AUSTRALIA Patents Act 1990 COMPLETE PATENT SPECIFICATION Name of Applicant: Amcor Limited Actual Inventors: George Ganzenmuller Andrew Kerr Address for Service: Cullens Patent & Trade Mark Attorneys Level 32, 239 George Street Brisbane QLD 4000 Australia Invention Title: A Container The following statement is a full description of this invention, including the best method of performing it, known to the applicant: A CONTAINER FIELD OF THE INVENTION 5 The present invention relates to a container that is erectable from a blank. The present invention also relates to a blank from which the container can be erected. BACKGROUND TO THE INVENTION 10 Seafood and other produce that may have a short shelf life often requires storage and handling under chilled conditions. For example, seafood is often transported in cartons or boxes that also have ice packaged therein. The ice acts to keep the seafood or other produce cool. However, this can place significant demands on the cartons in which the seafood or other produce is stored. 15 One solution to this problem has involved storing and transporting seafood in boxes made from expanded polystyrene. These boxes are typically moulded from expanded polystyrene and have a separate lid that is placed on the box to insulate the contents of the box from ambient conditions. However, expanded polystyrene boxes are not inexpensive and are 20 quite easily broken. A significant disadvantage of expanded polystyrene container assemblies of the aforementioned type is that they usually cannot be configured so that they are able to occupy less space when they are not being used to store anything. Consequently, a relatively large amount of space is required to store empty expanded polystyrene container assemblies compared to the amount of space that is required to store 25 container assemblies that are able to be configured so that they are able to occupy less space. Thus empty expanded polystyrene container assemblies can be expensive to store and transport compared to other types of container assemblies. Furthermore, production of expanded polystyrene products involves certain environmental difficulties arising from expanded polystyrene not being biodegradable. 30 Other solutions to transporting seafood have involved providing boxes or cartons made from fluted or corrugated paperboard material (such as fluted cardboard or corrugated 2 cardboard), with the fluted paperboard material being provided with a substantially water impermeable lining. The substantially water impermeable lining is typically laminated onto the paperboard material from which the carton is made. 5 BRIEF DESCRIPTION OF THE INVENTION It is an object of the present invention to provide a container that is erectable from a blank, the container having enhanced thermal installation. 10 In one aspect, the present invention provides a carton erectable from a blank, the carton comprising a base, opposed side walls and opposed end walls, wherein the side walls or the end walls comprise a first wall panel, the first wall panel having a ledge panel hinged thereto by a fold line, the ledge panel having a second wall panel hinged thereto, the second wall panel having a bottom flap hinged thereto, wherein in the erected carton the second 15 wall panel extends the substantial extent of the first wall panel and is spaced from the first wall panel by the ledge panel and the bottom flap maintains the second wall panel in spaced relationship from the first wall panel. In one embodiment, the bottom flap is connected to the base to maintain the second wall 20 panel in spaced relationship from the first wall panel. In some embodiments, the second wall panel is positioned exteriorly to the first wall panel and the bottom flap is folded inwardly to connect to the base. In some embodiments, the bottom flap is glued to the base. In other embodiments, the bottom flap may be held in 25 place on the base by use of appropriate tabs. In some embodiments, the second wall panel includes end flaps, the end flaps being foldable to cover the space between the first wall panel and the second wall panel to thereby minimise airflow through the space. The end flaps may be retained in position 30 covering the space between the first wall panel and the second wall panel.
