Collapsible bulk bin and methods for constructing the same

A container configured to be selectively moved between a substantially flat position and a deployed position, the container comprising:

• a plurality of side walls formed from a first blank of sheet material, the side walls having a top edge and a bottom edge;
• a plurality of end flaps, each end flap emanating from the bottom edge of a respective one of the side walls, at least two of the end flaps include a respective minor flap at least partially defined by a cut line;
• at least two tab joints, each tab joint comprises one of the at least two minor flaps coupled across a joint fold line to a respective adjacent one of the end flaps and adhered to the respective adjacent end flap in an at least partially overlapping manner;
• and
• a bottom wall formed from a second blank of sheet material, the second blank coupled to a first end flap and an opposing fourth end flap of the plurality of end flaps such that the second blank is (i) configured to fold along a bottom fold line into a position between the plurality of side walls when the container is in the substantially flat position, and (ii) at least partially supported by a second end flap, a third end flap, a fifth end flap, and a sixth end flap of the plurality of end flaps when the container is in the deployed position.

A method for constructing a container, the method comprising:

• folding a plurality of side panels of a first blank along a plurality of side fold lines, wherein the first blank includes a first side panel coupled across a first of the side fold lines to a second side panel, a third side panel coupled across a second of the side fold lines to the second side panel, a fourth side panel coupled across a third of the side fold lines to the third side panel, a fifth side panel coupled across a fourth of the side fold lines to the fourth side panel, and a sixth side panel coupled across a fifth of the side fold lines to the fifth side panel, the sixth side panel having a glue panel extending from an edge opposed to the fifth side panel, wherein the first blank further includes end flaps extending from a bottom edge of each of the side panels, at least two of the end flaps each include a minor flap at least partially defined by a cut line;
• coupling the glue panel to the first side panel to form a plurality of side walls of the container;
• folding and coupling each minor flap across a joint fold line to a respective adjacent one of the end flaps to form at least two foldable tab joints;
• and
• coupling each of a first end flap and an opposing fourth end flap of the first blank to a second blank, wherein the container is movable to a deployed position by positioning the second blank in communication with a second end flap, a third end flap, a fifth end flap, and a sixth end flap of the first blank to form a bottom wall of the container, and wherein the container is foldable to a substantially flat position such that the second blank folds along a bottom fold line into a position between the plurality of side walls.