Multi-ply collapsible bulk container

Abstract

A bulk container is disclosed, having a plurality of substantially planar walls, a plurality of corners connecting the walls, and a top and a bottom both formed by a plurality of foldable flaps. A first corner and a second corner opposite the first corner each have two substantially parallel score lines on an inner side of each corner allowing the corners to fold at an angle of substantially 0° while maintaining the structural integrity of the container. The walls of the container are constructed from a multi-ply corrugated cardboard sleeve made up of two layers of multi-ply corrugated cardboard laminated to each other. Two corrugated cardboard inserts, each having foldable top and bottom flaps are laminated to the sleeve. Also disclosed is a method of manufacturing the container using a number of blanks and inserts.

1 . A bulk container comprising: 
 a plurality of substantially planar walls;    a plurality of corners, each corner connecting two walls, wherein a first corner and a second corner opposite the first corner each have two substantially parallel score lines on an inner side allowing the first and second corners to fold at an angle of substantially 0° while maintaining the structural integrity of the container;    a top formed by a plurality of foldable flaps; and    a bottom formed by a plurality of foldable flaps.    
   
   
       2 . The bulk container of  claim 1  wherein the walls are comprised of at least first and second three-ply corrugated cardboard blanks and at least first and second two-ply corrugated cardboard inserts, wherein the inserts do not overlap each other.  
   
   
       3 . The bulk container of  claim 2 , wherein the walls are further comprised of at least third and fourth three-ply corrugated cardboard blanks.  
   
   
       4 . The bulk container of  claim 3 , wherein the inserts are located on an interior of the container.  
   
   
       5 . The bulk container of  claim 3 , wherein the inserts are located on an exterior of the container.  
   
   
       6 . The bulk container of  claim 1 , wherein a third inner corner and a fourth inner corner each have a score line allowing each of the third and fourth corners to fold at an angle of at least 90° while maintaining the structural integrity of the container.  
   
   
       7 . The bulk container of  claim 1 , wherein each wall is formed of at least eight-ply corrugated cardboard sheet.  
   
   
       8 . A bulk container comprising: 
 a multi-ply corrugated cardboard sleeve comprised of a first layer of multi-ply corrugated cardboard laminated to a second layer of multi-ply corrugated cardboard, the sleeve folded to form a plurality of walls and a plurality of corners defining a perimeter;    a first corrugated cardboard insert comprising a foldable top flap and a foldable bottom flap and laminated to a surface of the sleeve, the first insert extending approximately half the perimeter; and    a second corrugated cardboard insert comprising a foldable top flap and a foldable bottom flap and laminated to a surface of the sleeve, the second insert extending approximately half the perimeter and separate from the first insert,    wherein the top flaps fold inward to form a top of the container and the bottom flaps fold inward to form a bottom of the container.    
   
   
       9 . The bulk container of  claim 8 , wherein the first and second inserts are laminated to an interior surface of the sleeve.  
   
   
       10 . The bulk container of  claim 8 , wherein the first and second inserts are laminated to an exterior surface of the sleeve.  
   
   
       11 . The bulk container of  claim 8 , wherein a first corner and a second corner opposite the first corner each have two substantially parallel score lines on an inner side allowing the first and second corners to fold at an angle of substantially 0° while maintaining the structural integrity of the container.  
   
   
       12 . The bulk container of  claim 11 , wherein a third corner and a fourth corner each have a score line allowing each of the third corner and the fourth corner to fold at an angle of at least 90° while maintaining the structural integrity of the container.  
   
   
       13 . A method of constructing a bulk container having a top, a bottom, and a plurality of walls, comprising the steps of: 
 providing a first blank comprising a first panel and a second panel separated by a first fold line comprising a pair of substantially parallel score lines;    providing a second blank comprising a first panel and a second panel separated by a first fold line comprising a pair of substantially parallel score lines;    attaching a surface of the first blank to a surface of the second blank such that the fold line of the first blank is substantially aligned with the fold line of the second blank;    providing a first insert comprising a top flap, a bottom flap, and a first panel and a second panel separated by a fold line;    attaching a surface of the first insert to a surface of the second blank such that the first panel of the first insert is substantially aligned with one of the first panel and the second panel of the second blank; and    folding the first blank, the second blank, and the first insert at the fold lines to create a number of the walls of the bulk container.    
   
   
       14 . The method of  claim 13 , further comprising the steps of: 
 providing a third blank comprising a first panel and a second panel separated by a fold line comprising a pair of substantially parallel score lines;    providing a fourth blank comprising a first panel and a second panel separated by a fold line comprising a pair of substantially parallel score lines;    attaching a surface of the third blank to a surface of the fourth blank such that the fold line of the third blank is substantially aligned with the fold line of the fourth blank;    providing a second insert comprising a top flap, a bottom flap, and a first panel and a second panel separated by a fold line;    attaching a surface of the second insert to a surface of the fourth blank such that the first panel of the second insert is substantially aligned with the first panel of the fourth blank;    folding the third blank, the fourth blank, and the second insert at the fold lines to create a number of the walls of the bulk container; and    attaching the number of walls created by the first blank, the second blank, and the first insert to the number of walls created by the third blank, the fourth blank, and the second insert to create four walls and four substantially 90° corners of the bulk container.    
   
   
       15 . The method of  claim 13 , wherein the first blank further comprises a third panel, separated from the second panel by a second fold line comprising a score line, and a fourth panel, separated from the third panel by a third fold line comprising a pair of substantially parallel score lines, and the second blank further comprises a third panel, separated from the second panel by a second fold line comprising a score line, and a fourth panel, separated from the third panel by a third fold line comprising a pair of substantially parallel score lines, further comprising the steps of: 
 attaching a surface of the first blank to a surface of the second blank such that the first fold line of the first blank is substantially aligned with the first fold line of the second blank, the second fold line of the first blank is substantially aligned with the second fold line of the second blank, and the third fold line of the first blank is substantially aligned with the third fold line of the second blank;    providing a second insert comprising a top flap, a bottom flap, and a first panel and a second panel separated by a fold line;    attaching a surface of the second insert to a surface of the second blank such that the first panel of the second insert is substantially aligned with one of the third panel and the fourth panel of the second blank; and    folding the first blank, the second blank, the first insert, and the second insert at the fold lines to create four walls and four substantially 90° corners of the bulk container.    
   
   
       16 . The method of  claim 13 , wherein the pair of substantially parallel score lines allow the first blank and the second blank to fold at substantially a 180° angle while maintaining the structural integrity of the container.  
   
   
       17 . The method of  claim 13 , wherein the first blank is comprised of three-ply corrugated cardboard, the second blank is comprised of three-ply corrugated cardboard, and the insert is comprised of two-ply corrugated cardboard.  
   
   
       18 . The method of  claim 13 , wherein the second blank further comprises a second fold line creating a connecting flap, and the first blank and the second blank are attached in an offset manner, allowing the connecting flap to fold at the second fold line.  
   
   
       19 . The method of  claim 13 , wherein the first blank, the second blank, and the first insert are folded such that the first insert is located on an exterior of the bulk container.  
   
   
       20 . The method of  claim 13 , wherein the first blank, the second blank, and the first insert are attached by laminating with an adhesive.