US4989731A — Bulk container

Claim 1

Independent Claim 59 words

A container of the type comprising a rigid plastic pallet and a tubular sleeve adapted to be supported in upstanding fashion on the upper face of the pallet to form the container, characterized in that the wall of the sleeve has a sandwich cross-sectional configuration including an inner plastic layer, a central cardboard layer, and an outer plastic layer.

Claim 2

Dependent Claim 59 words

A container of the type comprising a rigid plastic pallet and a tubular sleeve adapted to be supported in upstanding fashion on the upper face of the pallet to form the container, characterized in that the wall of the sleeve has a sandwich cross-sectional configuration including an inner plastic layer, a central cardboard layer, and an outer plastic layer.

Claim 3

Dependent Claim 16 words

A container according to claim 1 wherein said central cardboard layer comprises a corrugated cardboard layer.

Claim 4

Dependent Claim 16 words

A container according to claim 2 wherein said inner and outer plastic layers comprise vinyl layers.

Claim 5

Dependent Claim 17 words

A container according to claim 2 wherein said corrugated cardboard layer comprises a multiple wall corrugated layer.

Claim 6

Dependent Claim 34 words

A container according to claim 4 wherein said multiple wall corrugated layer comprises an inner cardboard panel of multiple wall construction secured in back-to-back relation to an outer cardboard panel of multiple wall construction.

Claim 7

Dependent Claim 25 words

A container according to claim 5 wherein each of said cardboard panels has a triple wall construction so that said cardboard layer comprises six sublayers.

Claim 8

Dependent Claim 16 words

A container according to claim 6 wherein said inner and outer plastic layers comprise vinyl layers.

Claim 9

Dependent Claim 101 words

A container according to claim 5 wherein: each cardboard panel comprises a plurality of flat cardboard sheets interspersed with corrugated cardboard sheets; a supplemental flat cardboard sheet is secured to the outer face of said outer cardboard panel and a supplemental flat cardboard sheet is secured to the inner face of said inner cardboard panel; and said outer plastic layer comprises a vinyl sheet secured to the exposed face of the supplemental sheet of the outer cardboard panel and said inner plastic layer comprises a vinyl sheet secured to the exposed face of the supplemental sheet of the inner cardboard panel.

Claim 10

Dependent Claim 28 words

A container according to claim 1 wherein said pallet defines upwardly facing receiving means on its upper face for receipt of the lower peripheral edge of said sleeve.

Claim 11

Dependent Claim 17 words

A container according to claim 9 wherein said upwardly facing receiving means comprises upwardly opening groove means.

Claim 12

Dependent Claim 37 words

A container according to claim 10 wherein said container further comprises coacting means proximate said lower peripheral edge of said sleeve and on said pallet proximate said groove means for releasably securing said sleeve to said pallet.

Claim 13

Dependent Claim 54 words

A container according to claim 11 wherein said pallet includes downwardly extending legs defining downwardly opening tunnels therebetween extending across the lower face of the pallet for receipt of the forks of a forklift truck and the groove means are defined around the periphery of the upper face of the pallet over the tunnels.

Claim 14

Dependent Claim 20 words

A container according to claim 12 wherein said pallet, said groove means, and said sleeve each have a rectangular configuration.

Claim 15

Dependent Claim 22 words

A container according to claim 1 wherein said plastic layers further cover the upper and lower annular end edges of said sleeve.

Claim 16

Dependent Claim 47 words

A container according to claim 14 wherein said pallet includes a plurality of latch members, said sleeve includes a plurality of slots for respective receipt of said latch members to releasably secure the sleeve to the pallet, and said plastic layers form a lining for said slots.

Claim 17

Dependent Claim 107 words

A container according to claim 1 wherein said sleeve includes four side portions together defining a rectangle and four angled corner portions at the four corners of the sleeve, and said pallet defines an upwardly extending rim extending around the periphery of the pallet and having a continuous circumferentially inboard face sized to telescopically receive said sleeve and including four side portions sized to respectively embrace the outer surfaces of the lower edge portions of the four side portions of the sleeve and four corner portions sized to respectively embrace the outer surfaces of the lower edge portions of the four angled corner portions of the sleeve.

