AU2018201116A1 - Containers - Google Patents

Abstract

A container formed from a blank comprising a base, a flap sequence of two sidewall flaps extending from each of a first two opposed sides of said base, the first sidewall flap of each flap sequence being connected to the base at a first fold line, and the second sidewall of each flap sequence being connected to its associated first sidewall flap at a second fold line parallel to said first fold line, wherein said container has said second sidewall flap of each flap sequence inwardly of its associated first sidewall flap, and wherein said base component includes an end wall flap extending from each of a second two opposed sides of said base, and wherein along said second fold line are located at least one folded hinge region, separated along said second fold line by cut regions that defined upwardly facing cut support edges, and wherein each said first sidewall flap includes at each end a first extension portion, arranged at a right angle to said sidewall flap and adhesively bonded to an outside surface of a respective said end wall, and wherein said first extension portion further defines at each corner of said container and upwardly projecting indexing lug, and corresponding lower cutout. 19a 19b 5 Figure 1 4 11 3 14 / 20- -- 15 19 - -- 7--- -- - --- - - 18 -12 19a 19b 202b4 3 14 16 15 20b Figure 2

Description

CONTAINERS

FIELD OF THE INVENTION

The present invention relates to improvements in cardboard containers. More particularly, the invention relates to stackable cardboard containers with improved load bearing capabilities and/or ease of assembly.

BACKGROUND TO THE INVENTION

Cardboard containers are known for packing produce for transport, both domestically and internationally. Typically, these containers are constructed from corrugated cardboard and are usually designed to stack one atop the other. For example our DEFOR containers include indexing projections located on the sidewalls, adapted to engage with the base (via a cutout) of a like container stacked on top.

While these and other known containers work well, in some circumstances known designs are difficult to assemble accurately. If not assembled properly, overall performance can be impaired. In particular, it has been found that known designs requiring two closely spaced parallel folds, can be difficult to assemble both manually, and/or via machine.

For example, a known container (described in WO99/43560) is illustrated in figure 8. In this type of container, parallel double fold lines 8, are required to create a space between the layers of the sidewalls (typically glued together), and form a ledge that supports a like container stacked on top.

In this type of container, the spacing between double fold lines 8 can be very important. If the spacing is too wide, the load bearing performance of the sidewall can be impaired. However, if the spacing between double fold lines 8 is too small, it can be difficult to form the container. Further, this problem can increase in significance as the overall height of the container sidewall decreases. That is, with this type of side wall design, it is difficult to assemble lower (sidewall) height containers (ie less than approximately 75mm).

In this specification where reference has been made to patent specifications, other external documents, or other sources of information, this is generally for the purpose of providing a context for discussing the features of the invention. Unless specifically stated otherwise, reference to such external documents is not to be construed as an admission that such documents, or such sources of information, in any jurisdiction, are prior art, or form part of the common general knowledge in the art.

It is an object of the present invention to provide an improved stackable corrugated board container and/or at least to provide a useful choice.

SUMMARY OF THE INVENTION

In one aspect, the present invention broadly comprises a container formed from a blank comprising: a base, a flap sequence of two sidewall flaps extending from each of a first two opposed sides of said base, the first sidewall flap of each flap sequence being connected to the base at a first fold line, and the second sidewall of each flap sequence being connected to its associated first sidewall flap at a second fold line parallel to said first fold line, wherein said container has said second sidewall flap of each flap sequence inwardly of its associated first sidewall flap, and wherein said base component includes an end wall flap extending from each of a second two opposed sides of said base, and wherein along said second fold line are located at least one folded hinge region, separated along said second fold line by cut regions that defined upwardly facing cut support edges, and wherein wherein each said first sidewall flap includes at each end a first extension portion, arranged at a right angle to said sidewall flap and adhesively bonded to an outside surface of a respective said end wall, and wherein said first extension portion further defines at each corner of said container and upwardly projecting indexing lug, and corresponding lower cutout.