3 In some embodiments, the container comprises a base, opposed side walls and opposed end walls, the side walls or the end walls comprising a first wall panel hinged to the base about a first fold line, the first wall panel having a ledge panel hinged thereto by a second fold line, the ledge panel having a second wall panel hinged thereto about a third fold line, the 5 second wall panel having a bottom flap hinged thereto by a fourth fold line, the others of the side walls or the end walls comprising a third wall panel hinged to the base about a fifth fold line, a further panel hinged to the first wall panel by a sixth fold line, the further panel being hinged to the third wall panel by a seventh fold line, the further panel including an oblique fold line, wherein the further panel is folded about the oblique fold line, the sixth 10 fold line and the seventh fold line so that the further panel lies adjacent the third panel in the erected carton. In some embodiments, the container further includes a further ledge panel hinged to the third wall panel by a fold line, the further ledge panel including at least one opening and the 15 further panel includes a tab that, in the erected carton, extends into the at least one opening in the further ledge panel to assist in maintaining the further panel in position. In some embodiments, the further ledge panel includes at least one opening and the further panel includes a tab that, in the erected carton, extends into the at least one opening in the 20 further ledge panel to assist in maintaining the further panel in position. In this embodiment, the further ledge panel is positioned above the further panel. In some embodiments, each further panel includes two upstanding tabs that substantially lie adjacent to each other when the further panel is folded along the oblique fold line. In these 25 embodiments, both tabs on a further panel extend into one of the at least one openings in the further ledge panel. In some embodiments, the further ledge panel has an outer panel hinged thereto by a fold line, the outer panel at least partly overlying the folded further panels in the erected carton. 30 The outer panel may include end tabs, the end tabs being insertable into a slot or opening formed in the further panels or formed in the end flaps of the second wall panels. In this manner, the outer panel may be retained in place which, in turn, acts to retain the further 4 panels and/or the end flaps in position. Desirably, the end tabs are insertable into a slot or opening formed in the end flaps of the second wall panels. In this embodiment, the further panels may be folded along their oblique lines and then folded to lie next to an exterior surface of the third wall panels, the end flaps of the second wall panels then folded to at 5 least partly overlie the folded further flaps and the outer flap folded to at least partly overlie the end flaps. The opening or slots in the end flaps may be provided by providing a cut line in the end flaps, which cut line opens to form an opening or a slot when the end flaps are folded to at 10 least partly overlie the third wall panel. The cut line may comprise a cut line outlining three sides of a rectangle. In some embodiments of the present invention, the container is erected such that the ledge panel that is attached to the first wall panel is folded to extend generally horizontally and 15 the second wall panel is also folded to extend generally vertically (throughout this specification, directions such as "horizontally" and "vertically" are given in the context of the container sitting in its normal, upright position). This results in the second wall panel extending generally parallel to the first wall panel, but spaced apart from the first wall panel by the ledge panel. Suitably, the ledge panel is at the upper end of the first wall panel and 20 the second wall panel extends downwardly from the ledge panel. The second wall panel is suitably of a height that is substantially the same as the height of the first wall panel such that the second wall panel extends for the substantial extent of the first wall panel. In order to hold the lower part of the second wall panel in position relative to the first wall panel in the erected carton, the bottom flap that is connected to the second wall panel is folded such 25 that it extends generally parallel to the base and the bottom flap is then connected to or joined to the base. The bottom flap may be connected to or joined to the base using appropriate glue lines or adhesive. In this embodiment, the second wall panel is spaced apart from the first wall panel. Effectively, a wall of double thickness (constituted by the first wall panel and the second wall panel) is formed, which acts to increase the strength of 30 that wall of the carton. The combination of the first wall panel, ledge panel, second wall panel and the bottom flap connected to the base also functions as a box section, which further assist in increasing the strength of the side wall. Furthermore, as the second wall 5 panel is spaced from the first will panel, an air gap will exist between the first wall panel and the second wall panel. This air gap acts to increase the insulative capacity of the wall, thereby increasing the resistance to heat transfer through the wall. In embodiments where the second wall panel includes end flaps and the end flaps are folded to effectively close the 5 ends of the air gap between the first wall panel and the second wall panel, the box section becomes closed to further enhance strength. Further, airflow (such as convective currents) through the gap or space between the first wall panel and the second wall panel are largely prevented. It will be understood that this also acts to increase the insulation capacity of that wall of the carton. 