Claim 18

Dependent Claim 121 words

A container comprising: a plastic pallet defining upwardly opening groove means around the periphery of the upper face of the pallet; a tubular sleeve assembly comprising inner and outer tubular sleeves respectively formed of first and second corrugated cardboard structures with said inner sleeve positioned telescopically within said outer sleeve to form a composite sleeve assembly having a thickness approximating the width of said groove means so that the lower peripheral edge of said sleeve assembly may be received snugly in said groove means to define said container; and coacting means on said sleeve assembly proximate said lower peripheral edge and on said pallet proximate said groove means for releasably securing said lower edge of said sleeve assembly to said pallet.

Claim 19

Dependent Claim 121 words

A container comprising: a plastic pallet defining upwardly opening groove means around the periphery of the upper face of the pallet; a tubular sleeve assembly comprising inner and outer tubular sleeves respectively formed of first and second corrugated cardboard structures with said inner sleeve positioned telescopically within said outer sleeve to form a composite sleeve assembly having a thickness approximating the width of said groove means so that the lower peripheral edge of said sleeve assembly may be received snugly in said groove means to define said container; and coacting means on said sleeve assembly proximate said lower peripheral edge and on said pallet proximate said groove means for releasably securing said lower edge of said sleeve assembly to said pallet.

Claim 20

Dependent Claim 53 words

A container according to claim 17 wherein: each said corrugated cardboard structure comprises a multiple ply cardboard structure including a plurality of flat primary cardboard sheets interspersed with a plurality of corrugated cardboard sheets with flat primary inboard and outboard sheets disposed on the inner and outer surfaces respectively of each cardboard structure.

Claim 21

Dependent Claim 50 words

A container according to claim 18 wherein: said first cardboard structure further includes a flat auxiliary cardboard sheet secured to the outboard sheet of said first cardboard structure and said second cardboard structure further includes a flat auxiliary cardboard sheet secured to the inboard sheet of said second cardboard structure.

Claim 22

Dependent Claim 39 words

A container according to claim 17 wherein: said sleeve assembly further includes a plastic layer secured to the inner annular surface of said inner sleeve and a plastic layer secured to the outer annular surface of said outer sleeve.

Claim 23

Dependent Claim 23 words

A container according to claim 20 wherein: said plastic layers further cover the upper and lower annular end edges of said sleeve assembly.

Claim 24

Dependent Claim 42 words

A container according to claim 17 wherein: said coacting means comprises latch members on said pallet for sliding coaction with slots in said sleeve assembly approximate the lower peripheral edge thereof and said plastic layers further form a lining for said slots.

Claim 25

Dependent Claim 54 words

A container according to claim 17 wherein: said pallet includes downwardly extending legs defining downwardly opening tunnels therebetween extending across the lower face of the pallet for receipt of the forks of a forklift truck; and said groove means are defined around the periphery of the upper face of said pallet over said tunnels.

Claim 26

Dependent Claim 38 words

A container according to claim 23 wherein: said coacting means comprise slots in said lower peripheral edge of said sleeve assembly and a plurality of latch members mounted on the upper face of said pallet over said tunnels.

Claim 27

Dependent Claim 130 words

A pallet according to claim 17 wherein: each sleeve includes four side portions together defining a rectangle and four angled corner portions at the four corners of the sleeve so that said sleeve assembly includes four side portions in the form of a rectangle and four angled corner portions; and said pallet defines an upwardly extending rim extending around the periphery of the pallet and having a continuous circumferential inboard face sized to telescopically receive said sleeve assembly and including four side portions sized to respectively embrace the outer surfaces of the lower edge portions of the four side portions of the sleeve assembly and four corner portions sized to respectively embrace the outer surfaces of the lower edge portions of the four angled corner portions of the sleeve assembly.

Claim 28

Independent Claim 118 words

A method of forming a container for bulk materials comprising the steps of: providing a cardboard panel structure; forming a plastic layer on both side faces of the panel structure; forming the cardboard structure into a tubular sleeve so as to provide a plastic layer on the inner annular surface of the sleeve and a plastic layer on the outer annular surface of the sleeve encapsulating a cardboard core; forming a plastic pallet having upwardly facing receiving means around the periphery of the upper face of the pallet sized to accommodate the lower peripheral edge of said sleeve assembly; and positioning the lower peripheral edge of said sleeve assembly on said receiving means to form the bulk container.

