizontal band with no vertical ribs improves the ability of the container to withstand horizontal forces of the hoop stresses due to the internal head pressure of fluid. The deep ribs give the strength to better withstand vertical downward forces of stacking loads without buckling.
In accordance with yet another aspect of the invention, the comers of the bottle wrap around more than 90° to define a column. This column design withstands vertical downward forces of stacking loads without buckling.
Further features and advantages of the invention will be readily apparent from the specification and from the drawing.
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patent: 4887731 (1989-12-01), Pett et al.
patent: 5249684 (1993-10-01), Sterett
patent: 5253777 (1993-10-01), Schutz
patent: 5316174 (1994-05-01), Schutz
patent: 5597085 (1997-01-01), Rauworth et al.
patent: 5638983 (1997-06-01), Bazany
patent: 5657871 (1997-08-01), Waters et al.
patent: 5823382 (1998-10-01), Van Giezen et al.
Brochure, Hoover Materials Handling Group, Inc.
Bouc Gary L.
Faltys Michael
Hoover Materials Handling Group Inc.
Moy Joseph M.
Wood Phillips VanSanten Clark & Mortimer
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