AU2005201330A1 - A Stackable Container and Blank Therefor - Google Patents

Description

AUSTRALIA

Patents Act 1990 COMPLETE SPECIFICATION FOR A STANDARD PATENT Name of Applicant: Actual Inventors: Address for Service: Invention Title: Amcor Limited Gordon Mellis CULLEN CO Patent Trade Mark Attorneys, 239 George Street Brisbane QId 4000 Australia A Stackable Container and Blank Therefor Details of Associated Provisional Applications: Application No. 2004902466 filed 11 May 2004 The following statement is a full description of this invention, including the best method of performing it, known to us: o Field of the Invention The present invention relates generally to containers of the type that are terected from a blank of a foldable material and, in particular, to containers of the aforementioned type which include one or more upwardly extending stacking tabs.

Although the invention will be described with particular reference to manually-erectable stackable containers it will be appreciated that the invention may n be incorporated into other types of containers such as machine-erectable stackable containers.

Brief Discussion of the Prior Art Containers of the type that are erected from a blank of a foldable material and that include a pair of opposing side walls and a pair of opposing end walls extending upwardly from a base, sometimes include one or more stacking tabs extending upwardly from either or both the side or end walls so that another container having a base with stacking tab receiving apertures can be stacked in a relatively secure manner on top of the first-mentioned container such that the stacking tabs of the lower container are received by the stacking tab receiving apertures of the upper container.

The stacking tabs are often of the same thickness as the foldable material and are prone to being bent or otherwise damaged, particularly if the foldable material is relatively easy to bend.

Summary of the Invention It is an object of the present invention to provide a container which overcomes, or at least ameliorates, one or more of the deficiencies of the prior art containers mentioned above, or to provide the consumer with a useful or commercial choice.

Other objects and advantages of the present invention will become apparent from the following description, taken in connection with the accompanying illustrations, wherein, by way of illustration and example, a preferred embodiment of the present invention is disclosed.

According to an aspect of the present invention there is provided a container o erected from a blank of a foldable material, the container comprising a base, a pair of opposing side walls extending upwardly from the base, a pair of opposing end walls extending upwardly from the base, and a plurality of corner gusset panels, wherein each side wall comprises an outer side wall panel hinged to the base by a fold line, and an inner side wall panel that overlies the outer side wall panel and that is hinged to the outer side wall panel by a fold line, and wherein each end wall comprises an n end wall panel hinged to the base by a fold line, a pair of outer flaps that overlie the end wall panel and that are each hinged to an end of a respective outer wall panel by a respective fold line, and a pair of inner flaps that each overlie a respective outer flap and that are each hinged to a respective corner gusset panel by a respective fold line, wherein each corner gusset panel is also hinged to an end of a respective inner side wall panel by a respective fold line, and wherein each outer and inner flap comprises a respective stacking tab extending from an upper edge thereof, wherein the stacking tabs of each pair of overlying outer and inner flaps overlie each other.

Each pair of overlying stacking tabs forms a single reinforced stacking tab whose thickness is equal to the combined thickness of each of the overlying stacking tabs. Compared to the individual stacking tabs of the outer and inner flaps, the reinforced stacking tab is less prone to being bent or otherwise damaged.

The container may be of any suitable size and shape. In a preferred form, the container is generally rectangular in shape.

The container may be a manually-erectable container or a machine-erectable container.

The blank from which the container is erected may be made from any suitable foldable material. For example, the foldable material may be cardboard or fibreboard. In a particular preferred form, the foldable material is corrugated fibreboard.

The base of the container may be of any suitable size and shape and may be composed of one or more panels. In a particular preferred form, the base is rectangular in shape and is composed of a single base panel.

It is preferred that the base includes one or more locking apertures located adjacent each of the side walls. In a particular preferred form, the base includes two O locking apertures located adjacent each of the side walls.

It is also preferred that the base includes at least one stacking aperture located adjacent each of the end walls.

The side walls and the end walls may be of any suitable size and shape. In one preferred form, the side walls and the end walls are generally rectangular in shape.

It is preferred that the side walls are longer than the end walls. However, in O alternative embodiments, the side walls and end walls may be of the same length.

It is preferred that the side walls and the end walls are perpendicular with respect to each other.

The outer side wall panels of the side walls may be of any suitable size and shape. In a preferred form, the outer side wall panels are substantially rectangular in shape.

The fold lines which hinge the outer side wall panels to the base may or may not be parallel with respect to each other. However, in a preferred form, the fold lines are parallel with respect to each other.