Claim 29

Independent Claim 118 words

A method of forming a container for bulk materials comprising the steps of: providing a cardboard panel structure; forming a plastic layer on both side faces of the panel structure; forming the cardboard structure into a tubular sleeve so as to provide a plastic layer on the inner annular surface of the sleeve and a plastic layer on the outer annular surface of the sleeve encapsulating a cardboard core; forming a plastic pallet having upwardly facing receiving means around the periphery of the upper face of the pallet sized to accommodate the lower peripheral edge of said sleeve assembly; and positioning the lower peripheral edge of said sleeve assembly on said receiving means to form the bulk container.

Claim 30

Dependent Claim 114 words

A method according to claim 26 wherein: said step of providing a cardboard panel structure comprises providing inner and outer multiple ply cardboard structures; said plastic layer forming step comprises providing a plastic layer on the outer face of said outer cardboard structure and providing a plastic layer on the inner face of said inner cardboard structure; and said forming step comprises forming said outer cardboard structure into an outer tubular sleeve, forming said inner cardboard structure into an inner tubular sleeve, positioning said inner tubular sleeve telescopically within said outer tubular sleeve, and securing the outer annular face of said inner tubular sleeve to the inner annular face of said outer tubular sleeve.

Claim 31

Dependent Claim 104 words

A method according to claim 27 wherein: said inner and outer cardboard structures each comprise two cardboard panels arranged end-to-end; one cardboard panel of the outer cardboard structure is secured to one panel of the inner cardboard structure in staggered relation and the secured panels are formed into a first partial sleeve assembly; the other cardboard panel of the outer cardboard structure is secured to the other panel of the inner cardboard structure in staggered relation and the second panels are formed into a second partial sleeve assembly; and the first and second partial sleeve assemblies are brought together to form the sleeve assembly.

Claim 32

Independent Claim 177 words

A method of forming a container comprising the steps of: providing a first elongated corrugated cardboard panel; securing a vinyl sheet to the outer face of the first cardboard panel; providing a second elongated corrugated cardboard panel; securing a vinyl sheet to the inner face of the second cardboard panel; securing the inner face of the first cardboard panel to the outer face of the second cardboard panel in staggered relation; forming the first and second cardboard panels into a partial sleeve assembly; repeating the above steps with respect to a third and fourth cardboard panel to provide a second partial sleeve assembly; bringing the first and second partial sleeve assemblies together to form a total sleeve assembly having a central cardboard core and inner and outer vinyl layers; forming a plastic pallet having upwardly facing receiving means around the periphery of the upper face of the pallet sized to accommodate the lower peripheral edge of said sleeve assembly; and positioning the lower peripheral edge of said sleeve assembly on said receiving means to form the container.

Claim 33

Independent Claim 177 words

A method of forming a container comprising the steps of: providing a first elongated corrugated cardboard panel; securing a vinyl sheet to the outer face of the first cardboard panel; providing a second elongated corrugated cardboard panel; securing a vinyl sheet to the inner face of the second cardboard panel; securing the inner face of the first cardboard panel to the outer face of the second cardboard panel in staggered relation; forming the first and second cardboard panels into a partial sleeve assembly; repeating the above steps with respect to a third and fourth cardboard panel to provide a second partial sleeve assembly; bringing the first and second partial sleeve assemblies together to form a total sleeve assembly having a central cardboard core and inner and outer vinyl layers; forming a plastic pallet having upwardly facing receiving means around the periphery of the upper face of the pallet sized to accommodate the lower peripheral edge of said sleeve assembly; and positioning the lower peripheral edge of said sleeve assembly on said receiving means to form the container.

