US20130327680A1

US20130327680A1 - Combination bulk container and pallet

Info

Publication number: US20130327680A1
Application number: US13/793,773
Authority: US
Inventors: Robert James Reynolds, Jr.; Terrance Dale Moore, JR.
Original assignee: Illinois Tool Works Inc
Current assignee: Signode Industrial Group LLC
Priority date: 2012-05-25
Filing date: 2013-03-11
Publication date: 2013-12-12

Abstract

The present disclosure provides a combination bulk container and pallet having an assembled configuration and a collapsed configuration. In one embodiment, the combination bulk container and pallet includes: a pallet including a bottom tray, a material supporter, and a plurality of support legs positioned between the bottom tray and the material supporter; a collapsible sidewall structure having a collapsed configuration when the combination bulk container and pallet is in the collapsed configuration and an expanded configuration when the combination bulk container and pallet is in the assembled configuration; and a cover. When the combination bulk container and pallet is in the collapsed configuration, the cover covers the sidewall structure (which is in the collapsed configuration). When the combination bulk container and pallet is in the assembled configuration, the cover covers a material holding area defined by the sidewall structure (which is in the expanded configuration) and the material supporter.

Description

PRIORITY CLAIM

This application is a non-provisional of, and claims priority to and the benefit of, U.S. Provisional Patent Application No. 61/651,859, filed on May 25, 2012, and U.S. Provisional Patent Application No. 61/659,259, filed on Jun. 13, 2012, the entire contents of each of which are incorporated herein by reference.

COPYRIGHT NOTICE

A portion of the disclosure of this patent document contains or may contain material which is subject to copyright protection. The copyright owner has no objection to the photocopy reproduction by anyone of the patent document or the patent disclosure in exactly the form it appears in the Patent and Trademark Office patent file or records, but otherwise reserves all copyright rights whatsoever.

BACKGROUND

Various bulk containers, also referred to as bulk boxes or bins; skid containers, boxes, or bins; and Gaylord containers, boxes, or bins, are well known. These known bulk containers are used to move, store, and/or transport a wide range of products, parts, components, items, and other materials. Bulk containers typically include a bottom section and a sidewall structure configured to hold and support the materials. The bottom sections of certain collapsible bulk containers include flaps that enable these bulk containers to be folded from an expanded configuration into a relatively flat, collapsed configuration. The bottom sections of certain non-collapsible bulk containers do not include such flaps and thus do not enable the bulk containers to be folded from an expanded configuration into a collapsed configuration. Many bulk containers also include a top section or cover configured to cover a material holding area defined by the bottom section and the sidewall structure of the bulk container.
Bulk containers are typically manufactured from a variety of different materials, such as corrugated fiberboard, plastic, wood, aluminum, and steel. Due to the relatively large size and the relatively heavy weight of many known bulk containers, especially when holding materials, such known bulk containers typically rest on pallets (such as wooden pallets) to facilitate moving the bulk containers. Specifically, the pallets enable a user to lift or otherwise move the bulk containers using a pallet jack and/or a forklift, depending on the configuration of the pallet. These pallets are typically wooden, though pallets made of other materials are also used.
One conventional non-collapsible bulk container that is widely commercially implemented is made from corrugated fiberboard and rests on a wooden pallet to facilitate movement of this non-collapsible bulk container. There are numerous disadvantages to this non-collapsible bulk container and pallet combination.
Since the non-collapsible bulk container cannot collapse into a folded configuration, the size of the non-collapsible bulk container is the same regardless of whether the non-collapsible bulk container is holding any materials. As a result, the amount of space required to store the non-collapsible bulk container and pallet combination and, in certain circumstances, the cost to store the non-collapsible bulk container and pallet combination, does not change when the non-collapsible bulk container is empty. Thus, manufacturers of the non-collapsible bulk container and/or customers who purchase the non-collapsible bulk container require the same amount of space to store the non-collapsible bulk container and pallet combination and, in certain circumstances, pay the same amount to store the non-collapsible bulk container and pallet combination whether or not the non-collapsible bulk container holds materials. For example, a customer rents a storage shelf for $500. Five of these non-collapsible bulk container and pallet combinations fit on the storage shelf. Thus, regardless of whether the five non-collapsible bulk containers hold any materials, only five of the non-collapsible bulk container and pallet combinations fit on the storage shelf. Accordingly, the customer must pay $500 to store the five non-collapsible bulk container and pallet combinations, even if those non-collapsible bulk containers hold nothing but air.
The fact that the non-collapsible bulk container and the pallet are distinct, separate structures also increases various manufacturing and shipping costs. For example, since different processes are used to manufacture the non-collapsible bulk container and the pallet, at least two separate, distinct processes must be performed to manufacture these structures. This increases manufacturing costs. Additionally, when the non-collapsible bulk container and the pallet are manufactured at two different facilities, the non-collapsible bulk container and the pallet must be separately shipped to customers, which increases shipping costs and handling costs.
The non-collapsible bulk container and pallet combination also promotes waste of non-recyclable materials. Specifically, each non-collapsible bulk container rests on its own pallet. Over time, the wooden pallets tend to become damaged and, eventually, rendered unusable. Since the wooden pallets are not recyclable, these unusable wooden pallets must be transported to a landfill and replaced with new pallets. Thus, not only do these non-biodegradable pallets take up space in a landfill, there is a cost associated with transporting them to the landfill.
One conventional collapsible bulk container that is widely commercially implemented is made from corrugated fiberboard and rests on a wooden pallet to facilitate movement of this collapsible bulk container. Since the collapsible bulk container is collapsible, when the collapsible bulk container does not hold materials it may be folded into the collapsed configuration for storage to save space. For example, twenty of the collapsible bulk containers in the collapsed configuration may be stacked atop one another and stored on a single pallet. Although the collapsible bulk container in some instances appears to solve the storage issues plaguing the non-collapsible bulk container described above, it nevertheless has numerous disadvantages.
Since each stacked collapsible bulk container (in the collapsed configuration) is not stacked atop its own pallet in certain instances, to fill one of the stacked collapsible bulk containers with materials, a user: (a) locates a pallet, (b) locates a pallet jack or a forklift, (c) uses the pallet jack or the forklift to move the pallet near the stack of collapsible bulk containers, (d) retrieves a collapsible bulk container from the stack, (e) unfolds the retrieved collapsible bulk container from the collapsed configuration into the expanded configuration, and (f) rests the retrieved collapsible bulk container on the pallet. Thus, the user must perform numerous tedious steps to prepare a collapsible bulk container stored in a stack of collapsible bulk containers to hold materials. This requires much time and effort from the user, especially when a large quantity of collapsible bulk containers must be filled with materials.
Further, since each collapsible bulk container needs to rest on its own wooden pallet (when filled with materials) to be moved, the collapsible bulk container and pallet combination does not solve the above-described problems regarding increased manufacturing costs, handling costs, shipping costs, and material waste.
Certain collapsible plastic bulk containers have also been commercialized. In one such collapsible plastic bulk container, a user may remove all or part of the sidewall structure to manipulate the collapsible plastic bulk container from an expanded configuration into a collapsed configuration. In another such collapsible plastic bulk container, a user may fold all or part of the sidewall structure to manipulate the collapsible plastic bulk container from an expanded configuration into a collapsed configuration.
While such plastic bulk containers may provide a space-saving feature in certain instances, they nonetheless have numerous disadvantages. These plastic bulk containers are relatively expensive to manufacture compared to the above-described non-collapsible and collapsible bulk containers manufactured from corrugated fiberboard and, therefore, are relatively more expensive for customers than the non-collapsible and collapsible bulk containers. Additionally, these plastic bulk containers are relatively heavy compared to the above-described non-collapsible and collapsible bulk containers. This relatively high weight increases the cost of shipping these plastic bulk containers, and also renders them more difficult to lift and move. Further, certain of these plastic bulk containers are not recyclable, unlike the above-described conventional bulk container made from corrugated fiberboard (which is a recyclable material). This causes material waste in addition to the material waste caused by the use of wooden pallets when the plastic bulk container breaks and is rendered useless.
Accordingly, there is a need for new and improved bulk containers that overcome these disadvantages.

