Sleeve pack

A sleeve pack to be used with a pallet base and cover to form a container for shipping bulk goods, the sleeve pack comprising:

• four rectangular vertical wall panels each having an inside face, an outside face and two opposed vertical side edges;
• four corner pieces attached to the side edges of the wall panels to configure the vertical wall panels into a generally rectangular sleeve, each corner piece comprising two corner panels connected by a connector panel, each corner and connector panel having an inner and outer face and two opposed vertical side edges, the two corner panels and connector panel of each corner piece being oriented such that the corner panels of each corner piece are orthogonal to each other and each corner panel is at an obtuse angle to the connector panel;
• each vertical wall panel being made of corrugated plastic with the corrugations being vertical;
• each corner piece being made of corrugated plastic with the corrugations being horizontal;
• and
• a vertical side edge of each corner panel abutting and being welded in an edge-to-edge relationship to a vertical side edge of a vertical wall panel.

A method of making a sleeve pack having an open top and open bottom to be used with a pallet base and a cover to form a container for shipping bulk goods, comprising the steps of:

• butt welding four generally rectangular pieces of corrugated plastic together into a blank in edge-to-edge relationship, the blank having an inner face, outer face, an upper and lower edge and two opposed side edges, two of the pieces of corrugated plastic having horizontal corrugations parallel the upper and lower edges of the blank and two of the pieces of corrugated plastic having vertical corrugations parallel the side edges of the blank, each piece having vertical corrugations having two cut-out vertical slots separating the piece into two wall panels, each slot extending from the lower edge of the piece of corrugated plastic to proximate the upper edge of the piece of corrugated plastic and having two slot walls;
• folding the blank along a horizontal fold line in order to form a two-ply blank, the two-ply blank having a top and bottom edge, inner and outer face and two opposed vertical side edges;
• folding the two-ply blank along vertical fold lines creating four two-ply wall panels;
• butt welding the two vertical side edges of the two-ply blank together creating a generally rectangular two-ply sleeve pack assembly.

A method of making a sleeve pack, the sleeve pack having an open top and an open bottom and comprising four rectangular two-ply wall panels to be used with a pallet base and a cover to form a container for shipping bulk goods, comprising the steps of:

• providing four generally rectangular pieces of corrugated plastic, each piece of corrugated plastic having an inner face, outer face, a width defined between an upper and lower edge, and a length defined between two opposed side edges, the length of each piece being greater than the width, two of the pieces having horizontal corrugations parallel the upper and lower edges of the piece and two of the pieces having vertical corrugations parallel the opposed side edges of the piece, the two pieces having vertical corrugations each having two cut-out slots extending from the lower edge of the piece to proximate the upper edge of the piece, each slot having two slot walls;
• orienting the two pieces of corrugated plastic having horizontal corrugations beside one another with opposing side edges abutting, the two pieces having vertical corrugations beside one another with opposing side edges abutting and the lower edge of each piece having horizontal corrugations abutting the upper edge of the piece having vertical corrugations immediately therebelow;
• butt welding adjacent pieces along the abutments into a blank;
• folding the blank along a horizontal fold line, creating a two-ply blank, the two-ply blank having an upper and lower edge, inner and outer face and two opposed vertical side edges;
• folding the two-ply blank along vertical fold lines creating four wall panels of double wall thickness;
• butt welding the two vertical side edges of the two-ply blank.

A plastic sleeve pack to be used with a pallet base and cover to form a container for shipping bulk goods, the sleeve pack comprising:

• four vertically oriented plastic corrugated wall panels, each wall panel having vertically oriented corrugations and two opposed vertical side edges;
• four corner pieces butt welded to the side edges of the wall panels to configure the wall panels into a generally rectangular sleeve, each corner piece being of corrugated plastic with horizontally oriented corrugations;
• and
• a vertical side edge of each corner panel abutting and being welded in edge-to-edge relationship to a vertical side edge of a wall panel.