Claim 34

Independent Claim 151 words

A method of forming a container for bulk materials comprising the steps of: providing a first strip of corrugated cardboard material; providing a second strip of corrugated cardboard material; forming said first strip into a first tubular sleeve; forming said second strip into a second tubular sleeve; positioning said second tubular sleeve telescopically within said first tubular sleeve to form a composite sleeve assembly; forming a plastic pallet having upwardly opening groove means around the periphery of the upper face of the pallet having a width approximating the thickness of said composite sleeve assembly; positioning the lower peripheral edge of said composite sleeve in said pallet groove means to form the bulk container; and providing coacting means on said lower peripheral edge of said composite sleeve assembly and on said pallet proximate said groove means for releasably securing said sleeve assembly to said pallet to selectively form and disassemble said container.

Claim 35

Independent Claim 151 words

A method of forming a container for bulk materials comprising the steps of: providing a first strip of corrugated cardboard material; providing a second strip of corrugated cardboard material; forming said first strip into a first tubular sleeve; forming said second strip into a second tubular sleeve; positioning said second tubular sleeve telescopically within said first tubular sleeve to form a composite sleeve assembly; forming a plastic pallet having upwardly opening groove means around the periphery of the upper face of the pallet having a width approximating the thickness of said composite sleeve assembly; positioning the lower peripheral edge of said composite sleeve in said pallet groove means to form the bulk container; and providing coacting means on said lower peripheral edge of said composite sleeve assembly and on said pallet proximate said groove means for releasably securing said sleeve assembly to said pallet to selectively form and disassemble said container.

Claim 36

Dependent Claim 105 words

A method according to claim 30 wherein: said step of providing a first strip of corrugated cardboard material comprises providing a standard multiple-ply cardboard strip and adding an auxiliary cardboard sheet to the outboard surface of said multiple-ply cardboard strip; and said step of providing a second strip of corrugated cardboard material comprises providing a standard multiple-ply cardboard strip and adding an auxiliary cardboard sheet to the inboard surface of said multiple-ply cardboard strip so that, when said second tubular sleeve is positioned telescopically within said first tubular sleeve, said auxiliary cardboard sheets form the inner and outer annular surfaces of the composite sleeve assembly.

Claim 37

Dependent Claim 51 words

A method according to claim 31 and comprising the further steps of securing a vinyl sheet to the exposed outer surface of the auxiliary cardboard sheet of said first tubular sleeve and securing a vinyl sheet to the exposed inner surface of the auxiliary cardboard sheet of the second tubular sleeve.

Claim 38

Dependent Claim 61 words

A tubular sleeve for use with a container of the type including a plastic pallet and a tubular sleeve adapted to be supported on the upper face of the pallet to form the container, characterized in that the wall of the sleeve has a sandwich cross-sectional configuration including an inner plastic layer, a central cardboard layer, and an outer plastic layer.

Claim 39

Dependent Claim 61 words

A tubular sleeve for use with a container of the type including a plastic pallet and a tubular sleeve adapted to be supported on the upper face of the pallet to form the container, characterized in that the wall of the sleeve has a sandwich cross-sectional configuration including an inner plastic layer, a central cardboard layer, and an outer plastic layer.

Claim 40

Dependent Claim 17 words

A tubular sleeve according to claim 33 wherein said central cardboard layer comprises a corrugated cardboard layer.

Claim 41

Dependent Claim 17 words

A tubular sleeve according to claim 34 wherein said inner and outer plastic layers comprise vinyl layers.

Claim 42

Dependent Claim 18 words

A tubular sleeve according to claim 34 wherein said corrugated cardboard layer comprises a multiple wall corrugated layer.

Claim 43

Dependent Claim 35 words

A tubular sleeve according to claim 36 wherein said multiple wall corrugated layer comprises an inner cardboard panel of multiple wall construction secured in back-to-back relation to an outer cardboard panel of multiple wall construction.

Claim 44

Dependent Claim 26 words

A tubular sleeve according to claim 37 wherein each of said cardboard panels has a triple wall construction so that said cardboard layer comprises six sublayers.

Claim 45

Dependent Claim 17 words

A tubular sleeve according to claim 38 wherein said inner and outer plastic layers comprise vinyl layers.

