AU2002317525B1 - A Container - Google Patents

Description

Name of Applicant Actual Inventor Address for Service: Invention Title:

AUSTRALIA

Patents Act 1990 COMPLETE SPECIFICATION FOR A STANDARD PATENT Amcor Limited Mr Gordon Mellis CULLEN CO Patent Trade Mark Attorneys, 239 George Street Brisbane QId 4000 Australian A Container Details of Associated Provisional Applications PS2507 filed on 23 May 2002 The following statement is a full description of this invention, including the best method of performing it, known to us: Field of the Invention This invention relates to containers of the type which are erected from a blank of a foldable material. In particular, the invention relates to containers of the type which are erected from a blank of a foldable material and which have reinforced end or side walls.

The invention will be described by way of example with reference to stackable containers, however it will be appreciated that this is by way of example only and that the invention may be used in connection with non-stackable containers.

Description of the Prior Art Stackable containers which are erected from blanks of foldable material are known. A common deficiency with these containers is that they have poor stacking strength due to the configuration of their side walls which are prone to buckling and sometimes collapsing when under load. If a plurality of such containers are stacked upon each other and a side wall of a lower container buckles, the container which is immediately above the lower container will usually telescope into the lower container. This is obviously undesirable as the contents of the lower container are likely to be damaged.

Although stackable containers are known which overcome, or at least minimise, the aforementioned deficiency, these containers are often expensive to manufacture due to their complicated design.

An example of a known stackable container which attempts to address the problem of poor compressive stacking strength is illustrated in 3 Fig. 1 of the drawings. The container has a basic configuration which is well known in the art and which is of a relatively simple design. The end walls of the container have been reinforced to improve their stacking strength. Each reinforced end wall is of double thickness and includes a pair of overlying end wall panels which are hinged to each other by a fold-line. Each reinforced end wall also has a vent or scallop in an upper region thereof to provide ventilation for the interior of the container, and each vent is provided by a recess defined by an edge of an aperture which extends through both of the overlying wall panels.

Although the container illustrated in Fig. 1 has improved stacking strength, it has been found that the reinforced end walls thereof are still susceptible to buckling when subjected to a moderate compressive load due to their inability to adequately disperse the load. If an end wall of the container buckled while the container was supporting another container, the supported container would probably telescope into the first mentioned container.

French Patent No. FR 2,263,940 A (Societe Normande de Carton Ondule Barrez) discloses a stackable corrugated cardboard fruit tray which has a base, a pair of upstanding and opposing end walls extending from the base, and a pair of upstanding and opposing side walls extending from the base. Each of the side walls are reinforced and include a vent in an upper region thereof. Also, each side wall of the tray includes a first side wall panel hinged to the base by a first fold-line, a ledge panel hinged to the first side wall panel by a second fold-line, and a second side wall panel hinged to the ledge panel by a third fold-line. A flap is cut out of the side wall and ledge panels and is hinged to the first side wall panel by a fourth fold-line. The panels and the flap are folded with respect to each other and the base along the fold-lines such that the side wall panels overlie each other with the ledge panel extending therebetween at the upper region of the side wall and with the flap sandwiched between the side wall panels below the vent. The vent is in the form of a recess defined by an edge of the panels which bordered the flap before it was cut out therefrom and by the fourth fold-line hinging the flap to the first side wall panel.

The tray disclosed by the '940 patent has improved stacking strength compared to the prior art container illustrated in Fig. 1 owing to the presence of the ledge panels and flaps in the reinforced side walls. However, the presence of the flaps can result in glue, which has been applied to a region on a surface of each second side wall panel to adhere the flaps to their respective second side wall panels, being wiped off either panel by an edge of the flap hinged thereto if the edge contacts the panel while the panel and flap are being folded.

It is an object of the present invention to provide an improved container which overcomes, or at least ameliorates, the deficiencies of the prior art or which provides the public with a useful or commercial choice.