SUMMARY

Various embodiments of the present disclosure provide a combination bulk container and integrated pallet. The combination bulk container and pallet has an assembled configuration in which a pallet and a collapsible sidewall structure in an expanded configuration form a material holding area for holding materials during shipping and/or storage. The combination bulk container and pallet also has a collapsed configuration in which the collapsible sidewall structure is folded into a collapsed configuration to save space, thus enabling the combination bulk container and pallet itself to be efficiently shipped and/or stored while taking up a relatively small amount of space when the combination bulk container and pallet is not holding materials. Thus, the combination bulk container and integrated pallet of the present disclosure eliminates the need for separate pallets, thereby reducing costs and material waste.
In one embodiment, the combination bulk container and pallet includes: (a) a pallet including a bottom tray, a material supporter configured to support materials, and a plurality of support legs positioned between the bottom tray and the material supporter; (b) a collapsible sidewall structure having a collapsed configuration when the combination bulk container and pallet is in the collapsed configuration and an expanded configuration when the combination bulk container and pallet is in the assembled configuration; and (c) a cover. When the combination bulk container and pallet is in the collapsed configuration, the cover covers the collapsible sidewall structure (which is in the collapsed configuration). When the combination bulk container and pallet is in the assembled configuration, the cover covers a material holding area defined by the collapsible sidewall structure (which is in the expanded configuration) and the material supporter. It should thus be appreciated that the combination bulk container and pallet of the present disclosure is a bulk container including an integrated pallet that has an assembled configuration for holding materials and a collapsed configuration facilitating efficient storage and shipping when not holding materials.
In certain embodiments, the combination bulk container and pallet also includes a plurality of combination cover supports/cut-strap protectors. When the combination bulk container and pallet is in the collapsed configuration, the combination cover supports/cut-strap protectors support the cover. When the combination bulk container and pallet is in the assembled configuration, the combination cover supports/cut-strap protectors protect certain portions of the bottom tray and the cover from being damaged by cut-straps wrapped around the combination bulk container and pallet.
In one embodiment, the ratio of the height of the combination bulk container and pallet in the assembled configuration to the height of the combination bulk container and pallet in the collapsed configuration is approximately 3.3 to 1, and the ratios of the width and length of the combination bulk container and pallet in the assembled configuration to the width and length of the combination bulk container and pallet in the collapsed configuration are each approximately 1 to 1.
Thus, in this embodiment, the combination bulk container and pallet of the present disclosure provides an advantage over the non-collapsible bulk container and pallet combination described above in that the combination bulk container and pallet of the present disclosure is configured to collapse from the assembled configuration into a collapsed configuration that is approximately one-third the size of the assembled configuration. This enables a manufacturer or a customer to save storage space (and costs) associated with storing empty bulk containers. Specifically, this enables three combination bulk container and pallets in the collapsed configuration to be stored in the same amount of space as one combination bulk container and pallet in the assembled configuration.
Additionally, in this embodiment, the combination bulk container and pallet of the present disclosure provides an advantage over both the non-collapsible and the collapsible bulk container and pallet combinations described above in that the combination bulk container and pallet of the present disclosure includes an integrated pallet. This eliminates the need for separate pallets, thereby eliminating the costs associated with separate pallets, such as manufacturing costs, handling costs, shipping costs, storage costs, and waste removal costs.
Moreover, since the combination bulk container and pallet of the present disclosure may be constructed from relatively light, recyclable, biodegradable, and cost-effective materials such as corrugated fiberboard and kraft paper honeycomb, the combination bulk container and pallet is, in certain instances, recyclable, sustainable, and environmentally friendly.
Additional features and advantages of the present invention are described in, and will be apparent from, the following Detailed Description of and the Figures.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top perspective view of an embodiment of the combination bulk container and pallet of the present disclosure in the collapsed configuration.

FIG. 2 is a bottom perspective view of the combination bulk container and pallet of FIG. 1.

FIG. 3 is an exploded top perspective view of the combination bulk container and pallet of FIG. 1.

FIG. 4 is a partially exploded top perspective view of the combination bulk container and pallet of FIG. 1.

FIG. 5 is a top plan view of the pallet of the combination bulk container and pallet of FIG. 1, and includes hidden lines showing the locations of the bottom tray tine receiving openings, the wheel receiving openings, and the support legs.

FIG. 6 is a top perspective view of the combination bulk container and pallet of FIG. 1 in the assembled configuration.

FIG. 7 is a cross-sectional side elevational view of the combination bulk container and pallet of FIG. 6 along line VII-VII of FIG. 6.

FIG. 8 is an exploded top perspective view of the combination bulk container and pallet of FIG. 6.

FIG. 9 is an exploded bottom perspective view of the combination bulk container and pallet of FIG. 6.

FIG. 10 is a top plan view of an example of the bottom tray of the present disclosure in an unfolded configuration.

FIG. 11 is a top plan view of an example of the material supporter of the present disclosure, and includes hidden lines showing the locations of example support legs.

FIG. 12 is a side elevational view of the material supporter and the support legs of FIG. 11.

FIG. 13 is a side elevational view of an example of the collapsible sidewall structure of the present disclosure in a disconnected state.

FIG. 14 is a top plan view of an example of the cover of the present disclosure in an unfolded configuration.

FIG. 15 is a top perspective view of an example of the combination cover support/cut-strap protector of the present disclosure.

FIG. 16 is an exploded top perspective view of another embodiment of the combination bulk container and pallet of the present disclosure in the collapsed configuration.

FIG. 17 is a partially exploded top perspective view of the combination bulk container and pallet of FIG. 16.

FIG. 18 is a top perspective view of the combination bulk container and pallet of FIG. 16 in the assembled configuration

FIG. 19 is an exploded top perspective view of the combination bulk container and pallet of FIG. 18.

FIG. 20 is an exploded bottom perspective view of the combination bulk container and pallet of FIG. 18.