According to another aspect said second fold line includes at least 2 said hinge regions.

According to another aspect said second fold line includes at least 3 hinge said regions.

According to another aspect the majority of the length of said fold line is made up of said cut support edges.

According to another aspect said cut support edges are located between said hinge support regions.

According to another aspect said first sidewall flaps are adhesively bonded to said second sidewall flaps.

According to another aspect said sidewall flaps do not include an indexing projection.

According to another aspect said sidewalls are substantially vertical.

According to another aspect said in walls are substantially vertical.

According to another aspect said second sidewall flap includes at each end a second extension portion, arranged at a right angle to said sidewall flap and adhesively bonded to an inner surface of a respective said end wall.

According to another aspect said second sidewall flap includes an angled section triangulating the corner of the container defining a triangular column extending vertically upwards.

According to another aspect said upwardly extending indexing lug is substantially "L" shaped in cross-section, and extends at least part way along said sidewall and said end wall.

According to another aspect the invention broadly comprises a blank substantially as herein described with reference to Figure 2 of the accompanying drawings.

According to another aspect the invention broadly comprises a container substantially as herein described with reference to Figure 1 of the accompanying drawings.

According to another aspect the invention broadly comprises in the use of blanks and/or containers in accordance with any one of the previous clauses.

Definition of terms

The term "comprising" as used in this specification and claims means "consisting at least in part of". When interpreting each statement in this specification and claims that includes the term "comprising", features other than that or those prefaced by the term may also be present. Related terms such as "comprise" and "comprises" are to be interpreted in the same manner.

This invention may also be said broadly to consist in the parts, elements and features referred to or indicated in the specification of the application, individually or collectively, and any or all combinations of any two or more said parts, elements or features, and where specific integers are mentioned herein which have known equivalents in the art to which this invention relates, such known equivalents are deemed to be incorporated herein as if individually set forth.

The invention consists in the foregoing and also envisages constructions of which the following gives examples only.

BRIEF DESCRIPTION OF THE DRAWINGS

Preferred embodiments of the invention will be described by way of example only and with reference to the drawings, in which:

Figure 1 is a perspective view of a preferred construction of an improved cardboard container.

Figure 2 is a plan view of a preferred blank that assembles to form the improved container of figure 1.

Figure 3 is a perspective view of the blank of figure 2 shown in a completely flat state.

Figure 4 partially assembled view of the blank of figure 3 shown with the second side wall flaps folded.

Figure 5 is a partially assembled schematic view of the container of Figure 4 showing side extension flaps raised.

Figure 6 is a partially assembled schematic view of the container of Figure 5 showing the end flaps raised.

Figure 7 is a perspective view of the fully assembled container.

Figure 8 is a perspective view of a prior art container.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

With reference to Figures 1 & 2, a preferred container and blank 1 therefor is shown. Preferably, the blank is cardboard. Most preferably the blank is corrugated cardboard defining a flute run direction 7.

The blank 1 includes a rectangular (or alternatively square) base 2, and end wall flaps 3, on opposed ends. The end wall flaps 3, are hinged along fold lines 4, to base 2.

The end wall flaps 3, may further include cutouts 11, or protruding features if desired. For example, a cutout 11 may be useful for allowing ventilation of the contents of the container when stacked one atop another. The end walls 3, are perpendicular to the base 2.

The blank 1 further includes first and second sidewall flaps 5,6 respectively, depending from each side of the base 2. First sidewall flaps 5, are connected to base 2 by fold lines 9. The second sidewall flaps 6 are connected to first sidewall flaps 5, via a fold line 10.

Along the length of fold line 10, is formed a number of hinging regions 12. Also along the length of fold line 10, are a number of cut regions 13. These cut regions 13 lie adjacent the hinge regions 12. When the container is assembled, these cut regions 13, provide upwardly facing cut surfaces which are particularly effective at bearing vertical loads.