The inner side wall panels of the side walls may be of any suitable size and shape. In a preferred form, the inner side wall panels are substantially rectangular in shape.

Each inner side wall panel preferably includes a pair of locking apertures extending therethrough for receiving a locking tab. The locking apertures of each inner side wall panel are preferably located adjacent opposite ends of the inner side wall panel.

It is also preferred that each inner side wall panel includes at least one locking tab extending from a free edge thereof. The locking tabs extending from the inner side wall panels preferably engage with locking apertures in the base.

The fold lines which hinge the inner side wall panels to the outer side wall panels may or may not be parallel with respect to the fold lines which hinge the outer side wall panels to the base. In a preferred form, the fold lines which hinge the inner side wall panels to the outer side wall panels are parallel with respect to the fold lines which hinge the outer side wall panels to the base.

The end wall panels may be of any suitable size and shape. In a preferred O form, the end wall panels are substantially rectangular in shape.

The fold lines which hinge the end wall panels to the base may or may not be parallel with respect to each other. However, in a preferred form, the fold lines are parallel with respect to each other.

It is preferred that each end wall panel includes at least one ventilation o aperture extending therethrough. In a particular preferred form, each end wall panel includes a pair of ventilation apertures extending therethrough.

o The outer flaps which overlie the end wall panels may be of any suitable size N and shape. Preferably, the outer flaps overlying each end wall panel are identical with respect to each other. In a particular preferred form, the outer flaps are generally rectangular in shape.

It is preferred that each outer flap includes at least one ventilation aperture extending therethrough and that the ventilation aperture of each outer flap is aligned with a corresponding ventilation aperture which extends through the end wall panel which the outer flap overlies.

The fold lines which hinge the outer flaps to each outer side wall1 panel may or may not be parallel with respect to each other. In a preferred form, the fold lines are parallel wit respect to each other.

The inner flaps which overlie the outer flaps may be of any suitable size and shape. Preferably, the inner flaps of each end wall are identical with respect to each other. Jn a particular preferred form, the inner flaps are generally rectangular in shape.

It is preferred that each inner flap includes at least one ventilation aperture extending therethrough and that the ventilation aperture of each inner flap is aligned with a corresponding ventilation aperture in the outer flap which the inner flap overlies.

The fold lines hinging the inner flaps to the corner gusset panels may or may not be parallel with respect to each other. However, in a preferred embodiment, the fold lines are parallel with respect to each other.

The inner flaps may completely overlie or may only partially overlie the outer flaps. Also, each inner flap may overlie one or both of the outer flaps.

The corner gusset panels may be of any suitable size and shape. It is o preferred that the corner gusset panels are identical to each other. Preferably, the corner gusset panels are rectangular in shape.

The fold lines which hinge the corner gusset panels to the inner side wall panels may or may not be parallel with respect to each other. In a preferred form, the 5 fold lines are parallel with respect to each other.

The corner gusset panels preferably extend diagonally between the end and en side walls of the container.

The stacking tabs of the outer and inner flaps may be of any suitable size and shape. In a preferred form, the stacking tabs of the outer and inner flaps are identical O 10 to each other. Preferably, the stacking tabs are generally rectangular in shape.

The stacking tabs of each pair of overlying outer and inner flaps preferably completely overlie each other. In other embodiments however, the outer and inner flaps may not completely overlie each other.

It is preferred that each end wall includes a respective extension panel. The extension panel of each end wall is preferably hinged to the end wall panel thereof by a fold line and is preferably adapted to secure the end wall panel, outer flaps, and inner flaps of the end wall relative to each other. In a particular preferred form, the extension panel includes at least one aperture for receiving the overlying stacking tabs.

The extension panels are preferably secured relative to the side walls of the container. Preferably, each extension panel has a pair of opposing end flaps hinged to opposite ends thereof by fold lines. Each end flap preferably has a locking tab hinged thereto by a fold line. Each locking tab is preferably adapted to be received by a corresponding locking aperture in an adjacent inner side wall panel such that the locking tab thereby secures the extension panel relative to the side walls.

The two pairs of overlying stacking tabs of each end wall may or may not be located beside each other. If the two pairs of stacking tabs are located beside each other, the tabs will thereby form a single composite stacking tab, If the two pairs of overlying stacking tabs are not located beside each other, the two pairs of tabs will form separate composite stacking tabs. For such a configuration, each pair of overlying stacking tabs may pass through a respective o aperture in an extension panel of the end wall which the tabs are associated with.