Claim 46

Dependent Claim 102 words

A tubular sleeve according to claim 37 wherein each cardboard panel comprises a plurality of flat cardboard sheets interspersed with corrugated cardboard sheets, a supplemental flat cardboard sheet is secured to the outer face of said outer cardboard panel and a supplemental flat cardboard sheet is secured to the inner face of said inner cardboard panel, and said outer plastic layer comprises a vinyl sheet secured to the exposed face of the supplemental sheet of the outer cardboard panel and said inner plastic layer comprises a vinyl sheet secured to the exposed face of the supplemental sheet of the inner cardboard panel.

Claim 47

Dependent Claim 23 words

A tubular sleeve according to claim 33 wherein said plastic layers further cover the upper and lower annular end edges of said sleeve.

Claim 48

Dependent Claim 30 words

A tubular sleeve according to claim 33 wherein said sleeve includes four side portions together defining a rectangle and four angled corner portions at the four corners of the sleeve.

Claim 49

Independent Claim 79 words

A method of forming a sleeve for use with a plastic pallet to form a container, said method comprising the steps of: providing a cardboard panel structure; forming a plastic layer on both side faces of the panel structure; and forming the cardboard structure into a tubular sleeve so as to provide a plastic layer on the inner annular surface of the sleeve and a plastic layer on the outer annular surface of the sleeve encapsulating a cardboard core.

Claim 50

Independent Claim 79 words

A method of forming a sleeve for use with a plastic pallet to form a container, said method comprising the steps of: providing a cardboard panel structure; forming a plastic layer on both side faces of the panel structure; and forming the cardboard structure into a tubular sleeve so as to provide a plastic layer on the inner annular surface of the sleeve and a plastic layer on the outer annular surface of the sleeve encapsulating a cardboard core.

Claim 51

Dependent Claim 112 words

A method according to claim 43 wherein said step of providing a cardboard panel structure comprises providing inner and outer multiple-ply cardboard structures, said plastic layer forming step comprises securing a plastic layer on the outer face of said outer cardboard structure and providing a plastic layer on the inner face of said inner cardboard structure, said forming step comprises forming said outer cardboard structure into an outer tubular sleeve, forming said inner cardboard structure into an inner tubular sleeve, positioning said inner tubular sleeve telescopically within said outer tubular sleeve, and securing the outer annular face of said inner tubular sleeve to the inner annular face of said outer tubular sleeve.

Claim 52

Dependent Claim 101 words

A method according to claim 44 wherein said inner and outer cardboard structures each comprise two cardboard panels arranged end-to-end, one cardboard panel of the outer cardboard structure is secured to one panel of the inner cardboard structure in staggered relation and the secured panels are formed into a first partial sleeve, the other cardboard panel of the outer cardboard structure is secured to the other panel of the inner cardboard structure in staggered relation and the secured panels are formed into a second partial sleeve, and the first and second partial sleeve assemblies are brought together to form the sleeve.

Claim 53

Independent Claim 94 words

A method of forming a tubular sleeve for use with a pallet to form a container, said method comprising the steps of: providing a first strip of corrugated cardboard material; providing a second strip of corrugated cardboard material; forming said first strip into a first tubular sleeve; forming said second strip into a second tubular sleeve; positioning said second tubular sleeve telescopically within said first tubular sleeve; and securing the outer annular face of said second tubular sleeve to the inner annular face of said first tubular sleeve to form a composite sleeve assembly.

Claim 54

Independent Claim 94 words

A method of forming a tubular sleeve for use with a pallet to form a container, said method comprising the steps of: providing a first strip of corrugated cardboard material; providing a second strip of corrugated cardboard material; forming said first strip into a first tubular sleeve; forming said second strip into a second tubular sleeve; positioning said second tubular sleeve telescopically within said first tubular sleeve; and securing the outer annular face of said second tubular sleeve to the inner annular face of said first tubular sleeve to form a composite sleeve assembly.

Claim 55

Dependent Claim 105 words

A method according to claim 46 wherein: said step for providing a first strip of corrugated cardboard material comprises providing a standard multiple-ply cardboard strip and adding an auxiliary cardboard sheet to the outboard surface of said multiple-ply cardboard strip; and said step for providing a second strip of corrugated cardboard material comprises providing a standard multiple-ply cardboard strip and adding an auxiliary cardboard sheet to the inboard surface of said multiple-ply cardboard strip so that, when said second tubular sleeve is positioned telescopically within said first tubular sleeve, said auxiliary cardboard sheets form the inner and outer annular surfaces of the composite sleeve assembly.