10 In some embodiments of the present invention, the further panel is hinged to both the first wall panel and the third wall panel. The further panel effectively extends between the first wall panel and the third wall panel. The further panel may have an inner corner in contact with or positioned very closely to a corner of the base. Desirably, the first wall panel, the 15 third wall panel and the further panel form a continuous layer of material with the base. In this manner, when the carton is erected from the blank, there are no holes or openings in the corner of the base through which liquid may escape. This is particularly useful in instances where the carton is used to contain ice for cooling or the produce contained in the carton exudes liquid during transport. By providing the carton with no holes or openings in the 20 corners of the base, any liquid inside the carton may be contained in the carton. The carton may be provided with an inner surface that is made from or coated with a substantially liquid impermeable material. 25 In some embodiments, the oblique fold line in the further panel comprises a diagonal fold line. The oblique fold line may extend from an inner corner of the further panel to an outer corner of the further panel. The present invention also encompasses a blank from which the carton described hearing 30 can be erected. BRIEF DESCRIPTION OF THE DRAWINGS 6 Figure 1 shows a top view of a blank in accordance with an embodiment of the present invention from which a carton in accordance with an embodiment of the present invention may be erected; and 5 Figures 2 to 12 show the various steps involved in erecting a carton from the blank shown in figure 1. DETAILED DESCRIPTION OF THE DRAWINGS 10 It will be appreciated that the drawings have been provided for the purpose of illustrating preferred embodiments of the present invention. Therefore, it will be understood that the present invention should not be considered to be limited to the features are shown in the drawings. 15 The blank 10 shown in figure 1 may be made from a corrugated paperboard, such as double faced corrugated board. The paperboard may be provided with a waterproof covering on one surface (typically, the surface that forms the inner surface in the erected carton). The layer of waterproof material may be laminated onto the papreboard material. 20 The blank 10 shown in figure 1 comprises a base 12. First side wall panels 14, 16 are hinged to the base by fold lines 13, 15, respectively. Ledge panels, 18, 20 are hinged to first wall panels 14, 16 by fold lines 17, 19. Second wall panels 22, 24 are hinged to respective ledge panels 18, 20 by fold lines 21, 23. Bottom flaps 26, 28 are hinged to respective 25 second wall panels 22, 24 by fold lines 25, 27. Second wall panel 22 has end flaps 30, 32 hinged thereto by fold 29, 31. Cut lines 33, 34 are cut into the blank. The cut lines 33, 34 form three sides of a rectangle. Similarly, second wall panel 24 has end flaps 36, 38 hinged thereto about fold lines 35, 37. Cut lines 39, 40 (that are of similar shape to cut lines 33, 34) are cut into the blank. 30 The blank 10 also includes end wall panels 42, 44. End wall panel 42 is hinged to base 12 about fold line 41 and end wall panel 44 is hinged to base 12 about fold line 43. The end 7 wall panels 42, 44 correspond to the third wall panels described in the brief description of the invention above. A ledge panel 46 is hinged to end wall panel 42 by fold line 45. A ledge panel 48 is hinged 5 to end wall panel 44 by fold line 47. A plurality of cut-outs 49, 50, 51, 52 are formed in respective ledge panels 46, 48. These cut-outs are of generally rectangular shape. Outer panel 54 is hinged to ledge panel 46 by fold line 53. Outer panel 56 is hinged to ledge panel 48 by fold line 55. Outer panels 54, 56 each include a further fold line 57, 58. Outer 10 panel 54 includes end ears or tabs 60, 62 that are hinged to the end panel 54 by fold lines 59, 61. End panel 56 is also provided with similar end ears or tabs that are hinged thereto by fold lines 63, 65. The blank 10 also includes a plurality of further panels 68, 70, 72, 74. Further panel 68 is 15 hinged to first side wall panel 14 about fold line 67. Further panel 68 is hinged to end wall panel 42 about fold line 69. Further panel 70 is hinged to side wall panel 16 about fold line 71. Further panel 70 is hinged to end wall panel 42 about fold line 73. 20 Further panel 72 is hinged to side wall panel 14 about fold line 75. Further panel 72 is hinged to end wall panel 44 about fold line 77. Further panel 74 is hinged to side wall panel 16 about fold line 79. Further panel 74 is 25 hinged to and panel 44 about fold line 81. Each further panel 68, 70, 72, 74 includes respective oblique fold lines 82, 83, 84, 85 that extend from an inner corner of the further panel (where it meets the base 12) to the diagonally opposite outer corner. Each further panel also includes two tabs. Further panel 30 68 includes tabs 86, 87. For convenience, the corresponding tabs on the other further panels 70, 72 and 74 are also denoted by the same reference numbers 86, 87.