Brief Description of the Illustrations In order that the invention may be more fully understood and put into practice, a preferred embodiment thereof will now be described with reference to the accompanying illustrations, in which: O Figure 1 illustrates a blank from which a stackable container according to a opreferred embodiment of the present invention may be erected; Figure 2 illustrates an initial stage in the erection of a stackable container from the blank illustrated in figure 1; Figure 3 illustrates a further stage in the erection of a stackable container from the blank illustrated in figure 1; Figure 4 is a perspective of an end of a stackable container erected from the blank illustrated in figure 1; Figure 5 is a perspective of the container which is erected from the blank illustrated in figure 1; and Figure 6 illustrates a blank from which a stackable container according to an alternative embodiment of the present invention may be erected.

Detailed Description of the Preferred Embodiments Referring to figure 1, there is illustrated a blank 10 from which a stackable container according to a preferred embodiment of the invention may be erected. The blank 10 is formed from a suitable foldable material such as corrugated fibreboard.

The blank 10 includes a rectangular base panel 11 that has respective pairs of locking apertures 12 located adjacent to the longer sides thereof, and respective stacking apertures 13 located adjacent to be shorter sides of the base panel 11.

Respective rectangular outer side wall panels 14 are hinged to opposite sides of the base panel 11 by fold lines 15. Each outer side wall panel 14 has a respective pair of outer flaps 16 hinged to opposite ends thereof by fold lines 17. Each outer flap 16 has a stacking tab 18 extending therefrom, and a ventilation aperture 19.

Each outer side wall panel 14 is hinged to a respective inner side wall panel o 20 by a double fold line 21. Each inner side wall panel 20 is generally rectangular in shape and includes a pair of locking tabs 22 extending therefrom, and respective locking apertures 23 located adjacent to opposite ends of the inner side wall panels Each inner side wall panel 20 has respective rectangular corner gusset panels 24 hinged to opposite ends thereof by fold lines Each corner gusset panel 24 is hinged to a respective inner flap 26 by a fold n line 27. Each inner flap 26 has a stacking tab 28 extending therefrom, and a ventilation aperture 29. The stacking tab 28 of each inner flap 26 is offset from the stacking tab 18 of an adjacent outer flap 16.

Respective generally rectangular end wall panels 30 are hinged to opposite sides of the base panel 11 by fold lines 31. Each end wall panel 30 includes a respective pair of ventilation apertures 32.

A respective extension panel 33 is hinged to each end wall panel 30 by a double fold line 34. Respective apertures 35 are provided partway along the double fold lines 34 and the apertures 35 extend partially into the extension panels 33.

Each extension panel 33 has a pair of opposing end flaps 36 that are hinged to opposite ends of the extension panel 33 by fold lines 37.

Each end flap 36 has a respective locking tab 38 hinged thereto by a fold line 39. The locking tabs 38 have a similar shape to the locking apertures 23 in the inner side wall panels A container is erected from the blank 10 by initially folding the inner side wall panels 20 relative to the outer side wall panels 14 along the fold lines 21 so that the inner side wall panels 20, corner gusset panels 24, and inner flaps 26 overlie the outer side wall panels 14 and outer flaps 16 as shown in figure 2.

The outer side wall panels 14 are then folded relative to the base panel 11 along the fold lines 15, and the locking tabs 22 of the inner side wall panels 20 are inserted into the locking apertures 12 of the base panel 11. The resultant upstanding and overlying outer and inner side wall panels 14, 20 form the side walls of the container.

Each pair of overlying outer and inner flaps 16, 26 and their associated corner gusset panels 24 are then folded along the fold lines 17, 25, and 27 relative to the 0 o outer and inner side wall panels 14, 20 so that the outer and inner flaps 16, 26 extend at right angles to the side wall panels 14, 20, and the gusset panels 24 extend across the corners formed by the outer flaps 16 and the outer side wall panels 14. The angle at which the corner gusset panels 24 extend across the aforementioned corners is such that the stacking tabs 18, 28 and ventilation apertures 19, 29 of the overlying flaps 16, 26 also overlie each other. The ends of adjacent pairs of overlying outer and inner en flaps 16, 26 meet midway along the shorter sides of the base panel 11 so that the ostacking tabs 18, 28 of each of those adjacent pairs flaps 16, 26 form respective single double thickness composite stacking tabs at each end of the partially erected container 40 as illustrated in figure 3. The double thickness of the composite stacking tabs increases their strength relative to that of the individual stacking tabs 18, 28.

The end wall panels 30 are then folded relative to the base panel 11 along the fold lines 31 until they extend upwardly from the base panel 11 at right angles thereto and overlie the outer flaps 16.

