Bulk materials container and method

1. A bulk materials container, comprising:

a first wall-forming blank of corrugated paperboard scored to provide a plurality of first main panels foldably joined together, each of the plurality of first main panels defining a side wall and having a first closure flap foldably joined to a first edge thereof;

a plurality of reinforcement panel assemblies, each of the plurality of reinforcement panel assemblies mounted to a respective side wall of the first main panel of the first wall-forming blank of corrugated paperboard, each of the plurality of reinforcement panel assemblies comprising:

a pad having opposing planar sides with opposing first side edges and opposing second side edges;

a pair of first support members each disposed adjacent a respective one of the opposing first side edges of the pad;

a pair of second support members each disposed adjacent a respective one of the opposing second side edges of the pad; and

a pair of liner sheets,

each of the pair of liner sheets folded to define a U-shaped channel having opposing interior surfaces that attach to a respective one of the opposing planar sides of the pad in overlying relation to the pad, the pair of first support members, and a respective one of the pair of second support members on the respective one of the opposing second side edges of the pad,

each of the pair of liner sheets extending a length substantially between respective outer edges of the pair of first support members and extending to a distal edge remote from an edge of the respective one of the pair of second support members, configured to secure the pair of first support members and the respective one of the pair of second support members to the pad; and

a second wall-forming blank of corrugated paperboard scored to provide a plurality of second main panels foldably joined together, each of the plurality of second main panels having a second closure flap foldably joined to an edge portion thereof, the second wall-forming blank laminated in overlying relation with a respective one of the plurality of second main panels attached to a respective one of the plurality of reinforcement panel assemblies,

whereby the first wall-forming blank and the second wall-forming blank, being folded on the respective scores, forms the side walls of the bulk materials container and the respective one of the first closure flap and the second closure flap, being folded on the respective scores, close an end opening thereof.

2. The bulk materials container as recited in claim 1 , wherein the first wall-forming blank of corrugated paperboard further comprises at least a flute member sandwiched between opposing liner sheets.

3. The bulk materials container as recited in claim 1 , wherein at least one of the first main panels of the first wall-forming blank of corrugated paperboard further comprises a third closure flap foldably joined to a second edge of the first main panel opposing the first edge.

4. The bulk materials container as recited in claim 1 , wherein the second wall-forming blank of corrugated paperboard comprises at least a flute member attached to a liner sheet.

5. The bulk materials container as recited in claim 1 , wherein at least one of the second main panels of the second wall-forming blank of corrugated paperboard further comprises a fourth closure flap foldably joined to a second edge of the second main panel opposing the first edge.

6. The bulk material container as recited in claim 1 , wherein the pad comprises a corrugated paperboard sheet.

7. The bulk material container as recited in claim 1 , wherein the pad comprises fibreboard.

8. The bulk materials container as recited in claim 1 , wherein the opposing interior surfaces of each of the pair of liner sheets attach adhesively to the pad, the pair of first support members and the pair of second support members.

9. A bulk materials container, comprising:

a first wall-forming blank of corrugated paperboard scored to provide a plurality of first main panels foldably joined together, each of the plurality of first main panels defining a side wall and having a first closure flap foldably joined to a first edge of the side wall and a second closure flap foldably joined to a second edge of the side wall wherein the second edge opposes the first edge;

a plurality of reinforcement panel assemblies, each of the plurality of reinforcement panel assemblies mounted to a respective one of the side walls of the first main panel of the first wall-forming blank of corrugated paperboard, each of the plurality of reinforcement panel assemblies, comprising:

a pad having opposing planar sides with opposing first side edges and opposing second side edges;

a pair of first support members each disposed adjacent a respective one of the opposing first side edges of the pad;

a pair of second support members each disposed adjacent a respective one of the opposing second side edges of the pad; and

a pair of liner sheets,

each of the pair of liner sheets folded to define a U-shaped channel that attaches in overlying relation to the pad, the first support members and a respective one of the second support members on a respective one of the second side edges of the pad, each of