DETAILED DESCRIPTION

Referring now to the drawings, FIGS. 1 to 15 illustrate one example embodiment of a combination bulk container and pallet of the present disclosure. The combination bulk container and pallet, which is generally indicated by numeral 50, has: (a) an assembled configuration for holding materials during shipping and/or storage, and (b) a collapsed configuration enabling the combination bulk container and pallet itself to be efficiently shipped and/or stored when the combination bulk container and pallet is not holding materials. More specifically (and as described in detail below), FIGS. 1 and 2 illustrate combination bulk container and pallet 50 in the collapsed configuration, and FIGS. 6 and 7 illustrate combination bulk container and pallet 50 in the assembled configuration.
As generally shown in FIGS. 1 to 9, combination bulk container and pallet 50 includes: (a) a pallet 100 including a bottom tray 200, a material supporter 300 configured to support materials, and a plurality of support legs 310 positioned between bottom tray 200 and material supporter 300; (b) a collapsible sidewall structure 400 having: (i) a collapsed configuration (as shown in FIGS. 3 and 4) when combination bulk container and pallet 50 is in the collapsed configuration, and (ii) an expanded configuration (as shown in FIGS. 6, 8, and 9) when combination bulk container and pallet 50 is in the assembled configuration; and (c) a cover 500. When combination bulk container and pallet 50 is in the collapsed configuration, cover 500 covers collapsible sidewall structure 400 (which is in the collapsed configuration). When combination bulk container and pallet 50 is in the assembled configuration, cover 500 covers a material holding area defined by collapsible sidewall structure 400 (which is in the expanded configuration) and material supporter 300. In this illustrated embodiment, combination bulk container and pallet 50 also includes a plurality of combination cover supports/cut-strap protectors 600. When combination bulk container and pallet 50 is in the collapsed configuration, combination cover supports/cut-strap protectors 600 support cover 500. When combination bulk container and pallet 50 is in the assembled configuration, combination cover supports/cut-strap protectors protect certain portions of bottom tray 200 and cover 500 from being damaged by cut-straps wrapped around combination bulk container and pallet 50.
As shown in FIGS. 1 to 10, in this illustrated embodiment, bottom tray 200 includes: (a) a rectangular lower or bottom wall 201 having an interior surface 201 a and an exterior surface 201 b; (b) opposing, spaced apart, rectangular first and second or front and back walls 212 and 216 having interior surfaces 212 a and 216 a, respectively, and exterior surfaces 212 b and 216 b, respectively; and (c) opposing, spaced apart, rectangular third and fourth or right and left walls 214 and 218 having interior surfaces 214 a and 218 a, respectively, and exterior surfaces 214 b and 218 b, respectively. Bottom wall 201 includes or defines a plurality of spaced apart rectangular wheel receiving openings 231 a, 231 b, 231 c, and 231 d configured to receive wheels of a pallet jack (described below); front wall 212 includes or defines a plurality of spaced apart rectangular bottom tray tine receiving openings 232 a and 232 b configured to receive the tines of a pallet jack or a forklift (described below); right wall 214 includes or defines a plurality of spaced apart rectangular bottom tray tine receiving openings 234 a and 234 b configured to receive the tines of a pallet jack or a forklift (described below); back wall 216 includes or defines a plurality of spaced apart rectangular bottom tray tine receiving openings 236 a and 236 b configured to receive the tines of a pallet jack or a forklift; and left wall 218 includes or defines a plurality of spaced apart rectangular bottom tray tine receiving openings 238 a and 238 b configured to receive the tines of a pallet jack or a forklift. Bottom tray tine receiving openings 232 a and 236 a a define a first set of aligned bottom tray tine receiving openings, bottom tray tine receiving openings 232 b and 236 b define a second set of aligned bottom tray tine receiving openings, bottom tray tine receiving openings 234 a and 238 a define a third set of aligned bottom tray tine receiving openings, and bottom tray tine receiving openings 234 b and 238 b define a fourth set of aligned bottom tray tine receiving openings. In this illustrated embodiment, the wheel receiving openings and the tine receiving openings are formed using a die cut process, though it should be appreciated that other suitable processes may be used to form the openings.
As generally shown in FIGS. 2 to 5, 7 to 9, 11, and 12, material supporter 300 is rectangular in shape and has a top or upper surface 301 a and a bottom or lower surface 301 b. As also shown in FIGS. 2 to 5, 7 to 9, 11, and 12, each of support legs 310 a, 310 b, 310 c, 310 d, 310 e, 310 f, 310 g, 310 h, and 310 i includes: (i) a top or upper surface 313 configured to contact bottom surface 301 b of material supporter 300 and an opposing bottom or lower surface 311 configured to contact top surface 201 a of bottom wall 201 of bottom tray 200; (ii) a first or front surface 312 and an opposing second or back surface (not shown); and (iii) a third or right surface 314 and an opposing fourth or left surface (not shown).
As noted above and as generally shown in FIGS. 3, 4, 6 to 9, and 13, collapsible sidewall structure 400 has: (a) a collapsed configuration when combination bulk container and pallet 50 is in the collapsed configuration, and (b) an expanded configuration when combination bulk container and pallet 50 is in the assembled configuration. FIGS. 3 and 4 show collapsible sidewall structure 400 in the collapsed configuration, and FIGS. 6 to 9 show collapsible sidewall structure 400 in the expanded configuration.
Collapsible sidewall structure 400 includes: (a) opposing, spaced apart, rectangular first and second or front and back panels or walls 412 and 416 including exterior surfaces 412 a and 416 a, respectively, and interior surfaces 412 b and 416 b, respectively; and (b) opposing, spaced apart, rectangular third and fourth or right and left collapsible panels or walls 414 and 418 including exterior surfaces 414 a and 418 a, respectively, and interior surfaces 414 b and 418 b, respectively. Front panel 412 includes or defines sidewall tine receiving openings 432 a and 432 b configured to receive the tines of a pallet jack or a forklift when combination bulk container and pallet 50 is in the assembled configuration (described below), right collapsible panel 414 includes or defines sidewall tine receiving openings 434 a and 434 b configured to receive the tines of a pallet jack or a forklift when combination bulk container and pallet 50 is in the assembled configuration, back panel 416 includes or defines sidewall tine receiving openings 436 a and 436 b configured to receive the tines of a pallet jack or a forklift when combination bulk container and pallet 50 is in the assembled configuration, and left collapsible panel 418 includes or defines sidewall tine receiving openings 438 a and 438 b configured to receive the tines of a pallet jack or a forklift when combination bulk container and pallet 50 is in the assembled configuration.
When in the expanded configuration: (a) sidewall tine receiving openings 432 a and 436 a define a first set of aligned sidewall tine receiving openings, (b) sidewall tine receiving openings 432 b and 436 b define a second set of aligned sidewall tine receiving openings, (c) sidewall tine receiving openings 434 a and 438 a define a third set of aligned sidewall tine receiving openings, and (d) sidewall tine receiving openings 434 b and 438 b define a fourth set of aligned sidewall tine receiving openings.