The extension panels 33 are then folded relative to the end wall panels along the fold lines 34 so that the stacking tabs 18, 28 extend through the apertures and the extension panels 33 overlie the inner flaps 26. As shown in figure 4, each end flap 36 overlies a respective corner gusset panel 24, and each locking tab 38 is received by a respective locking aperture 23 and forms an interference fit therewith so as to thereby lock or secure the extension panels 33 in position and complete the erection of the manually-erectable and stackable container 40 illustrated in figure The container 40 includes a pair of opposing side walls and a pair of opposing end walls extending upwardly from the base panel 11. The side walls are formed by the outer and inner side wall panels 14, 20, while the end walls are formed by the outer flaps 16, inner flaps 26, and end wall panels The container 40 may be modified in various ways. For example, the locking apertures 23 in the inner side wall panels 20 may be dispensed with and the locking tabs 38 maybe secured to the inner side wall panels 20 by other means such as glue.

A blank 50 from which a container according to another embodiment of the present invention is able to be erected is depicted in figure 6. For convenience, features of the blank 50 which are the same as or similar to features of the blank ohave been referenced with the same reference numbers.

N Blank 10 differs from blank 50 in that, unlike blank 50, blank 10 does not include locking apertures 12, locking tabs 22, extension panels 33, end flaps 36, and locking tabs 38.

A container is able to be erected from the blank 50 in a similar manner to the container 40 which is erected from the blank 10. The outer flaps 16, inner flaps 26, n and end wall panels 30 of the container which is erected from the blank 50 may be secured together with glue or some other suitable securing means.

Throughout the specification and the claims, unless the context requires otherwise, the term "comprise", or variations such as "comprises" or "comprising", will be understood to apply the inclusion of the stated integer or group of integers but not the exclusion of any other integer or group of integers.

Throughout the specification and claims, unless the context requires otherwise, the term "substantially" or "about" will be understood to not be limited to the value for the range qualified by the terms.

It will be appreciated by those skilled in the art that variations and modifications to the invention described herein will be apparent without departing from the spirit and scope thereof. The variations and modifications as would be apparent to persons skilled in the art are deemed to fall within the broad scope and ambit of the invention as herein set forth.

Claims (10)

1. A container erected from a blank of a foldable material, the container comprising a base, a pair of opposing side walls extending upwardly from the base, a pair of opposing end walls extending upwardly from the base, and a plurality of corner gusset panels, wherein each side wall comprises an outer side wall panel hinged to the base by a fold line, and an inner side wall panel that overlies the outer side wall panel and that is hinged to the outer side wall panel by a fold line, and wherein each end wall comprises an end wall panel hinged to the base by a fold line, a pair of outer flaps that overlie the end wall panel and that are each hinged to an end of a respective outer owall panel by a respective fold line, and a pair of inner flaps that each overlie a respective outer flap and that are each hinged to a respective corner gusset panel by a respective fold line, wherein each corner gusset panel is also hinged to an end of a respective inner side wall panel by a respective fold line, and wherein each outer and inner flap comprises a respective stacking tab extending from an upper edge thereof, wherein the stacking tabs of each pair of overlying outer and inner flaps overlie each other.

2. The container of claim 1, wherein an extension panel is hinged relative to the end wall panel by a fold line.

3. The container of claim 2, wherein the extension panel comprises at least one aperture for receiving the overlying stacking tabs.

4. The container of claim 2 or 3, wherein a respective end flap is hinged relative to each end of the extension panel by a fold line.

The container of claim 4, wherein a respective locking tab is hinged relative to each end flap by a fold line.

6. The container of claim 5, wherein each inner side wall panel comprises a locking aperture for receiving a respective locking tab such that the extension panel is secured relative to the inner side wall panel.

7. The container of any one of the preceding claims, wherein the two pairs of overlying stacking tabs are located adjacent to each other such that they form a single composite stacking tab.

8. The container of any one of the preceding claims, wherein the base comprises o at least one locking aperture located adjacent each of the side walls.

9. The container of claim 8, wherein each inner side wall panel comprises at least one locking tab extending from a free edge thereof, wherein each locking tab is Sengagable with a respective locking aperture in the base. C N

10. A container erected from a blank of a foldable material, the container being substantially as herein described with reference to figures 1 to 5, and figure 6 of the eC accompanying illustrations. C DATED this 29 th day of March 2005 0AMCOR LIMITED Cl By their Patent Attorneys CULLEN CO.