the pair of liner sheets extending a length substantially between respective outer edges of the pair of first support members and extending to a distal width edge distal from the second side edge and overlying an edge of the respective one of the pair of second support members adjacent the respective second side edge of the pad, configure to secure the pair of first support members and the respective one of the pair of second support members to the pad; and

a second wall-forming blank of corrugated paperboard scored to provide a plurality of second main panels foldably joined together, each of the plurality of second main panels having a third closure flap foldably joined to a first edge and a fourth closure flap foldably joined to a second edge opposing the first edge, the second wall forming blank laminated in overlying relation with a respective one of the plurality of second main panels attached to a respective one of the plurality of reinforcement panel assemblies,

whereby the first wall-forming blank and the second wall forming blank, being folded on the respective scores, forms side walls of the bulk materials container and the respective first and second closure flaps, being folded on the respective scores, close a respective end opening thereof.

10. The bulk materials container as recited in claim 9 , wherein the first wall-forming blank of corrugated paperboard further comprises at least a flute member sandwiched between opposing liner sheets.

11. The bulk materials container as recited in claim 10 , wherein the second wall-forming blank of corrugated paperboard comprises at least a flute member attached to a liner sheet.

12. The bulk material container as recited in claim 11 , wherein the pad comprises a corrugated paperboard sheet.

13. The bulk materials container as recited in claim 9 , wherein the second wall-forming blank of corrugated paperboard comprises at least a flute member attached to a liner sheet.

14. The bulk material container as recited in claim 9 , wherein the pad comprises a corrugated paperboard sheet.

15. The bulk material container as recited in claim 9 , wherein the pad comprises fibreboard.

16. The bulk materials container as recited in claim 9 , wherein the opposing interior surfaces of each of the pair of liner sheets attach adhesively to the pad, the pair of first support members and the pair of second support members.

17. A method of manufacturing a bulk materials container as called for in claim 1 , comprising the steps of:

(a) making a plurality of reinforcement panel assemblies, comprising the steps of:

i) disposing a pair of first support members adjacent a respective one of a pair of opposing first side edges of a pad having opposing planar surfaces;

ii) disposing a pair of second support members adjacent a respective one of a pair of opposing second side edges of the pad;

iii) securing the pair of first support members and a respective one of the pair of second support members with a respective one of a pair of U-shaped channels that each attaches in overlying relation to the pad, the pair of first support members and a respective one of the pair of second support members on a respective one of the opposing second side edges of the pad, the U-shaped channel extending a length substantially between respective outer edges of the pair of first support members and extending to a distal width edge remote from and overlapping an edge of the respective one of the pair of second support member, for securing the pair of first support members and the respective one of the pair of second support members to the pad;

(b) scoring a first wall-forming blank of corrugated paperboard to define a plurality of first main panels foldably joined together;

(c) attaching one of the plurality of reinforcement panel assemblies to a respective first main panel of the first wall-forming blank of corrugated paperboard;

(d) scoring a second wall-forming blank of corrugated paperboard to define a plurality of second main panels foldably joined together; and

(e) attaching a respective one of the plurality of second main panel to a respective one of the plurality of reinforcement panel assemblies,

whereby the first and second wall-forming blanks, being folded on the respective scores, forms side walls of the bulk materials container.

18. The method as recited in claim 17 , further comprising the step of providing at least one of the first main panels with a first closure flap foldably joined to a first edge thereof.

19. The method as recited in claim 18 , further comprising the step of providing at least one of the first main panels with a second closure flap foldably joined to a second edge thereof opposing the first edge.

20. The method as recited in claim 17 , further comprising the step of providing at least one of the plurality of second main panels a third closure flap foldably joined to an edge portion thereof.

21. The method as recited in claim 20 , further comprising the step of providing at least one of the plurality of second main panels with a fourth closure flap foldably joined to a second edge thereof opposing the first edge.