To facilitate folding of collapsible sidewall structure 400 from the expanded configuration to the collapsed configuration (as further described below), and to facilitate unfolding of collapsible sidewall structure 400 from the collapsed configuration to the expanded configuration (as further described below): (a) interior surface 418 b of left collapsible panel 418 includes a vertical score 458 located approximately at the horizontal center of left collapsible panel 418 that facilitates folding left collapsible panel 418; (b) interior surface 414 b of right collapsible panel 414 includes a vertical score (not shown) located approximately at the horizontal center of right collapsible panel 414 that facilitates folding right collapsible panel 414; (c) collapsible sidewall structure 400 includes a first fold edge 422 located at the intersection of front panel 412 and right collapsible panel 414 that facilitates folding right collapsible panel 414; (d) collapsible sidewall structure 400 includes a second fold edge 424 located at the intersection of back panel 416 and right collapsible panel 414 that facilitates folding right collapsible panel 414; (e) collapsible sidewall structure 400 includes a third fold edge 426 located at the intersection of back panel 416 and left collapsible panel 418 that facilitates folding left collapsible panel 418; (f) collapsible sidewall structure 400 includes a fourth fold edge 428 located at the intersection of left collapsible panel 418 and front panel 412 that facilitates folding left collapsible panel 418; (g) collapsible sidewall structure 400 includes a fifth fold edge 444 located on exterior surface 414 a of right collapsible panel 414 opposite the vertical score (not shown) on interior surface 414 b of right collapsible panel 414 that facilitates folding right collapsible panel 414; and (f) collapsible sidewall structure 400 includes a sixth fold edge 448 located on exterior surface 418 a of left collapsible panel 418 opposite vertical score 458 on interior surface 418 b of left collapsible panel 418 that facilitates folding left collapsible panel 418.
To fold collapsible sidewall structure 400 from the expanded configuration into the collapsed configuration, a user applies pressure to: (a) an area of exterior surface 418 a of left collapsible panel 418 opposite vertical score 458 on interior surface 418 b of left collapsible panel 418, and (b) an area of exterior surface 414 a of right collapsible panel 414 opposite the vertical score (not shown) on interior surface 414 b of right collapsible panel 414. Such pressure causes: (a) left collapsible panel 418 to fold onto itself along fold edges 426, 428, and 448; and (b) right collapsible panel 414 to fold onto itself along fold edges 422, 424, and 444, resulting in collapsible sidewall structure 400 folding into the collapsed configuration shown in FIGS. 3 and 4. To unfold collapsible sidewall structure 400 from the collapsed configuration into the expanded configuration, the user reverses this process.
As shown in FIGS. 1 to 4, 6 to 9, and 14, cover 500 includes: (a) a rectangular upper or top wall 501 including an interior surface 501 a and an exterior surface 501 b; (b) opposing, spaced apart, rectangular first and second or front and back walls 512 and 516 including interior surfaces 512 a and 516 a, respectively, and exterior surfaces 512 b and 516 b, respectively; and (c) opposing, spaced apart, rectangular third and fourth or right and left walls 514 and 518 including interior surfaces 514 a and 518 a, respectively, and exterior surfaces 514 b and 518 b, respectively.
As generally shown in FIGS. 1 to 4, 6 to 9, and 15, in this illustrated embodiment, combination bulk container and pallet 50 includes a plurality of combination cover supports/cut-strap protectors 600. It should be appreciated, however, that in other embodiments the combination bulk container and pallet does not include any combination cover supports/cut-strap protectors 600. In this illustrated embodiment, each combination cover support/cut-strap protector 600 includes a first wall 610 having an interior surface 610 a and an exterior surface 610 b and a second wall 620 connected to and positioned perpendicular to first wall 610 and including an interior surface 620 a and an exterior surface 620 b. That is, first wall 610 and second wall 620 are positioned and oriented relative to one another such that the cross section of combination cover support/cut-strap protector is an “L-shaped” cross section.
Pallet 100 is assembled or formed from bottom tray 200, material supporter 300, and support legs 310 by: (a) connecting top surfaces 313 of support legs 310 a to 310 i to bottom surface 301 b of material supporter 300, and (b) connecting bottom surfaces 311 of support legs 310 a to 310 i to top surface 201 a of bottom wall 201 of bottom tray 200. Specifically, in this illustrated embodiment, pallet 100 is assembled by: (a) connecting top surfaces 313 of support legs 310 a to 310 i to bottom surface 301 b of material supporter 300 via a lamination process using an adhesive, and (b) connecting bottom surfaces 311 of support legs 310 a to 310 i to top surface 201 a of bottom wall 201 of bottom tray via a lamination process using an adhesive. As best illustrated in FIG. 5, support legs 310 a to 310 i are positioned and sized such that when pallet 100 is assembled, support legs 310 a to 310 i do not: (a) prevent a wheel from being received in bottom tray wheel receiving openings 231 a, 231 b, 231 c, and 231 d; or (b) prevent the tines of a pallet jack or a forklift from being received in bottom tray tine receiving openings 232 a, 232 b, 234 a, 234 b, 236 a, 236 b, 238 a, and 238 b.
Further, as shown in FIG. 5, when pallet 100 is assembled, bottom tray 200, material supporter 300, and support legs 310 a to 310 i define a sidewall receiving channel 700 including a plurality of sidewall receiving channel portions 710, 720, 730, and 740. More specifically, in this illustrated embodiment: (a) sidewall receiving channel portion 710 is formed between: (i) interior surface 212 a of front wall 212; and (ii) front surfaces 312 a, 312 b, and 312 c of support legs 310 a, 310 b, and 310 c and the front edge of material supporter 300; (b) sidewall receiving channel portion 720 is formed between: (i) interior surface 214 a of right wall 214 of bottom tray 200; and (ii) right surfaces 314 c, 314 f, and 314 i of support legs 310 c, 310 f, and 310 i and the right edge of material supporter 300; (c) sidewall receiving channel portion 730 is formed between: (i) interior surface 216 a of back wall 216 of bottom tray 200; and (ii) the back surfaces (not shown) of support legs 310 g, 310 h, and 310 i and the back edge of material supporter 300; and (d) sidewall receiving channel portion 740 is formed between: (i) interior surface 218 a or left wall 218 of bottom tray 200; and (ii) the left surfaces (not shown) of support legs 310 a, 310 d, and 310 g and the left edge of material supporter 300. It should be appreciated that the width of sidewall receiving channel 700 is slightly larger than the thickness of collapsible sidewall structure 400 such that collapsible sidewall structure 400 may be inserted into sidewall receiving channel 700 (as further described below).
Pallet 100 of this illustrated embodiment of combination bulk container and pallet 50 is specifically configured to take into account that various different lifting and moving vehicles or equipment may be used to lift and move combination bulk container and pallet 50 when combination bulk container and pallet 50 is: (a) manufactured, (b) transported to a material loading facility, (c) at a material loading facility, (d) moved and positioned in a transport vehicle at the material loading facility after materials are loaded into the combination bulk container and pallet, (e) removed from a transport vehicle at the material unloading facility, (f) at a material unloading facility, and (g) moved and positioned in a transport vehicle at the material unloading facility after the materials are unloaded from the combination bulk container and pallet. More specifically, such facilities typically have either a conventional pallet jack and/or a conventional forklift used to move combination bulk container and pallet 50. As further described below, combination bulk container and pallet 50 and, specifically, pallet 100 of combination bulk container and pallet 50, is configured to account for the use of such forklifts that are configured to: (a) lift the combination bulk container and pallet off of the ground, (b) move the combination bulk container and pallet, (c) stack multiple combination bulk container and pallets on top of one another, and (d) un-stack stacked combination bulk container and pallets from one another. As also further described below, combination bulk container and pallet 50 and, specifically, pallet 100 of combination bulk container and pallet 50, is also configured to account for the use of such pallet jacks that are configured to: (a) lift the combination bulk container and pallet off of the ground, and (b) move the combination bulk container and pallet, but that are not configured to stack combination bulk container and pallets on top of one another or to un-stack stacked combination bulk container and pallets from one another.