Summary of the Invention According to an aspect of the present invention there is provided a container erected from a blank of a foldable material, the container including a base, a pair of upstanding and opposing end walls extending from the base, and a pair of upstanding and opposing side walls extending from the base, each of the end or side walls being reinforced and including a vent in an upper region thereof, a first wall panel hinged to the base by a first foldline, a ledge panel hinged to the first wall panel by a second fold-line, a second wall panel hinged to the ledge panel by a third fold-line and a section cut out of the panels such that at least part of the section remains as a flap hinged to one of the wall panels by a fourth fold-line, the panels and the flap being folded with respect to each other and the base along the fold-lines such that the wall panels overlie each other with the ledge panel extending therebetween at the upper region of the wall and with the flap sandwiched between the wall panels below the vent, the vent being in the form of a recess defined by an edge of the panels which bordered the cut out section and by the fourth fold-line, and the flap including a foot portion which is located so as to be able to contact the wall panel to which the flap is not hinged as the panels are folded to thereby substantially prevent an edge of the flap which is adjacent the foot portion from contacting the wall panel which is contactable by the foot portion while the panels are being folded and consequently wiping an adhesive off the contactable wall panel.

According to a preferred form of the invention the flap includes two foot portions with the flap edge extending therebetween.

Preferably, one of the wall panels of each reinforced wall has post panels hinged to opposed sides thereof for forming corner posts at corners of the container.

One of the wall panels of each reinforced wall may have extension panels hinged to opposed sides thereof.

Preferably, the container includes stacking tabs extending from one of the wall panels of each reinforced wall and corresponding stacking cutouts at corners of the base. In another preferred form the container may include stacking tabs extending from one of the wall panels of each reinforced wall and stacking cut-outs in the base at locations along the first fold-lines.

Preferably, each of the other walls includes a wall panel hinged to opposed sides of the base by respective fold-lines. Also each said wall panel of the other walls may have a recessed edge.

For each reinforced wall a section of the contactable wall panel which is adjacent the flap may be removed to provide increased clearance between the flap edge and the contactable wall panel as the panels are folded.

In order that the invention may be more fully understood and put into practice, various preferred embodiments thereof will now be described with reference to the accompanying drawings.

Brief Description of the Drawings Fig. 1 is a perspective view of a prior art container; Fig. 2 illustrates a blank from which a container according to a first embodiment of the present invention can be erected; Fig. 3 illustrates a first stage in the erection of the container from the blank illustrated in Fig. 2; Fig. 4 illustrates a second stage in the erection of the container from the blank illustrated in Fig. 2; Fig. 5 illustrates a third stage in the erection of the container from the blank illustrated in Fig. 2; Fig. 6 illustrates a fourth stage in the erection of the container from the blank illustrated in Fig. 2; Fig. 7 illustrates a fifth stage in the erection of the container from the blank illustrated in Fig. 2; Fig. 8 is a perspective view of the container erected from the blank illustrated in Fig. 2; Fig. 9 illustrates a blank from which a container according to a second embodiment of the present invention can be erected; Fig. 10 is a perspective view of the container erected from the blank illustrated in Fig. 9; Fig. 11 illustrates a blank from which a container according to a third embodiment of the present invention can be erected; Fig. 12 is a perspective view of the container erected from the blank illustrated in Fig. 11; and Fig. 13 illustrates a blank from which a container according to a fourth embodiment of the present invention can be erected.

Detailed Description A blank 10 of a foldable material such as corrugated fibreboard from which a container can be erected is illustrated in Fig. 2. Blank 8 includes a substantially rectangular base panel 11, a pair of side wall panels 12, 13 and a pair of end wall assemblies 14, Side wall panels 12, 13 are hinged to opposing sides of the base panel 11 by fold-lines, 16, 17. Each side wall panel 12, 13 includes an edge 18 which is recessed from a main edge 19 which is spaced from the fold lines 16, 17. When the blank 10 is assembled into a container, the recessed edges 18 provide ventilation for the interior of the container.