As shown in figure 1, the sidewalls (made up of first and second sidewall flaps 5,6) are vertically oriented. This further increases the sidewalls ability to resist vertical loads.

This improved load bearing feature is a result of the cut regions of the sidewall flaps 5,6 only minimally disrupting the corrugated board structure in those regions. Any local disruptions (such as folds, creases and/or dents etc), tend to increase the likelihood that the wall will buckle under a vertically applied load. This tendency to buckle can significantly decrease the load bearing capability of the sidewall. However, where the cut surfaces 13 are achieved with minimal disruption to the board, they tend to form sturdy columns that are less prone to buckling.

Further, the intimate and matching contact between the first sidewall flap 5 and second sidewall flap 6, provides that they can be adhesively bonded together, in a way that allows them to act like a continuous piece. The quality and consistency of the bond between the first and second sidewall flaps 5,6 has been found to be an important factor in determining the overall load-bearing capability of the sidewall, and container.

As best illustrated in the example shown in figure 1, when the first and second sidewall flaps 5,6 are folded together (and project upwards from the base 2), the discrete hinge regions 12, allow the respective side wall flaps 5,6 to abut each other in a close contacting relationship. In contrast, if the hinging region(s) were continuous along the length of the sidewall flaps (or at least the majority of the length), then the corrugated board material doesn't fold as flat, due to the thickness of the board.

Without a close contacting relationship, it is more difficult for the glue to bond the sidewall flaps 5,6 together so that they act as one.

At each end of the sidewall flaps 5,6 there is preferably a depending extension tab section 14,15 defined by fold lines 16,17 respectively and arranged generally perpendicular to fold lines 9.

Each depending extension 14, also includes an indexing lug 19, and indent or cutout 20. In preferred forms the cutout 20 substantially corresponds to the shape of indexing lug 19. In alternative forms, the cutout may not correspond precisely to the shape of the indexing lug, but is still able to receive the profile of an indexing lug (from another container) as described in more detail later.

In a preferred form, the indexing lug 19 comprises two portions 19a and 19b, spanning either side of fold line 16. This feature forms substantially "L" shaped indexing lugs in cross section.

With reference to Figure 1, it is shown that indexing lug 19 (when assembled) projects vertically upwards, beyond the level of the cut load supporting edges 13. Similarly, cutout region 20 forms a recess in the bottom of the sidewall flap 5, and depending region 14 respectively.

It will be appreciated, that this structure leads to a container 1 that has upwardly projecting indexing lugs 19 at each of the four corners of the container 1. When assembled, two like trays can be stacked one on top of the other, such that the indexing lugs 19 of a lower container project into the cutouts 20 of the upper container. This indexing provides interaction between adjacent stacked containers, thereby improving the overall stacking ability, and load carrying capability of the container stack.

With reference to Figures 3-7, a preferred assembly sequence will be described in detail. It will be appreciated however, that other suitable sequences will also result in an assembled container. In order to make a container, a blank 1 is assembled.

As shown in Figure 4, second sidewall flaps 6 are folded upwards about fold lines 10, until the sidewall extension flaps 6 abut the first sidewall flaps 5. Preferably sidewall flap 6 is adhesively secured to sidewall flap 5. For example, one or more lines of adhesive (not shown) extending lengthways down the sidewall may be applied. Preferably the adhesive is of a hot melt glue type. Alternatively any other suitable adhesive means may be employed. As noted previously, fold line 10 includes cut regions 13 and discrete hinge regions 12, that allow the two sidewall flaps to fold over and bond better.

With reference to figure 5, the extension flap tabs 15 of the second sidewall flaps 6, are folded approximately 90 degrees. Preferably, the extension tabs 15 are adhesively bonded with the inner surfaces of end walls 3 (for example via a hot melt glue or any other suitable adhesive). This partially assembled state is shown in figure 6. In preferred forms, the extension tab 15 also includes a triangulated portion 18, which when assembled (as shown in figure 6), provides a loadbearing column and cut edge upper surface, to assist with supporting a like container stacked on top.