Accordingly, when pallet 100 is assembled: (a) a first tine receiving channel configured to receive a tine of a pallet jack or a forklift is generally formed by: (i) the first set of aligned bottom tray tine receiving openings 232 a and 236 a; (ii) right surfaces 314 a, 314 d, and 314 g of support legs 310 a, 310 d, and 310 g, respectively; and (iii) the left surfaces (not shown) of support legs 310 b, 310 e, and 310 h; (b) a second tine receiving channel configured to receive a tine of a pallet jack or a forklift is generally formed by: (i) the second set of aligned bottom tray tine receiving openings 232 b and 236 b; (ii) right surfaces 314 b, 314 e, and 314 h of support legs 310 b, 310 e, and 310 h, respectively; and (iii) the left surfaces (not shown) of support legs 310 c, 310 f, and 310 i; (c) a third tine receiving channel configured to receive a tine of a pallet jack or a forklift is generally formed by: (i) the third set of aligned bottom tray tine receiving openings 234 a and 238 a; (ii) the back surfaces (not shown) of support legs 310 a, 310 b, and 310 c; and (iii) front surfaces 312 d, 312 e, and 312 f of support legs 310 d, 310 e, and 310 f, respectively; and (d) a fourth tine receiving channel configured to receive a tine of a pallet jack or a forklift is generally formed by: (i) the fourth set of aligned bottom tray tine receiving openings 234 b and 238 b; (ii) the back surfaces (not shown) of support legs 310 d, 310 e, and 310 f; and (iii) front surfaces 312 g, 312 h, and 312 i of support legs 310 g, 310 h, and 310 i, respectively.
In one example, when combination bulk container and pallet 50 located on a floor, to move combination bulk container and pallet 50 using a pallet jack, a user: (a) manipulates the pallet jack such that the tines of the pallet jack are inserted into the first and second tine receiving channels via either bottom tray tine receiving openings 232 a and 232 b or bottom tray tine receiving openings 236 a and 236 b; (b) manipulates the pallet jack such that the tines of the pallet jack are pushed through first and second tine receiving channels until the wheels of the pallet jack located on the tines contact the floor through either wheel receiving openings 231 c and 231 d (when the tines are inserted into the first and second tine receiving channels via bottom tray tine receiving openings 232 a and 232 b) or wheel receiving openings 231 a and 231 b (when the tines are inserted into the first and second tine receiving channels via bottom tray tine receiving openings 236 a and 236 b); and (c) manipulates the pallet jack to lift the tines such that the tines contact bottom surface 301 b of material supporter 300 and lift combination bulk container and pallet 50 off of the floor.
In another example, when combination bulk container and pallet 50 located on a floor or stacked on top of another combination bulk container and pallet, to move combination bulk container and pallet 50 using a forklift, a user: (a) manipulates the forklift such that the tines of the forklift are inserted into the third and fourth tine receiving channels via either bottom tray tine receiving openings 234 a and 234 b or bottom tray tine receiving openings 238 a and 238 b; (b) manipulates the forklift such that the tines of the forklift are pushed through third and fourth tine receiving channels until the tines protrude from either tine receiving openings 238 a and 238 b (when the tines are inserted into the third and fourth tine receiving channels via bottom tray tine receiving openings 234 a and 234 b) or bottom tray tine receiving openings 234 a and 234 b (when the tines are inserted into the third and fourth tine receiving channels via bottom tray tine receiving openings 238 a and 238 b); and (c) manipulates the forklift to lift the tines such that the tines contact bottom surface 301 b of material supporter 300 and lift combination bulk container and pallet 50 off of the floor or off of the other combination bulk container and pallet.
In certain embodiments, such as the embodiment illustrated in FIGS. 1 to 15, each tine receiving channel is configured to receive a tine of a pallet jack and a tine of a forklift. That is, in this illustrated embodiment, a user may lift and move the combination bulk container and pallet by inserting the tines of a pallet jack or a forklift into either: (i) the first and second tine receiving channels, or (ii) the third and fourth tine receiving channels. In other embodiments, either the first and second tine receiving channels or the third and fourth tine receiving channels are not configured to receive the tines of a pallet jack. In certain embodiments, either the first and second tine receiving channels or the third and fourth tine receiving channels are not configured to receive the tines of a forklift. In one embodiment, none of the tine receiving channels are configured to receive the tines of a pallet jack. That is, in this embodiment, the combination bulk container and pallet cannot be lifted and moved using a pallet jack, but can be lifted and moved using a forklift. In another embodiment, none of the tine receiving channels are configured to receive the tines of a forklift. That is, in this embodiment, the combination bulk container and pallet cannot be lifted and moved using a forklift, but can be lifted and moved using a pallet jack.
As described above, combination bulk container and pallet 50 has a collapsed configuration and an assembled configuration. FIGS. 1 to 4 generally illustrate combination bulk container and pallet 50 in the collapsed configuration. In this illustrated embodiment, in the collapsed configuration, a combination cover support/cut-strap protector 600 is positioned in a vertical orientation at each corner of sidewall receiving channel 700 such that a bottom edge of each combination cover support/cut-strap protector 600 faces and, in this embodiment, abuts interior surface 201 a of bottom wall 201 of bottom tray 200. Additionally, in the collapsed configuration, exterior surface 416 a of back panel 416 of collapsible sidewall structure 400 (which is in the collapsed configuration) faces and rests on top surface 301 a of material supporter 300 (as shown in FIG. 4). Further, in the collapsed configuration, cover 500 substantially covers collapsible sidewall structure 400 and combination cover supports/cut strap protectors 600 such that: (i) a top edge of each combination cover support/cut-strap protector 600 faces and, in this embodiment, abuts and supports a different corner of interior surface 501 a of top wall 501 of cover 500 (as shown in FIGS. 1 and 2); and (ii) exterior surface 412 a of front panel 412 of collapsible sidewall structure 400 (which is in the collapsed configuration) faces interior surface 501 a of cover 500.
Although the combination bulk container and pallet illustrated in FIGS. 1 and 2 includes a gap or space between the bottom edges of the front, back, right, and left walls of the cover and the top edges of the front, back, right, and left walls of the bottom tray, it should be appreciated that in other embodiments the front, back, right, and left walls of the cover abut and top edges of the front, back, right, and left walls of the bottom tray, respectively, such that such a gap is not formed when the combination bulk container and pallet is in the collapsed configuration.
FIGS. 6 to 9 generally illustrate combination bulk container and pallet 50 in the assembled configuration. In this illustrated embodiment, in the assembled configuration, a bottom portion of each of the panels of collapsible sidewall structure 400 (which is in the expanded configuration) is received by sidewall receiving channel 700 such that bottom tray tine receiving openings 232 a, 232 b, 234 a, 234 b, 236 a, 236 b, 238 a, and 238 b align with sidewall tine receiving openings 432 a, 432 b, 434 a, 434 b, 436 a, 436 b, 438 a, and 438 b, respectively, and a bottom edge of each of the panels faces and, in this embodiment, abuts interior surface 201 a of bottom wall 201 of bottom tray 200. The bottom portions of the panels received by sidewall receiving channel 700 are held in a friction engagement fit by the walls, edges, and support legs that define sidewall receiving channel 700. Additionally, in the assembled configuration, cover 500 is positioned atop the top edges of the panels of collapsible sidewall structure 400 such that cover 500 covers the material holding area formed by the panels of collapsible sidewall structure 400 and material supporter 300. That is, cover 500 is positioned such that the top edges of the panels of collapsible sidewall structure 400 face and, in this embodiment, abut interior surface 501 a of top wall 501 of cover 500. Further, in the assembled configuration of this illustrated embodiment, a combination cover support/cut-strap protector 600 is positioned in a horizontal orientation: (i) on the exterior surfaces of front wall 512 and top wall 501 of cover 500 at approximately the horizontal center of front wall 512 and top wall 501, (ii) on the exterior surfaces of back wall 516 and top wall 501 of cover 500 at approximately the horizontal center of back wall 516 and top wall 501, (iii) on the exterior surfaces of front wall 212 and bottom wall 201 of bottom tray 200 at approximately the horizontal center of front wall 212 and bottom wall 201, and (iv) on the exterior surfaces of back wall 216 and bottom wall 201 of bottom tray 200 at approximately the horizontal center of back wall 216 and bottom wall 201 of bottom tray 200.