Each end wall assembly 14, 15 includes a first end wall panel having a pair of first post panels 31 hinged to opposing sides thereof by foldlines 32, 33. Second post panels 34 are hinged to the first post panels 31 by fold-lines 35, and third post panels 36 are hinged to the second post panels 34 by fold-lines 37. The first end wall panels 30 are hinged to opposing sides of the base panel 11 by fold-lines 20, 21.

Ledge panels 40 are hinged to the first end wall panels 30 by fold-lines 41.

Second end wall panels 50 are hinged to the ledge panels 40 by fold-lines 51. A pair of first extension panels 52 are hinged to opposing sides of each second end wall panel 50 by fold-lines 53, 54. Second extension panels 55 are hinged to the first extension panels 52 by fold-lines 56.

A flap 60 is cut out of each first end wall panel 30, ledge panel and second end wall panel 50. The flaps 60 are hinged to the first end wall panels 30 by double fold-lines 61, 62. A pair of foot portions 63, 64 extend from a side of the flaps 60 which is opposite to the fold-lines 61, 62.

Also, foot portions 63, 64 are spaced from each other by an edge 65 of the flaps The blank 10 is adapted to be erected into a stackable container having lug receiving recesses at the lower corners thereof and upwardly extending locating lugs. The lug receiving recesses are adapted to receive the locating lugs of a lower container and the locating lugs are adapted to be received by the lug receiving recesses of an upper container. Cut-outs which are located at the corners of the base panel 11, are adapted to form the lug receiving recesses of the container. Tabs 71 of the end wall panel assemblies 14, 15 are adapted to provide the locating lugs of the container.

Referring to Fig. 3, a first stage in the erection of the container from the blank 10 is illustrated. The first post panels 31 have been folded with respect to the first end wall panels 30 along the fold-lines 32, 33 so that the first post panels 31 extend perpendicularly from the first end wall panels Also, the second and third post panels 34, 36 are folded with respect to the first post panel 31 along the fold-lines 35, 37 so that the third post panels 36 lie flat against the interior surface of the first end wall panels 30 and are fixed thereto with a suitable fixing means such as glue to form hollow reinforcing posts whose sides are provided by the first post panels 31, second post panels 34, and a portion of the first end wall panels The next stage in the erection of the container from the blank is illustrated in Fig. 4. Apertures are formed in the blank 10 by folding the flaps 60 with respect to the first end wall panels 30 along the fold-lines 61, 62 towards the interior surface of the first end wall panels 30. The second end wall panels 50 are then folded with respect to the first end wall panels along the fold-lines 41, 51 so that the foot portions 63, 64 of the flaps contact the interior surface of the second end wall panels 50. As the second end wall panels 50 are folded, the flaps 60 continue to be folded with respect to the first end wall panel 30 as a consequence of the foot portions 63, 64 contacting the second end wall panels 50. Because the edges 65 of the flaps are recessed from the foot portions 63, 64, the edges 65 are substantially prevented from contacting the second end wall panels 50 as the second end wall panels 50 and flaps 60 are folded. In the case where a strip of glue is applied to the inner surface of the end wall assemblies 14, 15 such that the glue strip extends linearly across the second end wall panels 50 and the central region of the flaps 60 between the foot portions 63, 64, the foot portions 63, 64 function to prevent the edges 65 of the flaps 60 from wiping the glue from the second end wall panels 50 as the second end wall panels and the flaps 60 are folded.

A subsequent stage in the erection of the container from the blank 10 is illustrated in Fig. 5. The second end wall panels 50 have been folded to such an extent that the ledge panels 40 extend perpendicularly between the first end wall panels 30 and the second end wall panels Also, the second end wall panels 50 substantially overlie the first end wall panels 30. Further, the flaps 60 are sandwiched between the first end wall panels 30 and the second end wall panels 50. The first end wall panels second end wall panels 50 and the flaps 60 are fixed to each other with a suitable fixing means such as glue.