With reference to figure 6 and figure 7, the depending tabs 14 (from first sidewall flaps 5), are folded 90 degrees to abut the outside of respective end walls 3. Preferably, tabs 14 are glued to end wall 3 (for example via a hot melt glue or any other suitable adhesive).

The resulting assembled structure provides a container with good stacking strength, and an ability to index with a like container stacked on top, via the corresponding indexing projections 19 and recesses 20.

In some preferred embodiments the main body is of corrugated board and the flute run direction 7 is such that the side walls have a vertical flute run when assembled. Alternatively, the flute run direction of the main body may be perpendicular to 7.

The foregoing description of the invention includes preferred forms thereof. Modifications may be made thereto without departing from the scope of the invention as defined by the accompanying indicative claims.

Claims (18)

1. We claim:

   1. A container formed from a blank comprising: a base, a flap sequence of two sidewall flaps extending from each of a first two opposed sides of said base, the first sidewall flap of each flap sequence being connected to the base at a first fold line, and the second sidewall of each flap sequence being connected to its associated first sidewall flap at a second fold line parallel to said first fold line, wherein said container has said second sidewall flap of each flap sequence inwardly of its associated first sidewall flap, and wherein said base component includes an end wall flap extending from each of a second two opposed sides of said base, and wherein along said second fold line are located at least one folded hinge region, separated along said second fold line by cut regions that defined upwardly facing cut support edges, and wherein wherein each said first sidewall flap includes at each end a first extension portion, arranged at a right angle to said sidewall flap and adhesively bonded to an outside surface of a respective said end wall, and wherein said first extension portion further defines at each corner of said container and upwardly projecting indexing lug, and corresponding lower cutout.
2. 2. A container as claimed in the previous claim, wherein said second fold line includes at least 2 said hinge regions.
3. 3. A container as claimed in the previous claim, wherein said second fold line includes at least 3 hinge said regions.
4. 4. A container as claimed in any one of the previous claims, wherein the majority of the length of said fold line is made up of said cut support edges.
5. 5. A container as claimed in any one of the previous claims, wherein said cut support edges are located between said hinge support regions.
6. 6. A container as claimed in any one of the previous claims wherein said first sidewall flaps are adhesively bonded to said second sidewall flaps.
7. 7. A container as claimed in any one of the previous claims, wherein said sidewall flaps do not include an indexing projection.
8. 8. A container as claimed in any one of the previous claims, wherein said sidewalls are substantially vertical.
9. 9. A container as claimed in any one of the previous claims, wherein said in walls are substantially vertical.
10. 10. A container as claimed in any one of the previous claims, wherein said second sidewall flap includes at each end a second extension portion, arranged at a right angle to said sidewall flap and adhesively bonded to an inner surface of a respective said end wall.
11. 11. A container as claimed in the previous claim, wherein said second sidewall flap includes an angled section triangulating the corner of the container defining a triangular column extending vertically upwards.
12. 12. A container as claimed in any one of the previous claims, wherein said upwardly extending indexing lug is substantially "L" shaped in cross-section, and extends at least part way along said sidewall and said end wall.
13. 13. A container as claimed in any one of the previous claims, wherein the sidewall flaps are less than approximately 90mm tall.
14. 14. A container as claimed in any one of the previous claims, wherein the sidewall flaps are less than approximately 75mm tall.
15. 15. A container as claimed in any one of the previous claims, wherein the sidewall flaps are less than approximately 65mm tall.
16. 16. A blank substantially as herein described with reference to Figure 2 of the accompanying drawings.
17. 17. A container substantially as herein described with reference to Figure 1 of the accompanying drawings.
18. 18. The use of blanks and/or containers in accordance with any one of claims 1 to 14.