To convert this illustrated embodiment of combination bulk container and pallet 50 from the collapsed configuration into the assembled configuration, a user removes cover 500 from combination cover supports/cut-strap protectors 600 and removes cover supports/cut-strap protectors 600 from the corners of sidewall receiving channel 700. The user unfolds collapsible sidewall structure 400 from the collapsed configuration into the expanded configuration as generally described above. The user slides the bottom portions of the panels of collapsible sidewall structure 400 into sidewall receiving channel 700 such that: (i) bottom tray tine receiving openings 232 a, 232 b, 234 a, 234 b, 236 a, 236 b, 238 a, and 238 b align with sidewall tine receiving openings 432 a, 432 b, 434 a, 434 b, 436 a, 436 b, 438 a, and 438 b, respectively; and (ii) the bottom edges of the panels of collapsible sidewall structure 400 face and, in this embodiment, abut interior surface 201 b of bottom wall 201 of bottom tray 200. This forms a material holding area defined by the panels of collapsible sidewall structure 400 and material supporter 300. The user covers the material holding area with cover 500 by positioning cover 500 atop the top edges of the panels of collapsible sidewall structure 400 such that the top edges of the panels face and, in this embodiment, abut interior surface 501 b of top wall 501 of cover 500. If desired, the user positions combination cover supports/cut-strap protectors 600 in the positions described above or in any other desired positions.
Conversely, to convert combination bulk container and pallet 50 from the assembled configuration into the collapsed configuration, a user removes combination cover supports/cut-strap protectors 600, if any. The user removes cover 500 from collapsible sidewall structure 400, and removes collapsible sidewall structure 400 from sidewall receiving channel 700. The user folds collapsible sidewall structure 400 from the expanded configuration into the collapsed configuration as generally described above, and rests the exterior surface of one of the panels of collapsible sidewall structure 400 on top surface 301 a of material supporter 300. If desired, the user inserts one of combination cover supports/cut-strap protectors 600 at each corner of sidewall receiving channel 700 such that the bottom edge of each combination cover support/cut-strap protector 600 faces and, in this embodiment, abuts interior surface 201 a of bottom wall 201 of bottom tray 201. The user uses cover 500 to cover collapsible sidewall structure 400 by positioning cover 500 such that: (a) the top edge of each combination cover support/cut-strap protector 600 faces and, in this embodiment, abuts and supports a different corner of interior surface 501 a of top wall 501 of cover 500; and (b) an exterior surface of one of the panels of collapsible sidewall structure 400 faces interior surface 501 b of top wall 501 of cover 500.
In one embodiment: (a) the bottom tray, the material supporter, the collapsible sidewall structure, and the cover are each made from 61 ECT (edge crush test units) double wall corrugated fiberboard; (b) the support legs are each made from a CT1 kraft paper honeycomb material; and (c) the combination cover supports/cut strap protectors are each made from 0.120 inch (0.3048 centimeter) pasted chipboard material. It should be appreciated that various elements of the combination bulk container and pallet may be manufactured from a variety of different materials. In one example, the bottom tray, the material supporter, the collapsible sidewall structure, and the cover are each made from a different gauge corrugated fiberboard. In another example, the support legs are each made from a different gauge kraft paper honeycomb material. In another example, the combination cover supports/cut strap protectors are made from a different sized pasted chipboard material. In another embodiment, certain of the elements of the combination bulk container and pallet are made of plastic.
In one embodiment, the bottom tray is formed from a single piece of corrugated fiberboard. That is, in this embodiment, the bottom tray is folded along a plurality of fold lines from a flat or unfolded configuration into a folded configuration. FIG. 10 is a top plan view of one example of the bottom tray of this embodiment in an unfolded configuration. The dashed lines represent fold lines along which the front wall, the back wall, the left wall, and the right wall of the bottom tray are folded to form the folded configuration generally shown in FIGS. 1 to 9 and described above.
In this illustrated embodiment: (a) bottom wall 201 is approximately 48.0625 inches (122.07875 centimeters) by approximately 45.375 inches (115.2525 centimeters); (b) front wall 212 and back wall 216 are each approximately 48.0625 inches (122.07875 centimeters) by approximately 5.625 inches (14.2875 centimeters); (c) right wall 214 and left wall 218 are each approximately 5.625 inches (14.2875 centimeters) by approximately 45.375 inches (115.2525 centimeters); (d) wheel receiving openings 231 a, 231 b, 231 c, and 231 d are each approximately 10.75 inches (27.305 centimeters) by approximately 9 inches (22.86 centimeters); (e) bottom tray tine receiving openings 232 a, 232 b, 236 a, and 236 b, are each approximately 10.75 inches (27.305 centimeters) by approximately 3.75 inches (9.525 centimeters); and (f) bottom tray tine receiving openings 234 a, 234 b, 238 a, and 238 b are approximately 3.75 inches (9.525 centimeters) by approximately 9 inches (22.86 centimeters). It should be appreciated that, in other embodiments, the elements of the bottom tray and the openings defined by the elements of the bottom tray may have other suitable sizes.
Although the elements of the bottom tray of this illustrated embodiment and the openings defined by the elements of the bottom tray of this illustrated embodiment are generally rectangular in shape, it should be appreciated that, in other embodiments, such elements and openings may take other suitable shapes.
FIG. 11 is a top plan view of an example of the material supporter of the present disclosure, and includes hidden lines showing the locations of example support legs. FIG. 12 is a side elevational view of the material supporter and the support legs of FIG. 11. In this illustrated embodiment: (a) material supporter 300 is approximately 46.5 inches (118.11 centimeters) by approximately 43.5 inches (110.49 centimeters) by approximately 1 inch (2.54 centimeters); (b) support legs 310 a to 310 i are each approximately 8 inches (20.32 centimeters) by approximately 8 inches (20.32 centimeters) by approximately 3.5 inches (8.89 centimeters); (c) support legs 310 a and 310 b, 310 b and 310 c, 310 d and 310 e, 310 e and 310 f, 310 g and 310 h, and 310 h and 310 i are spaced approximately 11.25 inches (28.575 centimeters) apart; and (d) support legs 310 a and 310 d, 310 d and 310 g, 310 b and 310 e, 310 e and 310 h, 310 c and 310 f, and 310 f and 310 i are spaced approximately 9.75 inches (24.765 centimeters) apart. It should be appreciated that, in other embodiments, the support legs may have other suitable sizes, and the support legs may be spaced apart by other suitable distances.
Although the material supporter of this illustrated embodiment is generally rectangular in shape, it should be appreciated that, in other embodiments, the material supporter may take other suitable shapes.