A vent 80 is formed in each of the end walls which include the 11 first end wall panels 30, second end wall panels 50 and flaps 60. The vents are provided in the end walls by edges thereof which are recessed from the ledge panels Referring to Fig. 6, the end walls formed by the first end wall panels 30, second end wall panels 50 and flaps 60 are folded with respect to the base panel 11 along the fold-lines 20, 21 until the end wall panels extend perpendicularly from the base panel 11. One of the upwardly extending locating lugs which are formed by the tabs 71 is visible in Fig. 6.

Referring to Fig. 7, the side wall panels 12, 13 are folded with respect to the base panel 11 along the fold-lines 16, 17 until the inner surface of each side wall panel 12, 13 abuts against the previously described reinforcing posts and the second extension panels 55, and the side wall panels 12, 13 extend perpendicularly from the base panel 11. The first extension panels 52 are glued to the reinforcing posts. Also, the second extension panels 55 are glued to the inner surface of the side wall panels 12, 13.

The container which is formed from the blank 10 is illustrated in Fig. 8. The container includes a base, which is provided by the base panel 11, a pair of upstanding and opposing end walls extending from the base, and a pair of upstanding and opposing side walls extending from the base. The side walls are provided by the side wall panels 12, 13, while the end walls are provided by the end wall assemblies 14, 15. The end walls provided by the end wall assemblies 14, 15 increase the stacking strength of the container owing to their reinforced construction and the provision of the ledges 12 A second embodiment of a container blank 100 and the container erected therefrom are illustrated in Figs. 9 and 10. For convenience, features of the blank 100 and container erected therefrom that are similar or correspond to features of the blank 10 and container erected therefrom have been referenced with the same reference numbers.

The blank 100 is similar to the blank 10 except that the end wall assemblies 14, 15 and the side wall panels 12, 13 of the blank 10 are now side wall assemblies 14, 15 and end wall panels 12, 13, respectively. Also, the cut-outs 70 of the blank 100 are not situated at the corners of the base panel 11 but are instead located adjacent to the fold-lines 20, 21. Further, the locating lugs 71 extend into the ledge panels 40 from second side wall panels so that each locating lug 71 is aligned with a corresponding cut-out A third embodiment of a blank 200 and container erected therefrom are illustrated in Figs. 11 and 12. For convenience, features of the blank 200 and container erected therefrom that are similar or correspond to features of the blank 10 and container erected therefrom have been referenced with the same reference numbers.

Unlike the blank 10, the blank 200 does not have second and third post panels 34, 36 coupled to first post panels 31. Additionally, the configuration of the cut-outs 70 is slightly different.

The container illustrated in Fig. 12 is erected from the blank 200 by firstly folding the flaps 60 towards the interior surface of the first end wall panels 30 along the fold-lines 61, 62 and then folding the second end wall panels 50 towards the first end wall panels 30 along the fold-lines 41, 51 until 13 the second end wall panels 50 substantially overlie the first end wall panels with the ledge panels 40 extending perpendicularly therebetween and with the flaps 60 sandwiched between the first and second end wall panels 30, The end wall panels 30, 50 and flaps 60 are fixed together with glue. The extension panels 52, 55 are then folded towards the interior surface of the end walls formed by the panels 30, 40, 50 and the flaps 60. The end walls formed by the first end wall panels 30, second end wall panels 50, ledge panels 40 and flaps 60 are then folded with respect to the base panel 11 along the fold-lines 20, 21 until the end walls extend perpendicularly from the base panel 11.