8 As can be seen from figure 1, the base 12, side wall panels 14, 16, end wall panels 42, 44 and further panels 68, 70, 72, 74 are all formed from a single piece of material. Accordingly, when the blank is erected so that the side wall panels 14, 16 and end wall panels 42, 44 are upstanding from the base 12, there are no openings formed at the lower 5 part of the base and sidewalls and end walls. Accordingly, if any liquid collects in the carton, there are no holes or openings in or near the base for the liquid to escape. In order to erect the carton from the blank, the side wall panels 14, 16 are folded upwardly, the ledge panels 18, 25 are folded horizontally, the second side wall panels 22, 24 are 10 folded downwardly and the bottom flaps 26, 28 are folded inwardly so that they at least partly overlie the base 12. This is shown in figure 2. A glue line or glue lines 90 are applied between the bottom flap 28 and the base 12 in order to secure or join the bottom flap 28 to the base 12. This results in the first side wall panel 16, ledge panel 20, second side wall panel 24 and bottom flap 28 defining a space 91 between the first side wall panel 15 16 and the second side wall panel 24. A similar space is defined on the other side wall of the carton. This space 91 defines an air gap between the first side wall panel 16 and the second side wall panel 24 and this air gap acts to increase the insulation of the side wall of the carton. 20 Figure 3 shows a plan view of the blank 10 in which the sidewalls of the blank have been largely erected. Figure 4 shows the next step in erection of the carton. In this next step, the end wall panels 42, 44 are folded upwardly relative to the base 12. As can be seen with reference to end wall panel 42, the further panels 68, 70 hinge upwardly about their respective fold lines where they are hinged to the respective first side wall panel and end 25 panel. At the same time, the further panels 68, 70 fold about their oblique fold lines. As this happens, they assume the orientation as shown by further panels 72, 74 in figure 4. Effectively, the inner surfaces of the further panels fold together about their oblique fold lines so that the further panels formed a generally triangular shape. This is more clearly shown in figure 5 and figure 6. Furthermore, as the further panels are folded about their 30 oblique fold lines, the tabs 86, 87 become positioned substantially adjacent to each other, as shown in figure 6. Figure 6 also shows the bottom flaps 26, 28 that are connected to the base 12 of the carton.
9 The further flaps are then folded so that they extend outwardly from the end wall of the carton. This is best shown with reference to further flaps 72, 74 in figure 4 and with reference to further flaps 68, 70 shown in figure 6. The further panels are then folded so 5 that they lies substantially parallel to the end wall of the carton. This is shown in figure 7, which shows further panels 68, 70 (in their now folded, generally triangular shape) overlying and being substantially parallel to end wall panel 42 of the carton. The ledge panel 46 is then folded to a generally horizontal orientation. The tabs 87 (and 86) of each of the further panel 68, 70 become inserted in the respective cut-outs 49, 50 formed in the 10 ledge panel 46. In this manner, the further panels 68, 70 are held in the position as shown in figure 7. As also shown in figure 7, the end flaps 30, 36 of the respective second side wall panels 22, 24 extend outwardly beyond the end of the carton. As shown in figure 8, end flap 36 is then 15 folded inwardly so that it overlies (at least partly) the further panel 70 and the end wall panel 42. Folding the end flap 36 inwardly also causes the end panel 36 to fold about the cut line 40. This results in an opening 94, that is defined by the cut line 40, appearing. Figure 9 shows both end flaps 30, 36 being folded inwardly so that they at least partly 20 overlie the end wall panel 42 and the further panels 68, 70. Figure 9 also shows the opening 96 that was formed by folding the end flap 30 inwardly, with the opening 96 being defined by the cut line 34. Figure 9 also shows the outer panel 54 having its end ears or tabs 60, 62. Figure 10 shows a top perspective view of the carton in the position shown in figure 9. As 25 can be seen from figure 10, the tabs 86, 87 extend through the cut-outs 49, 50 in the ledge panel 46. This retains the further panels in place. In order to complete erection of the carton, the end panel 54 is folded downwardly until it adopts a generally vertical orientation and the end ears or tabs 60, 62 are inserted into the 30 openings 94, 96 to thereby retain the end ears or tabs 60, 62 therein. Fold line 57 in end panel 54 assists in facilitating insertion of the end ears or tabs into the openings 94, 96 This holds the end panel 54 in position which, in turn, holds the end flaps 30, 36 in position.
10 Returning now to figure 7, the spaces 91, 93 defined between the respective first wall panels and second wall panels are clearly shown. Folding the respective end flaps 30, 36 inwardly to the position shown in figure 9 effectively closes the ends of the spaces 91, 93. 5 This minimises any airflow that may occur through the spaces 91, 93, thereby enhancing the insulative effects of the spaces 91, 93. Figures I I and 12 show the fully erected carton. 10 The carton in accordance with the present invention provides carton that is erectable from a blank. The carton has a side wall construction that provides enhanced strength and thermal installation. Throughout this specification, the term "comprising" and its grammatical equivalents shall 15 be taken to have an inclusive meaning unless the context of use indicates otherwise. Those skilled in the art will appreciate that the present invention may be susceptible to variations and modifications other than those specifically described. It will be understood that the present invention encompasses all such variations and modifications that fall within 20 its spirit and scope.