In one embodiment, the collapsible sidewall structure is formed from a single piece of corrugated fiberboard. That is, in this embodiment, opposing ends of the piece of corrugated fiberboard are joined (such as by an adhesive) to form the connected panels of the collapsible sidewall structure. FIG. 13 is a side elevational view of an example of the collapsible sidewall structure of the present disclosure. In this example, the free edges of the back panel and the left panel are joined to form the connected panels of the collapsible sidewall structure. The dashed lines represent the fold edges described above along which the panels are folded to form the collapsed configuration and unfolded to form the expanded configuration.
In this illustrated embodiment: (a) front panel 412 is approximately 47.065 inches (119.5451 centimeters) by approximately 32 inches (81.28 centimeters); (b) right collapsible panel 414 is approximately 44.065 inches (111.9251 centimeters) by approximately 32 inches (81.28 centimeters); (c) back panel 416 is approximately 46.907 inches (119.14378 centimeters) by approximately 32 inches (81.28 centimeters); (d) left collapsible panel 418 is approximately 43.907 inches (111.52378 centimeters) by approximately 32 inches (81.28 centimeters); (e) vertical score 438 is located approximately 21.953125 inches (55.7609375 centimeters) from fourth fold edge 428; (f) the vertical score (not shown) on inner surface 414 b of right collapsible wall 414 is approximately 22.032 inches (55.96128 centimeters) from first fold edge 422; (g) sidewall tine receiving openings 432 a, 432 b, 436 a, and 436 b are each approximately 10.75 inches (27.305 centimeters) by approximately 3.625 inches (9.2075 centimeters); and (h) sidewall tine receiving openings 434 a, 434 b, 438 a, and 438 b are each approximately 9 inches (22.86 centimeters) by approximately 3.625 inches (9.2075 centimeters). It should be appreciated that, in other embodiments, the elements of the collapsible sidewall structure and the openings defined by the elements of the collapsible sidewall structure may have other suitable sizes.
Although the elements of the collapsible sidewall structure of this illustrated embodiment and the openings defined by the elements of the collapsible sidewall structure of this illustrated embodiment are generally rectangular in shape, it should be appreciated that, in other embodiments, such elements and openings may take other suitable shapes.
In one embodiment, the cover is formed from a single piece of corrugated fiberboard. That is, in this embodiment, the cover is folded along a plurality of fold lines from a flat or unfolded configuration into a folded configuration. FIG. 14 is a top plan view of one example of the cover of this embodiment in an unfolded configuration. The dashed lines represent fold lines along which the front wall, the back wall, the left wall, and the right wall of the cover are folded to form the folded configuration generally shown in FIGS. 1 to 9 and described above.
In this illustrated embodiment: (a) top wall 501 is approximately 49.075 inches (124.6505 centimeters) by approximately 44.815 inches (113.8301 centimeters); (b) front wall 512 and back wall 516 are each approximately 49.075 inches (124.6505 centimeters) by approximately 4.093 inches (10.39622 centimeters); and (c) right wall 514 and left wall 518 are each approximately 4.25 inches (10.795 centimeters) by approximately 44.815 inches (113.8301 centimeters). It should be appreciated that, in other embodiments, the elements of the cover may have other suitable sizes.
FIG. 15 is a top perspective view of an example of the combination cover support/cut-strap protector of the present disclosure. In this illustrated embodiment, first wall 610 and second wall 620 are each approximately 2.5 inches (6.35 centimeters) by approximately 9 inches (22.86 centimeters) by approximately 0.120 inches (0.3048 centimeters). It should be appreciated that, in other embodiments, the elements of the combination cover support/cut strap protector may have other suitable sizes. It should also be appreciated that, in other embodiments, the cross section of the combination cover support/cut-strap protector may take other suitable shapes.
FIGS. 16 to 20 illustrate another example embodiment of a combination bulk container and pallet of the present disclosure. In this embodiment, the combination bulk container and pallet 150 includes eight cover supports/cut-strap protectors 1600. As best illustrated in FIGS. 16 and 17, in this embodiment, when combination bulk container and pallet 150 is in the collapsed configuration, a nested pair of cover supports/cut-strap protectors 1600 is positioned in a vertical orientation at each corner of the sidewall receiving channel such that a bottom edge of each combination cover support/cut-strap protector 1600 faces and, in this embodiment, abuts the interior surface of the bottom wall of bottom tray 1200. Additionally, in the collapsed configuration, cover 1500 substantially covers collapsible sidewall structure 1400 and combination cover supports/cut strap protectors 1600 such that: (i) a top edge of each combination cover support/cut-strap protector 1600 faces and, in this embodiment, abuts and supports a different corner of the interior surface of the top wall of cover 1500; and (ii) the exterior surface of the front panel of collapsible sidewall structure 1400 (which is in the collapsed configuration) faces the interior surface of cover 500.
FIGS. 18 to 20 generally illustrate combination bulk container and pallet 150 in the assembled configuration. In this embodiment, in the assembled configuration, a combination cover support/cut-strap protector 1600 is positioned in a horizontal orientation: (i) on the exterior surfaces of the front wall and the top wall of cover 1500 at approximately the horizontal center of each of the tine receiving openings defined by the front wall of bottom tray 1200, (ii) on the exterior surfaces of the back wall and the top wall of cover 1500 at approximately the horizontal center of each of the tine receiving openings defined by the back wall of bottom tray 1200, (iii) on the exterior surface of the front wall of bottom tray 1200 at approximately the horizontal center of each of the tine receiving openings defined by the front wall, and (iv) on the exterior surface of the back wall of bottom tray 1200 at approximately the horizontal center of each of the tine receiving openings defined by the back wall of bottom tray 1200.
In an alternative embodiment, the cover supports/cut-strap protectors are positioned on the exterior surfaces of the top wall and the right and left walls of the cover at approximately the horizontal center of each of the tine receiving openings defiled by the right and left walls of the bottom tray, and on the exterior surfaces of the right and left walls of the bottom tray at approximately the horizontal center of each of the tine receiving openings defined by the right and left walls of the bottom tray.
In one embodiment, the bottom tray includes additional reinforcing material near or around the openings. In one example, the additional material is the same material that the bottom tray is made from, while in another example the additional material is a different material than the material that the bottom tray is made from. Such reinforcing material reduces the risk that a pallet jack or a forklift will damage the bottom tray during operation, such as when the tines are being inserted into the tine receiving channels. In another embodiment, one or more of the openings is configured to receive a reinforcing insert configured to reinforce the material surrounding the openings. In one example, the insert is made of plastic that is more resistant to damage than the material of the bottom tray.
One widely commercially used conventional pallet jack that may be employed with various embodiments of the combination bulk container and pallet of the present disclosure has spaced apart non-movable forks or tines, wherein each of the tines is approximately 7.75 inches (19.69 centimeters) wide, and the space between the tines is approximately 8.50 inches (21.59 centimeters). One widely commercially used conventional forklift that may be employed with various embodiments of the combination bulk container and pallet of the present disclosure has adjustably spaced apart tines or tines, wherein each tine is approximately 5 inches (12.70 centimeters) wide, and the space between the tines is adjustable from approximately 4 inches (10.16 centimeters) to approximately 24 inches (60.96 centimeters).
It should be understood that modifications and variations may be effected without departing from the scope of the novel concepts of the present disclosure, and it should be understood that this application is to be limited only by the scope of the appended claims.