Claim 56

Dependent Claim 51 words

A method according to claim 47 and comprising the further steps of: securing a vinyl sheet to the exposed outer surface of the auxiliary cardboard sheet of said first tubular sleeve; and securing a vinyl sheet to the exposed inner surface of the auxiliary cardboard sheet of said second tubular sleeve.

Claim 57

Dependent Claim 131 words

A pallet formed of first and second plastic sheets selectively fused together, said pallet comprising: a platform section formed of spaced portions of said first and second sheets and defining a generally planar upwardly facing load receiving surface; a plurality of legs extending downwardly from said platform section at spaced locations about the periphery of said platform section; a plurality of cavities at spaced locations about the periphery of said platform section with each cavity opening at its upper end in said load receiving surface and extending at its lower end generally to the level of the bottom of said legs; and a circumferential lip extending around the periphery of said platform section in surrounding relation to said cavities and having an upper edge surface spaced above said load receiving surface.

Claim 58

Dependent Claim 131 words

A pallet formed of first and second plastic sheets selectively fused together, said pallet comprising: a platform section formed of spaced portions of said first and second sheets and defining a generally planar upwardly facing load receiving surface; a plurality of legs extending downwardly from said platform section at spaced locations about the periphery of said platform section; a plurality of cavities at spaced locations about the periphery of said platform section with each cavity opening at its upper end in said load receiving surface and extending at its lower end generally to the level of the bottom of said legs; and a circumferential lip extending around the periphery of said platform section in surrounding relation to said cavities and having an upper edge surface spaced above said load receiving surface.

Claim 59

Dependent Claim 42 words

A pallet according to claim 49 wherein: each leg is formed as a downwardly depending portion of each of said sheets fused together to form a pocket opening upwardly in said load receiving surface and defining a respective one of said cavities.

Claim 60

Dependent Claim 58 words

A pallet according to claim 50 wherein: a groove is defined between each adjacent set of cavities with each groove opening in said load receiving surface and defined at its outboard edge by the inboard surface of said lip and having a bottom surface located at a level intermediate said load receiving surface and said cavity lower ends.

Claim 61

Dependent Claim 142 words

A pallet comprising: a platform section defining a generally planar upwardly facing load receiving surface; a plurality of legs extending downwardly from said platform section at spaced locations about the periphery of said platform section; a plurality of cavities at spaced locations about the periphery of said platform section with each cavity opening at its upper end in said load receiving surface and extending at its lower end generally to the level of the bottom of said legs; a groove extending between each adjacent set of cavities with each groove opening in said load receiving surface and having a bottom surface located at a level intermediate said load receiving surface and said cavity lower ends; and a circumferential lip extending around the periphery of said platform section and defining at its inboard surface the outboard surfaces of said grooves and said cavities.

Claim 62

Dependent Claim 142 words

A pallet comprising: a platform section defining a generally planar upwardly facing load receiving surface; a plurality of legs extending downwardly from said platform section at spaced locations about the periphery of said platform section; a plurality of cavities at spaced locations about the periphery of said platform section with each cavity opening at its upper end in said load receiving surface and extending at its lower end generally to the level of the bottom of said legs; a groove extending between each adjacent set of cavities with each groove opening in said load receiving surface and having a bottom surface located at a level intermediate said load receiving surface and said cavity lower ends; and a circumferential lip extending around the periphery of said platform section and defining at its inboard surface the outboard surfaces of said grooves and said cavities.

Claim 63

Dependent Claim 16 words

A pallet according to claim 52 wherein: said legs are hollow and respectively define said cavities.

Claim 64

Dependent Claim 19 words

A pallet according to claim 53 wherein: said lip has an upper edge spaced above said load receiving surface.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	1994-02-04	1994-08-06	1995-02-05	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	1998-02-04	1998-08-06	1999-02-05	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	2002-02-04	2002-08-06	2003-02-05	$7700.00	Window Closed / Lapsed

Bulk container

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