The side wall panels 12, 13 are then folded with respect to the base panel 11 along the fold-lines 16, 17 until they extend perpendicularly from the base panel 11. The second extension panels 55 are then glued to the interior surfaces of the side wall panels 12, 13 such that the second extension panels 55 lie flat against the side wall panels 12, 13. The first post panels 31 are then folded with respect to the first end wall panels 30 along the fold-lines 32, 33 until they rest against the outer surface of the side wall panels 12, 13 and are fixed thereto with glue.

A fourth embodiment of a blank 300 is illustrated in Fig. 13. For convenience, features of the blank 300 that are similar to features of the blank 10 have been referenced with the same reference numbers.

Unlike the blank 10, the flaps 60 of blank 300 are hinged to the second end wall panels 50 instead of the first end wall panels 30. Also, a section 66 of the blank 300 has been completely removed from one of the 14 first end wall panels 30 so as to increase the initial clearance between the edge 65 of an associated flap 60 when the foot portions 63, 64 of that flap contact an associated one of the first end wall panels 30 when a container is being erected from the blank 300.

The foregoing describes three embodiments of the present invention and modifications, obvious to those skilled in the art, can be made thereto without departing from the scope of the present invention. For example, the flaps 60 could be provided with a different number of foot portions 63, 64 to that described. Also, the apertures left in the various blanks by cufftting out the flaps 60 may be formed by a combination of cutting out the flaps 60 and completely removing a section of material from appropriate panels such as the second end or side wall panels 50. In particular, a section of the blank between the foot portions 63, 64 could be removed.

Claims (11)

1. A container erected from a blank of a foldable material, the container including a base, a pair of upstanding and opposing end walls extending from the base, and a pair of upstanding and opposing side walls extending from the base, each of the end or side walls being reinforced and including a vent in an upper region thereof, a first wall panel hinged to the base by a first fold-line, a ledge panel hinged to the first wall panel by a second fold-line, a second wall panel hinged to the ledge panel by a third fold-line, and a section cut out of the panels such that at least part of the section remains as a flap hinged to one of the wall panels by a fourth fold-line, the panels and the flap being folded with respect to each other and the base along the fold-lines such that the wall panels overlie each other with the ledge panel extending therebetween at the upper region of the wall and with the flap sandwiched between the wall panels below the vent, the vent being in the form of a recess defined by an edge of the panels which bordered the cut out section and by the fourth fold-line, and the flap including a foot portion which is located so as to be able to contact the wall panel to which the flap is not hinged as the panels are folded to thereby substantially prevent an edge of the flap which is adjacent the foot portion from contacting the wall panel which is contactable by the foot portion while the panels are being folded and consequently wiping an adhesive off the contactable wall panel.

2. The container of claim 1 wherein the flap includes two foot portions with the flap edge extending therebetween.

3. The container of claim 1 or 2 wherein one of the wall panels of each 16 reinforced wall has post panels hinged to opposed sides thereof for forming corner posts at corners of the container.

4. The container of any one of claims 1 to 3 wherein one of the wall panels of each reinforced wall has extension panels hinged to opposed sides thereof.

The container of any one of claims 1 to 4 including stacking tabs extending from one of the wall panels of each reinforced wall and corresponding stacking cut-outs at corners of the base.

6. The container of any one of claims 1 to 4 including stacking tabs extending from one of the wall panels of each reinforced wall and stacking cut-outs in the base at locations along the first fold-lines.

7. The container of any one of claims 1 to 6 wherein each of the other walls includes a wall panel hinged to opposed sides of the base by respective fold-lines.

8. The container of claim 7 wherein each said wall panel of the other walls has a recessed edge.

9. The container of any one of claims 1 to 8 wherein for each reinforced wall a section of the contactable wall panel which is adjacent the flap is removed to provide increased clearance between the flap edge and the contactable wall panel as the panels are folded. A container substantially as herein described with reference to Figs. 2 to 8, Figs. 9 and

10, Figs.

11 and 12, or Figs. 13 of the drawings. 17 Dated this 1 9 t h day of May 2003 AMCOR LIMITED by its Patent Attorneys CULLEN CO