Claims

The invention is claimed as follows:

1. A combination bulk container and pallet comprising:

a pallet including:

(a) a bottom tray,

(b) a material supporter, and

(c) a plurality of support legs positioned between the bottom tray and the material supporter;

a cover; and

a collapsible sidewall structure having a collapsed configuration and an expanded configuration, the collapsible sidewall structure including a plurality of connected walls, wherein:

(a) in the collapsed configuration, an exterior surface of one of the walls faces a top surface of the material supporter, and an exterior surface of another one of the walls faces an interior surface of a first wall of the cover; and

(b) in the expanded configuration, the walls and the material supporter define a material holding area, bottom edges of the walls face an interior surface of a first wall of the bottom tray, and upper edges of the walls face the interior surface of the first wall of the cover.

2. The combination bulk container and pallet of claim 1, wherein the support legs are connected to the bottom tray and the material supporter.

3. The combination bulk container and pallet of claim 1, which includes a plurality of combination cover supports/cut-strap protectors.

4. The combination bulk container and pallet of claim 3, wherein, in the collapsed configuration, a bottom edge of one of the combination cover supports/cut-strap protectors faces the interior surface of the first wall of the bottom tray, and a top edge of the combination cover support/cut-strap protector faces the interior surface of the first wall of the cover.

5. The combination bulk container and pallet of claim 3, wherein, in the expanded configuration, an interior surface of one of the combination cover supports/cut-strap protectors faces an exterior surface of the first wall of the cover and an interior surface of another one of the combination cover supports/cut-strap protectors faces an exterior surface of a second wall of the cover.

6. The combination bulk container and pallet of claim 1, wherein the bottom tray includes a first wall defining a plurality of bottom tray tine receiving openings and a second wall defining a plurality of bottom tray tine receiving openings, wherein each of the bottom tray tine receiving openings defined by the first wall is aligned with a different one of the bottom tray tine receiving openings defined by the second wall.

7. The combination bulk container and pallet of claim 6, wherein a first plurality of the support legs and a first plurality of the aligned bottom tray tine receiving openings define a first tine receiving channel, and a second plurality of the support legs and a second plurality of the aligned bottom tray tine receiving openings define a second tine receiving channel.

8. The combination bulk container and pallet of claim 1, wherein the bottom tray, the material supporter, and the support legs define a sidewall receiving channel, and in the expanded configuration, bottom edges of the walls are received in the side wall receiving channel.

9. A combination bulk container and pallet comprising:

a pallet including:

(a) a bottom tray;

(b) a material supporter; and

(c) a plurality of support legs positioned between and connected to the bottom tray and the material supporter, the bottom tray, the material supporter, and the support legs defining a sidewall receiving channel; and

(a) in the collapsed configuration, an exterior surface of one of the walls faces a top surface of the material supporter; and

(b) in the expanded configuration, the walls and the material supporter define a material holding area, and bottom edges of the walls are received in the side wall receiving channel.

10. The combination bulk container and pallet of claim 9, which includes a cover, wherein in the collapsed configuration, an exterior surface of another one of the walls faces an interior surface of a first wall of the cover; and in the expanded configuration, upper edges of the walls face the interior surface of the first wall of the cover.

11. The combination bulk container and pallet of claim 10, which includes a plurality of combination cover supports/cut-strap protectors.

12. The combination bulk container and pallet of claim 11, wherein, in the collapsed configuration, a bottom edge of one of the combination cover supports/cut-strap protectors faces an interior surface of a first wall of the bottom tray, and a top edge of the combination cover supports/cut-strap protectors faces the interior surface of the first wall of the cover.

13. The combination bulk container and pallet of claim 11, wherein, in the expanded configuration, an interior surface of one of the combination cover supports/cut-strap protectors faces an exterior surface of the first wall of the cover and an interior surface of another one of the combination cover supports/cut-strap protectors faces an exterior surface of a second wall of the cover.

14. The combination bulk container and pallet of claim 9, wherein the bottom tray includes a first wall defining a plurality of bottom tray tine receiving openings and a second wall defining a plurality of bottom tray tine receiving openings, wherein each of the bottom tray tine receiving openings defined by the first wall is aligned with a different one of the bottom tray tine receiving openings defined by the second wall.

15. The combination bulk container and pallet of claim 14, wherein a first plurality of the support legs and a first plurality of the aligned bottom tray tine receiving openings define a first tine receiving channel, and a second plurality of the support legs and a second plurality of the aligned bottom tray tine receiving openings define a second tine receiving channel.

16. A combination bulk container and pallet comprising:

a pallet including:

(a) a bottom tray including:

(i) a first wall defining a plurality of bottom tray tine receiving openings; and

(ii) a second wall defining a plurality of bottom tray tine receiving openings, wherein each of the bottom tray tine receiving openings defined by the first wall is aligned with a different one of the bottom tray tine receiving openings defined by the second wall;

(b) a material supporter; and

(c) a plurality of support legs positioned between the bottom tray and the material supporter; and

(a) a first one of the walls defines a plurality of sidewall tine receiving openings;

(b) a second one of the walls defines a plurality of sidewall tine receiving openings; and

(c) in the expanded configuration:

(i) each of the sidewall tine receiving openings defined by the first one of the walls is aligned with a different one of the sidewall tine receiving openings defined by the second one of the walls; and

(ii) the bottom tray tine receiving openings defined by the first wall are aligned with the sidewall tine receiving openings defined by the first one of the walls, and the bottom tray tine receiving openings defined by the second wall are aligned with the sidewall tine receiving openings defined by the second one of the walls.

17. The combination bulk container and pallet of claim 16, wherein a first plurality of the support legs and a first plurality of the aligned bottom tray tine receiving openings define a first tine receiving channel, and a second plurality of the support legs and a second plurality of the aligned bottom tray tine receiving openings define a second tine receiving channel.

18. The combination bulk container and pallet of claim 16, wherein the bottom tray includes a third wall defining a plurality of wheel receiving openings.

19. The combination bulk container and pallet of claim 16, wherein in the collapsed configuration, an exterior surface of one of the walls faces a top surface of the material supporter.

20. The combination bulk container and pallet of claim 16, wherein the bottom tray, the material supporter, and the support legs define a sidewall receiving channel, and in the expanded configuration, bottom edges of the walls are received in the side wall receiving channel.

21. The combination bulk container and pallet of claim 16, which includes a cover, wherein in the collapsed configuration, an exterior surface of one of the walls faces an interior surface of a first wall of the cover.

22. The combination bulk container and pallet of claim 21, which includes a plurality of combination cover supports/cut-strap protectors.

23. The combination bulk container and pallet of claim 22, wherein, in the collapsed configuration, a bottom edge of one of the combination cover supports/cut-strap protectors faces an interior surface of a third wall of the bottom tray, and a top edge of the combination cover supports/cut-strap protectors faces the interior surface of the first wall of the cover.

24. The combination bulk container and pallet of claim 22, wherein, in the expanded configuration, an interior surface of one of the combination cover supports/cut-strap protectors faces an exterior surface of the first wall of the cover and an interior surface of another one of the combination cover supports/cut-strap protectors faces an exterior surface of a second wall of the cover.